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SAFETY
INSTR
SICHEURCHTEIIOTSN-S
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
PRO-TECH
GBC Pro-Tech
4151 Anderson Road
De Forest, Wisconsin 53532
Tel: 608-246-8844
Part Number 930-009 Rev. A
Fax: 608-246-8645
Download from Www.Somanuals.com. All Manuals Search And Download.
ORCA-IV Image Transfer Laminator Operation Manual
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Caution/Warning Label Locations.................................................................................... 1-5
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Preinstallation Checklist................................................................................................... 2-1
Unpacking........................................................................................................................ 2-4
Setup ............................................................................................................................... 2-5
Leveling ........................................................................................................................... 2-5
Startup ............................................................................................................................. 2-6
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Safety............................................................................................................................... 3-1
Audible Signals ............................................................................................................ 3-3
Operator Controls ............................................................................................................ 3-4
Front Control Panel...................................................................................................... 3-4
Front Clutch/Brake Panel............................................................................................. 3-6
Rear Control Panel ...................................................................................................... 3-8
Rear Clutch/Brake Panel ...........................................................................................3-10
Setup ............................................................................................................................. 3-11
Loading the Film ............................................................................................................ 3-11
Heating .......................................................................................................................... 3-11
Recommended Materials...............................................................................................3-12
Films (Excluding Vinyl Transfer and Overlamination) ................................................3-12
Vinyl Transfer and Overlamination Materials .............................................................3-12
Setting the Slitter ...........................................................................................................3-12
Paper Tips......................................................................................................................3-12
Positioning the Film and Centering the Web .................................................................3-13
Film Spacing..................................................................................................................3-14
Operational Tips and Tricks ...........................................................................................3-14
Changing Film and Paper ..........................................................................................3-14
Process Control Charts..................................................................................................3-15
Vinyl Transfer ................................................................................................................3-15
Setup..........................................................................................................................3-15
Procedure ..................................................................................................................3-16
Machine Shutdown ........................................................................................................3-16
Procedure ..................................................................................................................3-16
© GBC Pro-Tech 1998 October
iii
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ORCA-IV Image Transfer Laminator Operation Manual
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Cleaning .......................................................................................................................... 4-1
Lubrication....................................................................................................................... 4-3
Adjusting the Kick Cable.................................................................................................. 4-3
Contacting Technical Support.......................................................................................... 4-4
Output Troubleshooting Guide......................................................................................... 4-6
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Limited Warranty.............................................................................................................. 5-1
Exclusions to the Warranty .......................................................................................... 5-1
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iv
© GBC Pro-Tech 1998 October
Download from Www.Somanuals.com. All Manuals Search And Download.
ORCA-IV Image Transfer Laminator Operation Manual
Safety
The GBC Pro-Tech ORCA-IV is a powerful machine
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that is designed for vinyl transfer and over-lamination.
The forces required to accomplish these tasks are very
large.
DO NOT ATTEMPT TO OPERATE YOUR
ORCA-IV IMAGE TRANSFER LAMINATOR
UNTIL YOU HAVE READ THIS SECTION
CAREFULLY!
The air-cylinder system used to provide downward
pressure on the top roll is capable of producing forces
greater than 1000 pounds (454kg). This force is applied
to any object presented in the opening (called the nip)
between the two rolls.
Your safety, as well as the safety of others, is important
to GBC Pro-Tech. This section contains important
safety information.
Use care in lowering the top main roll and know how to
react quickly in an emergency. The laminator roll UP-
DOWN switch is located on the instrument panels.
This switch controls the up and down motion of the top
laminator roll. Before pressing this switch to the
DOWN position, ensure that nothing is in the nip area.
If any problem or danger should occur, depressing any
of the emergency buttons stops the rolls from closing
and raises them completely.
The following symbols are used throughout this man-
ual to indicate warnings and cautions.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
Note
☞
To quickly stop the machine in the event of an emer-
gency, press any of the emergency stop buttons or apply
force to either kick cable. This action stops the machine
completely and raises the rolls.
WARNING
In addition, the rolls of the ORCA-IV can reach tem-
peratures of over 290 °F (143 °C). At these tempera-
tures you can be burned if the rolls are touched during
set-up, operation or servicing.
Indicates a potentially hazardous situation
which, if not avoided, could result in death or
serious injury.
Opening any door of the image transfer laminator
causes the rolls to slow to 3.0 ft/min (1 m/min).
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, could result in minor or
moderate injury, or alerts against unsafe
practices, or alerts against actions which could
damage the product.
WARNING
Do not ever attempt to override the safety system
on the doors of the machine or the kick cables.
You could get your fingers or arms between the
rolls when they are turning or in the closed
position and you could be crushed or severely
burned.
IMPORTANT
Indicates important additional information.
The machine has a steel cabinet that is bolted closed to
isolate the electrical and drive system components for
the safety of the operator. Only a qualified service tech-
nician should open these cabinets.
The ORCA-IV Image Transfer Laminator has been
designed with safety as a primary consideration. How-
ever, you must become thoroughly familiar with the
controls, proper operation, proper service procedures,
and safety features of the image transfer laminator
before using or servicing the unit.
© GBC Pro-Tech 1998 October
1-1
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Safety
ORCA-IV Image Transfer Laminator Operation Manual
The machine is equipped with four emergency stop
buttons located on either side of the front and back of
the image transfer laminator. Any of these, if engaged,
stops the machine. To continue operation, all emer-
gency stop buttons must be in the out position and you
must perform the Machine Reset Procedure. See
“Machine Reset Procedure” on page 1-3.
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BACK
In addition, the ORCA-IV is equipped with two emer-
gency stop kick cables located at the lower front and
back of the image transfer laminator.
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Figure 1-2: Using the Emergency Stop Kick
Cables
Either of these, if stepped on or kicked, stops the lami-
nator and raises the rolls. To continue operation, press
the kick cable reset button. Then complete the Machine
Reset Procedure. See “Machine Reset Procedure” on
page 1-3.
1-2
© GBC Pro-Tech 1998 October
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ORCA-IV Image Transfer Laminator Operation Manual
Safety
Kick Cable
Reset Button
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PRO-TECH
Reset
Button
Figure 1-3: Kick Cable Reset Button
Machine Reset Procedure
W
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ACHTUNG
MISE EN GARDE
Power
Switch/
Lockout
Perform this procedure whenever an emergency stop
button or kick cable is activated or when the power to
the machine is turned on.
POWER
1. Make sure all emergency stop buttons and kick
cables are reset.
2. Press the main machine reset button above the
power switch on the back of the machine. See Fig-
ure 1-4: Machine Reset Button.
Figure 1-4: Machine Reset Button
Despite the safety features built into the ORCA-IV,
extreme caution must be used when operating or ser-
vicing the unit. READ THE FOLLOWING WARN-
INGS AND CAUTIONS BEFORE ATTEMPTING
TO OPERATE OR SERVICE THE ORCA-IV
IMAGE TRANSFER LAMINATOR.
3. Check the web force settings to make sure they are
what you require.
4. Turn the heater back on. It is necessary to restart
the heater as all power is turned off when an emer-
gency stop button or kick cable is activated.
5. Lock the shafts by closing the doors of the machine
and pressing either the shaft locking switch or the
FWD or REV arrow.
WARNING
6. Start the motor and increase the speed.
Secure long hair so that it cannot get caught in
the machinery. Do not wear ties, loose fitting
clothing or dangling jewelry while cleaning or
servicing the image transfer laminator. These
items can get caught in the nip and choke you or
you can be crushed or burned.
Note
☞
If the display does not have a decimal point in it, the
machine needs to be reset.
IMPORTANT
Use a lift to load and unload rolls larger than 50
yards. They can weigh up to 500 lbs and can
crush you.
© GBC Pro-Tech 1998 October
1-3
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Safety
ORCA-IV Image Transfer Laminator Operation Manual
IMPORTANT
IMPORTANT
Do not operate the image transfer laminator near
water. You can be severely shocked, electrocuted
or cause a fire.
Raise the upper main roll when the image
transfer laminator is not in operation. Prolonged
contact can damage the rolls.
DANGER
IMPORTANT
Remove and lockout power from the image
transfer laminator before servicing. You can be
severely shocked, electrocuted or cause a fire.
Do not leave the top roll heater on with the roll
raised. Heat builds up in a stationary roll and can
damage it.
IMPORTANT
IMPORTANT
Do not use liquid or aerosol cleaners on the image
transfer laminator. Do not spill liquid of any kind
on the image transfer laminator. You can be
severely shocked, electrocuted or cause a fire. Use
only a damp cloth for cleaning.
Excess pressure can damage the rolls. Always
select the minimum roll pressure necessary to
complete the task.
IMPORTANT
If silicone adhesive contacts the upper or lower
roll, remove it IMMEDIATELY using 80 %
isopropyl alcohol. It can harden within an hour
and ruin the roll.
IMPORTANT
Use only 80% (or stronger) isopropyl alcohol or a
rubber cement eraser to clean the rolls. Harsh
chemicals like toluene, acetone or MEK destroy
the silicone covering of the rolls.
IMPORTANT
The operating environment must be free of dust,
flammable liquids and vapors. You can be
injured by inhaling chemical vapors. Vapor build
up or stored flammable liquids can cause a fire.
Excessive dust can damage the image transfer
laminator.
IMPORTANT
Exercise care when cleaning the rolls with
80% (or stronger) isopropyl alcohol:
• Use only in a well ventilated area.
• Wear rubber gloves.
• Use only on cool rolls.
IMPORTANT
Cleaning heated rolls can ignite the fumes.
Do not use a knife or other sharp instrument
during installation or while servicing the image
transfer laminator. You can cause irreparable
damage to the rolls.
1-4
© GBC Pro-Tech 1998 October
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ORCA-IV Image Transfer Laminator Operation Manual
Safety
IMPORTANT
IMPORTANT
Do not attempt to move the image transfer
laminator across anything other than a flat, level
surface without trained and qualified riggers.
You can be crushed or seriously injured.
Do not open the side covers of the machine. Only
a qualified service technician should remove the
covers. You can be severely shocked,
electrocuted, or crushed.
The ORCA-IV Image Transfer Laminator is a
large and heavy piece of equipment. It is
necessary to employ LICENSED RIGGERS
ONLY to move the machine. The image transfer
laminator is not designed to be tipped up or
sideways in any way. Such action disturbs the
exact alignment of the rolling parts of the
machine and requires extensive realignment.
GBC Pro-Tech’s warranty does not cover
malfunction of the equipment due to mishandling
and/or tipping.
IMPORTANT
Never operate the machine with side covers open.
You can be severely shocked, electrocuted, or
crushed.
ALWAYS USE GOOD SAFETY PRACTICES
WHEN OPERATING OR SERVICING THE IMAGE
TRANSFER LAMINATOR AND KNOW HOW TO
REACT QUICKLY IN AN EMERGENCY.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
image transfer laminator improperly.
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On your ORCA-IV Image Transfer Laminator are
important safety labels. See Figure 1-5: Locations of
Safety Labels for the location of these labels.
WARNING
Only a qualified electrician should connect power
to the image transfer laminator. You can be
severely shocked, electrocuted or cause a fire if
power is improperly applied.
IMPORTANT
Do not operate the image transfer laminator if
the power cord is damaged or frayed. You can be
severely shocked, electrocuted or cause a fire.
Contact a qualified electrician to replace the
cord.
IMPORTANT
Do not allow anything to rest on the power cord.
Do not locate the cord where people can walk on
it. You or others can be severely shocked,
electrocuted or cause a fire.
© GBC Pro-Tech 1998 October
1-5
Download from Www.Somanuals.com. All Manuals Search And Download.
Safety
ORCA-IV Image Transfer Laminator Operation Manual
Located
WARNING
One Located At
Each Roll Load
Point (7 Total)
Inside
ACHTUNG
Cabinet
MISE EN GARDE
Located
Inside
Cabinet
CAUTION! EXPOSED ROLLER
Can cause personal injury.
Keep hands, long hair, ties, jewelry
and loose clothing away from this area.
Located Inside
Cabinet
©1994 Hazard Communication Systems, Inc. 800-748-0241
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WARNING
©1994 Hazard Communication Systems, Inc. 800-748-0241
P
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CAUTION
FOR CONTINUED PROTECTION AGAINST RISK OF FIRE,
REPLACE ONL WITH SAME TYPE AND RATING OF FUSE
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CONSIGNES DE
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Panels
HIGH LEAKAGE CURRENT!
Earth connection essential before
connecting supply
PRO-TECH
®
SEE INSTALLATION INSTRUCTIONS
BEFORE CONNECTING TO THE
SUPPLY
LISTED
I.T.E
6N10
Model No.
Serial No.
VAC
Hz
®
Amps
Phase
Wires
Emergency Stop Kick Cables Located Below.
Kick or Step on to Stop Laminating Process.
MADE IN U.S.A.
Located On Door
SAFETY
INSTRUCTIONS
≤ 100 PSI
≥ 700 KPa
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK
SICHERHEITS-
RICHTLINIEN
CONSIGNES DE
SÉCURITÉ
Figure 1-5: Locations of Safety Labels
1-6
© GBC Pro-Tech 1998 October
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ORCA-IV Image Transfer Laminator Operation Manual
Safety
The following are typical safety hazard decals used on GBC Pro-Tech machines, with a brief description (“Mean-
ing” column) of each decal.
Decal
Meaning
Decal
Meaning
WARNING!
WARNING!
WARNING
ACHTUNG
MISE EN GARDE
SAFETY
INSTRUCTIONS
Moving parts can
crush and cut.
1. Read and understand the Operation Manual and
all safety labels before operating this machine.
2. Only a trained person is to be permitted to operate
this machine. Training should include instruction
in operation under normal conditions and
emergency situations.
3. This machine is to be serviced only by trained and
authorized personnel. Follow lockout procedures
before servicing.
SICHERHEITS-
RICHTLINIEN
Do not operate with
guard or door open.
CONSIGNES DE
SÉCURITÉ
4. Never reach into the machine for any reason unless
the machine is at a COMPLETE STOP.
5. Never leave the machine stopped in such a manner
that another worker can start the machine while
you are working on or within the machine.
6. Never change or defeat the function of electrical
interlocks or other machine "shutdown" switches.
7. Before starting this machine, check that:
- All persons are clear of the machine.
- No maintenance work is being performed on
the machine.
WARNING!
WARNING
WARNING
ACHTUNG
MISE EN GARDE
Crush and burn
ACHTUNG
hazard. Stay clear of
moving rollers. Stop
machine and raise roll
before cleaning.
MISE EN GARDE
or
- All guards are in place.
- All parent rolls are well chucked in the unwind
stands.
- The machine is free of paper scraps, wraps and
jams.
WARNING!
WARNING
ACHTUNG
MISE EN GARDE
Carefully read
8. There is a potential hazard of entanglement in this
machine caused by items such as long hair, loose
clothing, and jewelry. Make sure your clothing and
hair fit closely to your body and that all jewelry,
rings and watches are removed.
Operator's Manual
before handling this
machine. Observe
instructions and safety
rules when operating.
CAUTION!
Air pressure must be less than 100 PSI (700 kPa) to
avoid damaging the machine.
WARNING!
≤ 100 PSI
HAZARDOUS
VOLTAGE.
≥ 700 KPa
©1997 HCS, Inc. 800-748-0241 No. 6101-52BVPK
or
To be serviced only by
trained and authorized
personnel.
Reset.
©1994 Hazard Communication Systems, Inc. 800-748-0241
Lockout power before
servicing.
WARNING!
C
CAUTION!
Surface is hot.
EMERGENCY STOP BUTTON
Press this button to stop the machine cycle, remove
electric power, and separate (open) rolls to eliminate a
pinch point (on some machines).
or
T
C
O
A burn hazard exists.
Electric power disconnect and lock out location.
CAUTION!
CAUTION!
Rolls are heavy.
Use proper lifting
techniques to prevent
injury.
CAUTION! EXPOSED ROLLER
Can cause personal injury.
Keep hands, long hair, ties, jewelry
and loose clothing away from this area.
EXPOSED ROLLER
Can cause personal injury. Keep hands, long hair, ties,
jewelry and loose clothing away from this area.
Emergency Stop Kick Cables Located Below.
Kick or Step on to Stop Laminating Process.
Emergency Stop Kick Cables Located Below. Kick or
Step on to Stop Laminating Process.
CAUTION!
SEE INSTALLATION INSTRUCTIONS
BEFORE CONNECTING TO THE
SUPPLY
SEE INSTALLATION INSTRUCTIONS BEFORE
CONNECTINGTOTHE SUPPLY.
For continued
protection against risk
of fire, replace only with
same type and rating
of fuse.
6
A
1
A
6
A
HIGH LEAKAGE CURRENT!
Earth connection essential before
connecting supply
HIGH LEAKAGE CURRENT!
Earth connection essential before connecting supply.
24VDC
6
1
A/250V 1/4
A/250V 1/4
X
X
1-1/4 IN
1-1/4 IN
[
[
5
5
X
X
20mm
20mm
]
]
CAUTION
FOR CONTINUED PROTECTION AGAINST RISK OF FIRE,
REPLACE ONL WITH SAME TYPE AND RATING OF FUSE
Y
Earth ground.
Machine identification
label.
®
LISTED
I.T.E
6N10
Model No.
Serial No.
VAC
Hz
®
Amps
Phase
Wires
MADE IN U.S.A.
© GBC Pro-Tech 1998 October
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Safety
ORCA-IV Image Transfer Laminator Operation Manual
Blank page.
1-8
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ORCA-IV Image Transfer Laminator Operation Manual
Installation
6HFWLRQꢁꢅꢁꢃꢁ,QVWDOODWLRQ
GBC Pro-Tech is committed to a program of ongoing
product improvement. As a result, we are providing
these instructions so that you can ensure that your new
ORCA-IV Laminator is properly and securely
unpacked, moved and installed.
IMPORTANT
The operating environment must be free of dust,
flammable liquids and vapors. You can be
injured by inhaling chemical vapors. Vapor build
up or stored flammable liquids can cause a fire.
Excessive dust can damage the image transfer
laminator.
Before an ORCA-IV Image Transfer Laminator can be
installed there are a few requirements that must be met.
Make certain that each of the requirements listed in the
following preinstallation checklist are met before
beginning installation.
IMPORTANT
Do not locate the image transfer laminator where
air is blowing directly on the machine. The air
flow can cool the rolls unevenly and result in poor
quality output.
IMPORTANT
Failure to follow the preinstallation checklist can
result in damage to the image transfer laminator.
❏ Have you contacted a certified electrician to both
hard wire the laminator and ensure that an adequate
power supply, having the appropriate capacity,
overcurrent protection, and safety lockouts is avail-
able?
3UHLQVWDOODWLRQꢁ&KHFNOLVW
❏ Are doorways and hallways wide enough for the
image transfer laminator to be moved to the instal-
lation site?
The laminator requires 4 wire North American
Delta 230 VAC, 50/60 Hz, three phase, 45A per
phase with the preheater option and 35A per phase
without the preheater option.
❏ Is there ample room for the image transfer lamina-
tor?
A work area must be established that allows for
operation in both the front and the rear of the
machine and provides space for efficient material
flow. See Figure 2-6: Machine Space Require-
ments for a typical machine area layout.
☞ Note
If you require setup for European power input (three
phase wye), please contact GBC Technical Support.
❏ Is the environment appropriate for the image trans-
fer laminator?
The image transfer laminator requires a clean, dust
and vapor free environment to operate properly,
such as an air conditioned office area with forced
10% make up air. However, the image transfer lam-
inator must not be located where there is air blow-
ing directly on it. Major fluctuation in temperature
and humidity are to be avoided.
CAUTION
Do not ever attempt to change the internal
jumper configurations. Only a qualified GBC
Service Technician can change these
configurations. You can severely damage the
machine.
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Installation
ORCA-IV Image Transfer Laminator Operation Manual
❏ Is there an appropriate filtered dry air supply avail-
able?
The machine requires filtered dry air at 1.5 cubic
feet per minute (cfm), 50 liters/minute at a pressure
of 100 pounds per square inch (psi) (700 kPa). The
air supply must be clean (free of dirt) and dry.
Moisture causes corrosion and particles block
pneumatic controls. Either problem can cause the
laminator to malfunction.
It is the customer's responsibility to provide appro-
priate filters and water traps for the air hose before
the air is routed to the laminator. Pro-Tech suggests
that the best approach to the air requirement is to
provide a dedicated small compressor for the lami-
nator. A standard light-duty ½ to ¾ horse power (1
kW) electric air compressor with 1.5 to 2.5 cfm
output with a 5 gallon (20 liter) storage tank is
appropriate.
IMPORTANT
The air supply to the laminator must be clean
and dry or the machine will be damaged.
2-2
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ORCA-IV Image Transfer Laminator Operation Manual
Installation
4' x 6'
(1.2m x 2m)
Work Table
on Wheels
Rear
Electrical
Supply
38.4"
(.98m)
(Standard
Inlet on
Bottom of
Machine)
50"
(1.27m)
Air Supply
24'
(7.3m)
(On Bottom of
Machine)
85" (2.16m)
Front
4' x 6'
(1.2m x 2m)
Work Table
on Wheels
20' (6m)
Figure 2-6: Machine Space Requirements
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Installation
ORCA-IV Image Transfer Laminator Operation Manual
8. Gently unwrap the shrink wrap from around the
image transfer laminator and remove the foam pro-
tecting the corners of the machine.
8QSDFNLQJ
☞ NOTE
ALL SHIPMENTS ARE EX- WORKS. At our dock title
passes to the buyer Please review your insurance cov-
erage prior to shipment, as you are responsible for all
subsequent freight charges and risks. Before signing
the Bill of Lading you should be sure to inspect the
machine for signs of damage or missing items; if appli-
cable, you should make a note of this on the Bill of Lad-
ing.
IMPORTANT
Do not use a knife or other sharp instrument
during installation or while servicing the image
transfer laminator. You can cause irreparable
damage to the rolls.
The ORCA-IV Image Transfer Laminator is shipped
encased in shrink wrap via Air Ride Van.
9. Carefully remove any accessories packed with the
machine. The accessory pack should contain:
To unpack the machine:
1 Towel, white
1 Slitting knife
7. Have the image transfer laminator rolled off the
Air Ride Van and placed on the floor by licensed
riggers.
1 Set, hex wrenches
4 Leveling pads
3 Fuses (6A, 250V)
1 Tape measure
1 Rubber cement pick-up
1 Strain relief
IMPORTANT
Do not attempt to move the image transfer
laminator across anything other than a flat, level
surface without trained and qualified riggers.
You can be crushed or seriously injured.
1 Manual
4 Slitter Assemblies
1
2 T-handle wrenches ( / ")
4
2 Web unwind spacers
The ORCA-IV Image Transfer Laminator is a
large and heavy piece of equipment. It is
necessary to employ LICENSED RIGGERS
ONLY to move the machine. The image transfer
laminator is not designed to be tipped up or
sideways in any way. Such action disturbs the
exact alignment of the rolling parts of the
machine and requires extensive realignment.
GBC Pro-Tech’s warranty does not cover
malfunction of the equipment due to mishandling
and/or tipping.
10. Remove any plastic strapping and packing paper
taped to the rolls.
IMPORTANT
Do not use a knife or other sharp instrument
during installation or while servicing the image
transfer laminator. You can cause irreparable
damage to the rolls.
GBC Pro-Tech bears no responsibility for
personal injury or damage due to moving the
image transfer laminator improperly.
11. Remove all packing materials to a safe distance
from the image transfer laminator.
12. Level the machine using the procedure included in
this section.
2-4
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ORCA-IV Image Transfer Laminator Operation Manual
Installation
NOTE
☞
/HYHOLQJ
A word about international shipments: As these are
heavy pieces of equipment, GBC Pro-Tech takes every
precaution to ensure that our image transfer lamina-
tors are properly crated to the highest standards.
Tools required:
•
•
Adjustable wrench
Carpenter's level (or equivalent)
Before machines leave our loading dock, they are pre-
treated with a VCI protective film to provide total cor-
rosion protection. This protective film is wrapped
around the machine and completely sealed. In addition,
moisture absorbing silicone desiccant packs are
packed inside the crate and machine cabinets.
To level the laminator:
1. Install the four level pads (included in the acces-
sory pack) on the ends of the foot bolts.
2. Remove the rear idler so that you can place a car-
petner’s level across the pull roll to the bottom
main roll.
Prior to start up of the machine, you must remove the
desiccant packs from each cabinet and discard. DO
NOT operate the machine with the desiccant packs
inside the cabinets.
6HWXS
Once the ORCA-IV Image Transfer Laminator has
been unpacked and moved into final position perform
the following setup procedure.
Tools required:
1
•
•
/ " hex wrench
8
Adjustable wrench
Setup Procedure
1. Inspect the machine for any obvious shipping dam-
age.
Figure 2-7: Leveling Front to Rear
3. Level this side of the machine front to rear, raising
or lowering the leveling pads by adjusting the nuts
on the foot bolts.
2. Remove the drive and control side cabinet covers
1
with the / " hex wrench by removing the screws
8
securing the covers to the machine. Lift the covers
off.
4. Move the level to the other side of the machine and
level front to rear.
3. Inspect all the bolts and tighten any that were loos-
ened during shipping.
5. Place the level directly on the chrome tie bar below
the pull rolls and level the back of the machine side
to side.
4. Have a certified electrician wire the machine
directly to a power source.
5. Connect the machine to the air supply.
6. Replace all cabinet covers.
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Installation
ORCA-IV Image Transfer Laminator Operation Manual
6WDUWXS
The first time the image transfer laminator is started
and every time it is serviced you should use the follow-
ing checklist to confirm that the unit is operating prop-
erly and that all safety mechanisms are functioning.
Startup Checklist
Start the image transfer laminator and go through the
following checklist.
❏ Are the emergency stop buttons working?
Push down on one of the emergency stop buttons.
The image transfer laminator should stop immedi-
ately. Reset the button by turning it clockwise until
it pops up. Press the reset button. See Figure 1-4:
Machine Reset Button to locate the main machine
reset button. Start the laminator. The machine
Figure 2-8: Leveling Side to Side
6. Place the level directly on the chrome tie bar in the
front of the machine and level the front of the
machine side to side.
should resume operation. Always check all four
buttons.
7. Recheck the front to rear level condition to ensure
that it has not changed. If it has, repeat the leveling
procedure.
IMPORTANT
Never operate the image transfer laminator
unless all of the emergency stop buttons are
functioning properly. You can be crushed or
burned.
8. Remove the four metal casters after the machine is
leveled (casters provided for transportation only).
❏ Are the emergency stop kick cables working?
With the laminator running, step on or kick the
front emergency stop kick cable. The rolls should
stop turning and rise, if they are lowered. Reset the
kick cable button. See Figure 1-3: Kick Cable
Reset Button to locate the kick cable reset button.
Then reset the main machine reset. See Figure 1-4:
Machine Reset Button to locate the main machine
reset button.
IMPORTANT
Never operate the image transfer laminator
unless both of the emergency stop kick cables are
functioning properly. You can be crushed or
burned.
2-6
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ORCA-IV Image Transfer Laminator Operation Manual
Installation
❏ Is the safety system on the doors functioning.
Open any door of the image transfer laminator. The
rolls should slow to 3.0 ft/min (1 m/min) with the
CAUTION
doors open. You should not be able to increase the
speed of the machine above 3.0 ft/min (1 m/min).
Never allow loose objects (pens, knife blades,
jewelry, etc.) close to the machine or web paths.
These objects can fall onto the web and can be
carried through to the roll. Severe roll damage
can occur.
Note
☞
The speed control works best with a slow, gradual
increase or decrease of the speed control knob.
Once you have completed the startup checklist you can
safely run a test sample.
IMPORTANT
Never operate the image transfer laminator
unless safety system on the doors is functioning
properly. You can be crushed or burned.
❏ Is the motor functioning?
Test the motor at various speeds ranging from
0-19 ft/min (0-5.8 m/min). At 0 the rolls should
stop turning.
Run the motor in both forward and reverse. In
reverse you should hear a beep once a second to
alert you that you are operating the machine in
reverse.
❏ Are the heaters working?
Verify that the heater controller heats the top roll.
(The bottom roll cannot be heated.)
❏ Is the temperature set correctly?
Check that the temperature is set to 290°F
(143.3 °C) for most transfer processes.
IMPORTANT
Never allow any film, packing material, object,
etc. to block the infrared temperature sensor. The
sensor has a cone-shaped view of the roll that
should never be obstructed. Severe roll damage
can occur.
© GBC Pro-Tech 1998 October
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Installation
ORCA-IV Image Transfer Laminator Operation Manual
Blank page.
2-8
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
6HFWLRQꢁꢆꢁꢃꢁ2SHUDWLRQ
WARNING
6DIHW\
Do not ever attempt to override the safety system
on the doors of the machine or the kick cables.
You could get your fingers or arms between the
rolls when they are turning or in the closed
position and you could be crushed or severely
burned.
The ORCA-IV Image Transfer Laminator has been
designed with safety as a primary consideration. How-
ever, you must become thoroughly familiar with the
controls, proper operation, proper service procedures,
and safety features of the image transfer laminator
before using or servicing the unit.
The GBC Pro-Tech ORCA-IV is a powerful machine
that is designed for vinyl transfer and over-lamination.
The forces required to accomplish these tasks are very
large.
The machine has a steel cabinet that is bolted closed to
isolate the electrical and drive system components for
the safety of the operator. Only a qualified service tech-
nician should open these cabinets.
The air-cylinder system used to provide downward
pressure on the top roll is capable of producing forces
greater than 1000 pounds (454kg). This force is applied
to any object presented in the opening (called the nip)
between the two rolls.
Use care in lowering the top main roll and know how to
react quickly in an emergency. The laminator roll UP-
DOWN switch is located on the instrument panels.
This switch controls the up and down motion of the top
laminator roll. Before pressing this switch to the
DOWN position, ensure that nothing is in the nip area.
If any problem or danger should occur, depressing any
of the emergency buttons stops the rolls from closing
and raises them completely.
Note
☞
To quickly stop the machine in the event of an emer-
gency, press any of the emergency stop buttons or apply
force to either kick cable. This action stops the machine
completely and raises the rolls.
In addition, the rolls of the ORCA-IV can reach tem-
peratures of over 290 °F (143 °C). At these tempera-
tures there is a danger of a severe burn if the rolls are
touched during set-up, operation or servicing.
Opening any door of the image transfer laminator
causes the rolls to slow to 3.0 ft/min (1 m/min).
© GBC Pro-Tech 1998 October
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
The machine is equipped with four emergency stop
buttons located on either side of the front and back of
the image transfer laminator. Any of these, if engaged,
stops the machine. To continue operation, all emer-
gency stop buttons must be in the up position and you
must perform the Machine Reset Procedure. See
“Machine Reset Procedure” on page 3-3.
FRONT
U
M
P
R
R
O
'
G
60
50
40
60
50
40
60
50
40
60
50
40
O
E
G
r
r
hn
r
Or
1
,
c
0
7
-2
o
de
o.0
PT
R
M
E
T
R
ps
0
0
0
42
35
Push any button
to stop the
Twist each button
to resume
operation - the
button pops out
IV™
ORCA
0
0
0
laminator
PRO-TECH
Emergency
Stop Kick
Cable
E
S
E
S
M
M
E
E
E
C
E
C
R
R
N
N
G
G
E
E
E
E
G
G
N
N
R U
'
R U
'
C
C
Y
Y
D
D
T
T
T
T
E
E
R
O P
O P
R
R
R
A
A
Figure 3-1: Using the Emergency Stop Buttons
BACK
In addition, the ORCA-IV is equipped with two emer-
gency stop kick cables located at the lower front and
back of the image transfer laminator.
R
E
M
E
R
R
E
T
O
'
R
G
E
%
%
%
PR
O-T
EC
H
G
R
E
M
I
E
E
T
O
'
C
l
t
a
s
l
r
e
Ors
s
e
Oe
e
psi
IV™
100
©9
90
80
70
60
50
40
30
20
10
kPa
700
630
560
490
420
350
280
210
140
70
,
n.
8-
t
4-
4
Rr
r
.0
-
i
ORCA
PRO
-TE
CH
0
0
2
3
PRO-TECH
Emergency
Stop Kick
Cable
Figure 3-2: Using the Emergency Stop Kick
Cables
Either of these, if stepped on or kicked, stops the lami-
nator and raises the rolls. To continue operation, press
the kick cable reset button. Then complete the Machine
Reset Procedure. See “Machine Reset Procedure” on
page 3-3.
3-2
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
6. Start the motor and increase the speed.
Kick Cable
Reset Button
N
E
C
Y
G
S
R
E
T
O
E
M
P
A
R
R
E
T
'
U
R
G
E
C
N E
%
10
0
90
80
70
60
50
40
30
20
10
%
10
0
90
80
70
60
50
40
30
20
10
%
10
0
90
80
70
60
50
40
30
20
10
Power
Switch
w/ Lock
PRO-TECH
Figure 3-3: Kick Cable Reset Button
Reset
Button
Machine Reset Procedure
Perform this procedure whenever an emergency stop
button or kick cable is activated or when the power to
the machine is turned on.
W
ARNING
ACHTUNG
MISE EN GARDE
Power
Switch/
Lockout
1. Make sure all emergency stop buttons and kick
cables are reset.
POWER
2. Press the main machine reset button above the
power switch on the back of the machine. See Fig-
ure 3-4: Machine Reset Button.
Figure 3-4: Machine Reset Button
3. Check the web force settings to make sure they are
what you require.
4. Restart the heater if it is being used.
For your safety, the machine has several audible signals
that are used to alert you to the status of the machine.
The following table lists the alert signals.
5. Lock the shafts by closing the doors of the machine
and pressing the shaft lock button or starting the
motor.
Table 3-1: Audible Signals
Audible Signal
Meaning
Continuous rapid beep
If the roll is down but
not turning, the machine
will begin beeping con-
tinuously after 10 sec-
onds.
Four beeps every 30 sec- If the roll is up and the
onds after 55 minutes of heater is on, the machine
inactivity
will begin beeping four
times every 30 seconds
after the machine has
been inactive for 55
minutes.
One beep per second
The machine is in
reverse.
© GBC Pro-Tech 1998 October
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
either a clutch or brake loads that force into the
internal computer, which then automatically
2SHUDWRUꢁ&RQWUROV
The operator controls for the ORCA-IV Image Transfer
Laminator are located on the front and rear of the
machine, to the right of the operator positions. The
names and functions of these controls are as follows:
adjusts the air pressure sent to the clutch/brake to
obtain the required web tension based on the roll
size. When you enter the setting and then turn the
motor on, the indicator changes from reading the
web force to the actual pressure sent to the brake to
attain the required web force calculated for that roll
size. In Manual Tension mode the display reads
actual pressure sent to the clutch/brake. This pres-
sure stays set until you change it. The computer
will not override your setting or change the display.
psi
100
90
80
70
60
50
40
30
20
10
kPa
700
630
560
490
420
350
280
210
140
70
Roll Temperature
Adjustment/Displa
8
9
1
CAL 3200
Main Roll
Pressure
Display
6. SPEED/ACCUMULATOR DISPLAY - Dis-
plays either the accumulator or speed, depending
on which you have selected with the SPEED/
ACCUMULATOR TOGGLE. A letter in the dis-
play before the speed readout indicates the mode of
operation:
Roll Heat
ON/OFF
Main Roll
UP/DOWN
2
3
10
11
Pull Roll
UP/DOWN
Main Roll
Pressure
Adjustment
Preheater
ON/OFF
(optional)
4
Cooling Fan
ON/OFF
Preheater
H - Manual mode with the preheater off.
P - Automatic mode with the preheater on.
L - Manual mode with the preheater on.
No letter - Automatic mode with the preheater off.
The following codes alert you to machine status:
.0 - The machine is reset and ready to be started.
8888 - Main power has just been turned on and the
main reset has not yet been pressed.
12
13
Temperature
Adjustment/Displa
(optional)
CAL 3200
5
6
Preheater Heat
ON/OFF
Accumulator
Reset
Speed/
Accumulator
Toggle
PRO-TECH
GBC Logo
Automatic/Manual
Mode Control
14
15
0 0 0 0
Speed/
Accumulator
Display
1 2 3 4
16
7
Motion Control
FORWARD/
STOP/REVERSE
Speed
Adjustment
In addition to these codes, if an emergency stop
button or kick cable is activated, the decimal point
will no longer be displayed (for example, 3.0 would
change to 3 0). Simply resetting the emergency stop
button or kick cable does not change the display.
You must also press the main machine reset button
for display to read .0 indicating the machine is
ready to be started. Note that you must reset the
emergency stop button or kick cable before press-
ing the main machine reset or the machine will not
be reset.
Figure 3-5: Front Control Panel
1. MAIN ROLL PRESSURE DISPLAY - Displays
the air pressure pushing the upper main roll down.
2. MAIN ROLL UP/DOWN - Sets the upper main
roll to the up (load) or down (operate) position.
3. MAIN ROLL PRESSURE CONTROL - Varies
the air pressure fed to the cylinders that drive the
upper main roll down.
4. PREHEATER ON/OFF (optional) - Turns on or
off the preheater. The preheater mode is indicated
by a P in the accumulator display.
7. SPEED ADJUSTMENT - Adjusts the speed of
the machine from zero to maximum as the control
is turned clockwise. Adjust the speed control
slowly for best results.
5. GBC LOGO AUTOMATIC/MANUAL MODE
CONTROL - Toggles between Automatic Tension
and Manual Tension mode. In Automatic Tension
mode, the system automatically adjusts the brake/
clutch pressure. In Manual Tension mode the sys-
tem doesn’t automatically adjust these pressures
(indicated by an H or L in the accumulator dis-
play). In the Automatic Tension mode with the
motor stopped, setting a web force (tension) for
3-4
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
8. ROLL TEMPERATURE - Provides a readout of
the temperature of the upper main roll and the set-
point for the desired temperature adjustment. Press
the star button on the temperature controller to see
or change the set point.
9. ROLL HEAT ON/OFF - Turns the heater control-
ler for the top roll on or off.
10. PULL ROLL UP/DOWN - Sets the pull roll to
the up (load) or down (operate) position.
11. COOLING FAN ON/OFF - Turns the cooling fan
on or off. Push once to turn only the cooling idlers
on, push again to turn only the cooling tubes on,
push a third time to turn both cooling idlers and
cooling tubes on, and push a fourth time for all
cooling off.
12. PREHEATER AIR TEMPERATURE
(optional) - Provides a readout of the temperature
of the air inside the preheater and the set-point for
the desired temperature.
13. PREHEATER HEAT ON/OFF - Turns the heater
controller in the preheater roll on or off.
14. ACCUMULATOR RESET - Resets the accumu-
lator.
15. SPEED/ACCUMULATOR TOGGLE - Toggles
control between the speed and the accumulator.
16. MOTION CONTROL FORWARD/STOP/
REVERSE - Controls the direction of the drive
system, forward, reverse, or stop.
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
arrow is pressed and the machine starts, the com-
puter calculates the appropriate pressure to attain
the required web force based on the roll size. The
indicator then changes to read the actual air pres-
sure (in psi) sent to the clutch/brake. If the machine
is in Manual Tension mode, the indicator reads the
actual air pressure (in psi) sent to the clutch/brake.
%
100
90
80
70
60
50
40
30
20
10
2
3
1
4
Upper Middle Clutc
Upper Middle
(Rewind) Pressure
Clutch (Rewind)
Percent Web
Force
Upper Middle Clutch
(Rewind) Indicator
%
100
90
80
70
60
50
40
30
20
10
5
6
Upper Front Clutch
(Rewind) Pressure
Upper Front
Clutch (Rewind)
Percent Web
Force
Upper Front Clutch
(Rewind) Indicator
5. UPPER FRONT CLUTCH (REWIND) PRES-
SURE - Adjusts the clutch pressure up or down.
%
100
90
80
70
60
50
40
30
20
10
8
9
7
Middle Front Brake
Pressure
Middle Front Brake
Percent Web Force
6. UPPER FRONT CLUTCH (REWIND) INDI-
CATOR - Indicates that this set of controls is for
the upper front clutch.
Middle Front
Brake Indicator
%
100
90
80
70
60
50
40
30
20
10
12
13
10
11
Unwind/Rewind Shaft
Locking System ON/OFF
Lower Front Brake
Pressure
PRO-TECH
Lowerr Front Brake
Percent Braking
Force
Lower Front Brake
Indicator
7. MIDDLE FRONT BRAKE PERCENT WEB
FORCE -Indicates the web force (tension) for this
brake as a percentage of the total possible tension
the brake can exert. What the pressure indicator
displays changes depending upon whether the
motor is on or off and what mode you are operating
the machine under. With the motor direction
arrows off and the machine in Automatic Tension
mode, the indicator displays the material web ten-
sion you set. Once the motor arrow is pressed and
the machine starts, the computer calculates the
appropriate pressure to attain the required web
force based on the roll size. The indicator then
changes to read the actual air pressure (in psi) sent
to the clutch/brake. If the machine is in Manual
Tension mode, the indicator reads the actual air
pressure (in psi) sent to the clutch/brake.
Figure 3-6: Front Brake Panel
1. UPPER MIDDLE CLUTCH (REWIND) PER-
CENT WEB FORCE - Indicates the web force
(tension) for this clutch as a percentage of the total
possible tension the clutch can exert. What the
pressure indicator displays will change depending
upon whether the motor is on or off and what mode
you are operating the machine under. With the
motor direction arrows off and the machine in
Automatic Tension mode, the indicator displays the
material web tension you set. Once the motor
arrow is pressed and the machine starts, the com-
puter calculates the appropriate pressure to attain
the required web force based on the roll size. The
indicator then changes to read the actual air pres-
sure (in psi) sent to the clutch/brake. If the machine
is in Manual Tension mode, the indicator reads the
actual air pressure (in psi) sent to the clutch/brake.
8. MIDDLE FRONT BRAKE PRESSURE -
Adjusts the brake pressure up or down.
9. MIDDLE FRONT BRAKE INDICATOR - Indi-
cates that this set of controls is for the middle front
brake.
2. UPPER MIDDLE CLUTCH (REWIND) PRES-
SURE - Adjusts the clutch pressure up or down.
10. UNWIND/REWIND SHAFT LOCKING SYS-
TEM ON/OFF - Engages/disengages the unwind/
rewind shaft locking system. The switch disen-
gages the locking system with the door either open
or closed with the motor off. The doors must be
shut to engage the system. If the doors are shut and
the unwind/rewind shafts are disengaged, pushing
the motion control engages them automatically.
Note the color coding on each shaft and the shaft
loading tray. Unwinds are marked with blue and
rewinds are marked with red. Always use the cor-
rect shaft in each loading position.
3. UPPER MIDDLE CLUTCH (REWIND) INDI-
CATOR - Indicates that this set of controls is for
the upper middle clutch.
4. UPPER FRONT CLUTCH (REWIND) PER-
CENT WEB FORCE - Indicates the web force
(tension) for this clutch as a percentage of the total
possible tension the clutch can exert. What the
pressure indicator displays changes depending
upon whether the motor is on or off and what mode
you are operating the machine under. With the
motor direction arrows off and the machine in
Automatic Tension mode, the indicator displays the
material web tension you set. Once the motor
3-6
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
11. LOWER FRONT BRAKE PERCENT BRAK-
ING FORCE - Indicates the web force (tension)
for this brake as a percentage of the total possible
tension the brake can exert. What the pressure indi-
cator displays changes depending upon whether the
motor is on or off and what mode you are operating
the machine under. With the motor direction
arrows off and the machine in Automatic Tension
mode, the indicator displays the material web ten-
sion you set. Once the motor arrow is pressed and
the machine starts, the computer calculates the
appropriate pressure to attain the required web
force based on the roll size. The indicator then
changes to read the actual air pressure (in psi) sent
to the clutch/brake. If the machine is in Manual
Tension mode, the indicator reads the actual air
pressure (in psi) sent to the clutch/brake.
12. LOWER FRONT BRAKE PRESSURE -
Adjusts the brake pressure up or down.
13. LOWER FRONT BRAKE INDICATOR - Indi-
cates that this set of controls is for the lower front
brake.
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
5. SPEED/ACCUMULATOR DISPLAY - Dis-
plays either the accumulator or speed, depending
on which you have selected with the SPEED/
ACCUMULATOR TOGGLE. A letter in the dis-
play before the speed readout indicates the mode of
Pull Roll Torque
ON/OFF
7
8
psi
100
90
80
70
60
50
40
30
20
10
psi
100
90
80
70
60
50
40
30
20
10
kPa
700
630
560
490
420
350
280
210
140
70
kPa
700
630
560
490
420
350
280
210
140
70
Roll Pull Force
Adjustment/Display
1
Pull Roll
Pressure
Display
operation:
H - Manual mode with the preheater off.
P - Automatic mode with the preheater on.
L - Manual mode with the preheater on.
No letter - Automatic mode with the preheater off.
The following codes alert you to machine status:
.0 - The machine is reset and ready to be started.
8888 - Main power has just been turned on and the
main reset has not yet been pressed.
In addition to these codes, if an emergency stop
button or kick cable is activated, the decimal point
will no longer be displayed (for example, 3.0 would
change to 3 0). Simply resetting the emergency stop
button or kick cable does not change the display.
You must also press the main machine reset button
for display to read .0 indicating the machine is
ready to be started. Note that you must reset the
emergency stop button or kick cable before press-
ing the main machine reset or the machine will not
be reset.
Pull Roll
Main Roll
UP/DOWN
9
2
3
UP/DOWN
10
Pull Roll
Pressure
Adjustment
Pull Roll Torque
Adjustment
11
Cooling Fan
ON/OFF
4
5
PRO-TECH
GBC Logo
Automatic/Manual
Mode Control
12
13
Accumulator
Reset
Speed/
Accumulator
Toggle
0 0 0 0
Speed/
Accumulator
Display
1 2 3 4
14
6
Motion Control
FORWARD/
STOP/REVERSE
Speed
Adjustment
Figure 3-7: Rear Control Panel
1. PULL ROLL PRESSURE DISPLAY - Displays
the air pressure pushing the upper pull roll down.
2. MAIN ROLL UP/DOWN - Sets the upper main
roll to the up (load) or down (operate) position.
3. PULL ROLL PRESSURE CONTROL - Varies
the air pressure fed to the cylinders that drive the
upper pull roll down.
6. SPEED ADJUSTMENT - Adjusts the speed of
the machine from zero to maximum as the control
is turned clockwise. Turn control knob slowly for
best results.
4. GBC LOGO AUTOMATIC/MANUAL MODE
CONTROL -Toggles between Automatic Tension
and Manual Tension mode. In Automatic Tension
mode, the system automatically adjusts the brake/
clutch pressure. In Manual Tension mode the sys-
tem doesn’t automatically adjust these pressures
(indicated by an H or L in the accumulator dis-
play). In the Automatic Tension mode with the
motor stopped, setting a web force (tension) for
either a clutch or brake loads that force into the
internal computer, which then automatically
7. PULL ROLL TORQUE ON/OFF - Allows you
to turn the pull roll clutch (torque) pressure on or
off without changing the pressure settings.
8. PULL ROLL PULL FORCE DISPLAY - Dis-
plays the air pressure of the clutch (torque or pull
force).
9. PULL ROLL UP/DOWN - Sets the pull roll to
the up (load) or down (operate) position.
10. PULL ROLL TORQUE CONTROL - Varies the
air pressure fed to the clutch that drives the lower
pull roll.
adjusts the air pressure sent to the clutch/brake to
obtain the required web tension based on the roll
size. When you enter the setting and then turn the
motor on, the indicator changes from reading the
web force to the actual pressure sent to the brake to
attain the required web force calculated for that roll
size. In Manual Tension mode the display reads
actual pressure sent to the clutch/brake. This pres-
sure stays set until you change it. The computer
will not override your setting or change the display.
11. COOLING FAN ON/OFF - Turns the cooling fan
on or off. Push once to turn only the cooling idlers
on, push again to turn only the cooling tubes on,
push a third time to turn both cooling idlers and
cooling tubes on, and push a fourth time for all
cooling off.
3-8
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
12. ACCUMULATOR RESET - Resets the accumu-
lator.
13. SPEED/ACCUMULATOR TOGGLE - Toggles
control between the speed and the accumulator.
14. MOTION CONTROL FORWARD/STOP/
REVERSE - Controls the direction of the drive
system, forward, reverse, or stop.
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
appropriate pressure to attain the required web
force based on the roll size. The indicator then
changes to read the actual air pressure (in psi) sent
to the clutch/brake. If the machine is in Manual
Tension mode, the indicator reads the actual air
pressure (in psi) sent to the clutch/brake. Note that
this clutch (laminate paper rewind) only operates
when the pull roll is down.
%
100
90
80
70
60
50
40
30
20
10
2
3
1
4
Upper Rear Brake
Upper Rear Brake
Pressure
Percent Web Force
Upper Rear Brake
Indicator
%
100
90
80
70
60
50
40
30
20
10
5
6
Middle Rear Clutch
Pressure
Middle Rear Clutch
Percent Web Force
Middle Rear
Clutch Indicator
%
100
90
80
70
60
50
40
30
20
10
5. MIDDLE REAR CLUTCH PRESSURE -
8
9
7
Lower Rear Clutch
Pressure
Lower Rear Clutch
Percent Web Force
Adjusts the clutch pressure up or down.
Lower Rear Clutch
Indicator
6. MIDDLE REAR CLUTCH INDICATOR - Indi-
cates that this set of controls is for the middle rear
clutch.
10
Unwind/Rewind
Shaft Locking
System ON/OFF
PRO-TECH
7. LOWER REAR CLUTCH PERCENT WEB
FORCE - Indicates the web force (tension) for this
clutch as a percentage of the total possible tension
the clutch can exert. What the pressure indicator
displays changes depending upon whether the
motor is on or off and what mode you are operating
the machine under. With the motor direction
arrows off and the machine in Automatic Tension
mode, the indicator displays the material web ten-
sion you set. Once the motor arrow is pressed and
the machine starts, the computer calculates the
appropriate pressure to attain the required web
force based on the roll size. The indicator then
changes to read the actual air pressure (in psi) sent
to the clutch/brake. If the machine is in Manual
Tension mode, the indicator reads the actual air
pressure (in psi) sent to the clutch/brake.
Figure 3-8: Rear Brake Panel
1. UPPER REAR BRAKE PERCENT WEB
FORCE - Indicates the web force (tension) for this
brake as a percentage of the total possible tension
the brake can exert. What the pressure indicator
displays changes depending upon whether the
motor is on or off and what mode you are operating
the machine under. With the motor direction
arrows off and the machine in Automatic Tension
mode, the indicator displays the material web ten-
sion you set. Once the motor arrow is pressed and
the machine starts, the computer calculates the
appropriate pressure to attain the required web
force based on the roll size. The indicator then
changes to read the actual air pressure (in psi) sent
to the clutch/brake. If the machine is in Manual
Tension mode, the indicator reads the actual air
pressure (in psi) sent to the clutch/brake.
8. LOWER REAR CLUTCH PRESSURE -
Adjusts the clutch pressure up or down.
2. UPPER REAR BRAKE PRESSURE - Adjusts
9. LOWER REAR CLUTCH INDICATOR - Indi-
cates that this set of controls is for the lower rear
clutch.
the brake pressure up or down.
3. UPPER REAR BRAKE INDICATOR - Indicates
that this set of controls is for the upper rear brake.
10. UNWIND/REWIND SHAFT LOCKING SYS-
TEM ON/OFF - Engages/disengages the unwind/
rewind shaft locking system. The switch disen-
gages the locking system with the door either open
or closed with one motor off. The doors must be
shut to engage the system. If the doors are shut and
the unwind/rewind shafts are disengaged, pushing
the motion control engages them automatically.
Note the color coding on each shaft and the shaft
loading tray. Unwinds are marked with blue and
rewinds are marked with red. Always use the cor-
rect shaft in each loading position.
4. MIDDLE REAR CLUTCH PERCENT WEB
FORCE -Indicates the web force (tension) for this
clutch as a percentage of the total possible tension
the clutch can exert. What the pressure indicator
displays changes depending upon whether the
motor is on or off and what mode you are operating
the machine under. With the motor direction
arrows off and the machine in Automatic Tension
mode, the indicator displays the material web ten-
sion you set. Once the motor arrow is pressed and
the machine starts, the computer calculates the
3-10
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
6HWXS
+HDWLQJ
Setup of the ORCA-IV Image Transfer Laminator is
quick and straightforward when instructions are fol-
lowed exactly.
Use the following instructions when heating the upper
main roll.
1. Set the heater switch to ON.
2. Adjust the temperature controller for the desired
operating temperature using the temperature con-
troller set point adjustment. To adjust the set point,
hold the star button down and press the up or down
arrow on the temperature controller.
/RDGLQJꢁWKHꢁ)LOP
IMPORTANT
Use a lift to load and unload rolls larger than 50
yards. They can weigh up to 500 lbs and can
crush you.
3. Allow the roll to come to temperature. After the
roll has come up to set temperature, let the rolls run
together for 5 minutes to produce even heat or you
can also simply start the process a little slower and
bring it up to speed as the roll reaches prime oper-
ating temperature.
Film is loaded on the appropriate unwinds indicated by
color coding. Blue shafts and loading trays indicate
unwinds, red shafts and loading trays indicate rewinds.
The process of loading and aligning film is the same
for both the top and the bottom unwinds/rewinds.
4. The temperature controller has an LED (light emit-
ting diode) readouts to indicate the status of the
heating system.
1. Be sure that rewind (clutch) shafts are in rewind
positions (loading trays) and unwind (brake) shafts
are in unwind positions so that the core gripping
mechanism engages properly.
5. It will take approximately 45 minutes for the upper
main roll to reach operating temperature. When the
preset operating temperature has been reached, the
machine is ready to use.
2. Slide the shaft over until the drive tang fits in the
slot before engaging the unwind/rewind shaft lock-
ing system.
3. Loosen the lock collar with a 1/4" hex wrench and
center the material before webbing the machine.
The film must be centered on the unwind for best
performance. This is vital when two films are fed
together. If the two films are not aligned, feed
problems, wrinkles and other assorted troubles will
occur. See Table 3-2 for centering and alignment
information.
IMPORTANT
Carefully align the two films being fed into the
nip. If not, you will obtain poor results.
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
5HFRPPHQGHGꢁ0DWHULDOV
6HWWLQJꢁWKHꢁ6OLWWHU
1. Turn the thumbscrew on the slitter counterclock-
wise until it stops.
The ORCA IV image transfer laminator is capable of
processing a wide range of pressure sensitive and ther-
mal laminates onto an equally wide range of image
materials. The primary considerations are:
•
Laminate adhesives are compatible with image
materials.
•
The materials properly activate below the maxi-
mum roll temperature and within the speed and roll
nip pressure ranges available on the laminator.
Figure 3-9: Slitter
It is the operator’s responsibility to ensure the compati-
bility and operational settings for any laminates/image
material combination. GBC Pro-Tech Technical Sup-
port is available at the number provided in the Mainte-
nance chapter for advice on some material
combinations.
2. Turn the thumbscrew one turn clockwise.
3. Set the slitter blade against the plastic covered
black roll.
4. Engage the slitter against the tube by allowing the
slitter to just touch the tube and then pressing it
1/16" further.
☞ Note:
This machine is designed to do transfer using complete
systems provided by companies such as GBC Pro-
Tech, 3M, or Rexam. This system includes the paper,
inks, vinyl and overlaminate films specifically matched
to offer excellent performance. Some vinyl materials
offered by other companies will emit chemicals that
will cause permanent damage to the rolls.
Setting the slitter to tight shortens the life of the blade
and the plastic tube.
5. Pull the material through the machine to test the
slitter. Adjust the thumbscrew to obtain the
required results.
3DSHUꢁ7LSV
•
•
•
•
Always cut the leading edge of a print straight so it
can be fed perpendicular to the rolls.
IMPORTANT
The paper must be trimmed to match the width of
the vinyl.
Substituting materials can cause severe damage
to your machine and is not recommended or
covered under our warranty.
The paper will wrinkle if it extends more than 1/2"
beyond the vinyl edge.
The trim can be neatly collected by threading it
behind the imaged transfer media roll and taping it
to the used transfer media core just to the outside of
the trimmed transfer media. The diameter of the
collected trim must be kept the same as the diame-
ter of the winding transfer media to obtain a good
quality windup.
It is the operator’s responsibility to ensure compatibil-
ity and operational settings for the transfer process.
Consult your transfer system supplier to ensure the cor-
rect combinations of materials are being used.
•
When trimming the final product, the trim can be
wound on the same core just outside of the edge of
the roll.
3-12
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
10. Load and web the overlaminate as indicated in the
drawing. The operator has the option of lowering
the pull roll now or waiting for the image to come
through.
3RVLWLRQLQJꢁWKHꢁ)LOPꢁDQGꢁ&HQWHULQJꢁ
WKHꢁ:HE
Tools required:
1
•
•
/ " T-handle wrench
11. Check the web force for all the unwinds and
rewinds and adjust as necessary.
4
Tape measure
12. Lower the main roll and start the motor. Start out at
a low speed (2-3 ft/min (.6-.9 m/min)) and then
increase the speed as needed after confirming that
everything is working well.
To load film:
1. Retract the shaft locking plungers and remove the
shafts.
2. Slide the shaft into the new roll of material until the
end plate is tight to the end of the material. Always
leave the end plate on the drive side locked down.
This insures that the material alignment will be the
same from roll to roll. See the material size chart to
determine what end plate setting to use for differ-
ent width materials.
13. Check for looseness at either edge of the paper just
before it enters the nip. If a loose edge is detected,
increase the brake 2-5 psi and, if the image is not
yet into the nip, “pop” the roll up and back down
quickly to help pull the web straight.
☞ Note:
Initial looseness on the edge is common, It is caused by
one of several things:
3. Make sure the end plates are tight to the edge of the
material. If the core protrudes out more than 1/8",
it will be necessary to use a plastic spacer to fill the
gap. (Provided in the accessory pack.)
•
No tension on the initial web before the roll comes
down.
4. Place the roll of material on the machine. Be sure
to line up with the drive tang and slide the shaft
over to engage it into the drive tang. Make sure the
shafts are slid over and engaged. This is critical to
prevent the material from shifting after the
machine is webbed.
•
•
Not webbed through perfectly straight.
Web expansion from the heat as that stays in the
nip area as the machine is webbed.
•
The roll does not come down evenly.
14. Close the doors and increase the speed as required.
5. Repeat steps 1 through 4 for the unwinds and
rewinds.
15. Observe the machine as it runs the material. Pay
close attention to the web. Look for loose webs or
spliced rolls and check the image quality.
6. When all the material is loaded on the unwinds and
all the empty cores are loaded on the rewinds, close
the doors and lock in the shafts.
IMPORTANT
7. Open the doors and verify that the paper edge
matches the edge of the vinyl by measuring from
the side plate to the edge of the rolls. If the paper or
vinyl do not match up, loosen the end plates and
adjust the material so they are exactly in line.
When the process is complete, stop the machine
and raise the roll. Do not let either paper or vinyl
run through the nip alone. The vinyl could stick
to the roll and the transfer paper would transfer
to the bottom roll resulting in a large clean up
job.
8. Web the vinyl as shown in the diagram and secure
it to the finished product rewind. For best results,
align one edge of the rewind core to match the
material edge measurement on the unwind.
9. Web the transfer paper and tape it to the front
rewind as shown in the diagram. If the paper is
wider than the vinyl, it will be necessary to use the
slitters to cut the paper down to match the width of
the vinyl. See “Setting the Slitter” on page 3-12.
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
To advance the vinyl without the paper:
)LOPꢁ6SDFLQJ
Release all the tension on the transfer media web. Start
the vinyl web. If the paper is not stuck to the vinyl,
only the vinyl web will advance.
Table 3-2: Film Spacing
DistanceFrom DistanceFrom
End of Shaft
to Material
Side Plate
Machine Side
to Material
Side Plate
Film Size
The recommended way to change over to new material
is to splice the new material to the old and let the old
material web pull the new material through the
machine.
54"
(137.16 cm)
7-15/16"
(20.16 cm)
7-1/2"
(19.05 cm)
To splice vinyl:
When splicing the vinyl, stop the machine before the
roll is totally used up.
49"
(124.46 cm)
10-7/16"
(26.51 cm)
10"
(25.40 cm)
1. Load a new roll of vinyl on the unwind shaft and
place it on the machine. Engage the shaft into the
drive tang.
48"
(121.92 cm)
10-15/16"
(27.78 cm)
10-1/2"
(26.67 cm)
2. The old material should be left long enough to lay
over the new roll. This provides a straight, firm
surface to splice onto.
☞ Note
Always set the drive side and keep it set as the base.
When changing film, remove the end plate on the con-
trol side of the shaft. The new roll should then be
pushed tight up to the plate on the drive side and the
shaft should be slid over and engaged in the drive.
3. Tape the new material to the old with a high quality
1-1/2" to 2" masking or vinyl tape. Make sure the
materials are straight before applying the tape so
that one side is not looser than the other.
4. Start the tape in the center and work outward.
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5. Lower the brake tension until the splice has cleared
the main roll.
Suggested leaders:
•
•
For vinyl: 65" (165.1 cm)
For paper: 75" (190.5 cm)
☞ Note
On machines without the preheater option it is possible
to splice the two materials together using the bottom
main roll as the firm, straight taping surface.
To advance the paper without the vinyl:
You may want to advance the paper without the vinyl
for several reasons:
To splice paper:
Splicing paper is also the recommended way to change
over to new material. The key to a successful splice is
to leave enough of the old paper to be able to wrap it on
the new roll and tape it on a square, firm surface.
•
At the beginning of a new roll to clear the splice
and reduce leader waste.
•
To get past a large white spot, a known extra, or a
bad image on a roll of images.
1. Load the new roll of transfer paper on the machine.
The key to advancing the paper without the vinyl is to
raise the main roll but let the material continue to run
through until the paper that is not stuck to the vinyl
clears the paper peal idler. Then, put the machine in
reverse briefly to release tension on the paper peal
idler, or release the pull roll clutch and turn it back by
hand. Lower the paper unwind and rewind tension and
hand turn the paper roll so that the paper is advanced
without the vinyl advancing.
2. Pull the old paper around the roll of images and
tension and smooth out evenly.
3. Overlap the old paper with the new paper and tape
securely. It is very important to have the new mate-
rial over the old so that, when the paper is peeled
off later, the new paper is lifted along with it and
does not pull the tape off.
3-14
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
4. Tape starting in the center and move to the sides.
The tighter and smoother the tape job, the less web
looseness that will have to be tensioned out later.
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Process control charts allow you to record the way you
thread film through the machine's rolls and idlers
(called webbing) and the control settings for each prod-
uct and process. Process control charts are an excellent
tool for training new operators. They provide a "road
map" for correct machine setup and operation.
5. Decrease the brake tension until the splice passes
through the nip. If slitters are being used, be sure
that they have cut through the two layers of paper
and the tape at the splice. It is best to run slow as
the splice passes through the slitters and finish the
cut, if necessary.
This section contains a completed chart for the basic
operation of the image transfer laminator.
GBC Pro-Tech image transfer laminators respond in a
very accurate and repeatable manner. The chart pro-
vides a way to set up each time, every time for repeat-
able performance by assuring that all controls are set to
optimum.
Tape
New
Paper
The process control chart should be kept in this manual
or in a book close to the image transfer laminator.
☞ NOTE
When trying new products and processes, remember
that GBC Pro-Tech's customer service representatives
are only a phone call away. In North America, call
1-608-246-8844 or fax 1-608-246-8645.
9LQ\Oꢁ7UDQVIHUꢁ
1. See process chart 3-1 and diagram 3-1a on page
3-17.
Figure 3-10: Splicing Paper
2. Set the controls as follows:
•
•
•
•
•
•
•
Main Roll Air Pressure: 100 psi (689 kPa).
Pull Roll Clutch Air Pressure: 35 psi (241 kPa).
Pull Roll Up/Down: Down
Pull Roll Air Pressure: 80 psi (552 kPa).
Speed Adjust: 1-10 fpm (.3-3.0 m/min).
Upper Heater Controller: 290 °F (143 °C).
Cooling: Idlers on, cooling tubes as needed
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
1. See process chart 3-1 and diagram 3-1a for mate-
rial mounting instructions and machine adjust-
ments.
2. Web the vinyl up around the bottom main roll and
over to the pull roll. Make sure the material is
webbed straight and lower the pull roll to hold the
vinyl.
3. Web the paper through as shown in diagram 3-1a.
Often, when paper is not on a core, hand tension must
be applied to the paper in order to maintain transfer
quality until the end of the transferred image.
0DFKLQHꢁ6KXWGRZQ
It is very important that the ORCA-IV Image Transfer
Laminator is shut down in proper manner. If not, the
rolls can be damaged or destroyed.
IMPORTANT
Failure to follow this procedure can result in
damage to the rolls.
1. Raise the upper main roll and upper pull roll so that
the rolls do not make contact with the bottom rolls.
2. Turn off the main power to the machine.
3. Disconnect the air supply to the machine if the
machine is not to be used for the next several days.
IMPORTANT
The main and pull rolls must always be in the up
position when the machine is not in use.
3-16
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ORCA-IV Image Transfer Laminator Operation Manual
Operation
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WEB FORCE SUGGESTED VALUES
Main Product Rewind (Finished Graphic)
Marking Film (Vinyl) Like 3M (8620, 8640, etc.)
Used Transfer Media (Rewind)
20 WF
20 WF
20WF
Transfer Media, 3M 8601i
15 WF
50 WF
30 WF
Overlaminate Unwind
Strip Release Liner (Laminate)
IMAGE TRANSFER LAMINATOR SETTINGS
Top Heater Status
290 °F (143 °C)
Pull Roll Position
Up or Down (optional unless
applying laminate)
Speed
1-10 fpm (.3-3.0 m/min) max
Forward
Main Roll Setting
Output Cooling
100 psi (689 kPa)
Drive Direction
Drive Mode
Idlers On, Cooling Tubes Optional
Automatic or Manual
352&(66ꢁ&21752/ꢁ',$*5$0ꢁꢆꢀꢂ$
Used
Transfer
Media
Optional
Paper Trim
Rewind
Over-
laminate
Imaged
Transfer
Media
Strip
Release
Liner
Cooling
Tube
Hot Roll
Paper
Peal
Idler
Chill
Idler
Cooling
Tube
Chill
Idler
Marking
Film
Finished
Graphic
Front/Input
Notes
__________________________________________________________________________________________
__________________________________________________________________________________________
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Operation
ORCA-IV Image Transfer Laminator Operation Manual
Blank page.
3-18
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ORCA-IV Image Transfer Laminator Operation Manual
Maintenance and Troubleshooting
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Tools required:
Performing regular maintenance on the ORCA-IV
Image Transfer Laminator is critical to the proper oper-
ation of the machine. A maintenance schedule and a
section of procedures for disassembling and reassem-
bling the serviceable areas of the image transfer lami-
nator are included in this section.
•
•
•
•
80% isopropyl alcohol (or dishwashing detergent)
Rubber cement eraser
Several lint free paper or 100% cotton terry cloths
Protective cotton gloves
Table 4-3: Maintenance Schedule
To clean the image transfer laminator rolls:
•
•
Clean the rolls and machine
1. Open the machine doors and gain access to the
rolls.
Daily
Inspect the area around the image
transfer laminator for possible haz-
ards (dust buildup, combustible
items stored too close, etc.)
IMPORTANT
Monthly
Exercise extreme caution while cleaning the
image transfer laminator. You can be caught in
the turning rolls and crushed or burned.
•
Lubricate core end plate bolts
•
•
Inspect the roll lift mechanism
Check the chain tension and lubri-
cate with heavy motor or gear oil.
2. While the image transfer laminator is at normal
operating temperature, put on cotton gloves and,
using a rubber cement eraser, remove any heat acti-
vated adhesive from the rolls.
•
Lubricate the grease fittings and
chain
EverySix
Months
•
•
Lubricate slitter collar bolts
Lubricate the roll lift mechanism
Check wire termination tightness
•
•
IMPORTANT
Disassemble the roll lift mechanism
and lubricate with lithium grease
Yearly
If silicone adhesive contacts the upper or lower
roll, remove it IMMEDIATELY using a rubber
cement eraser. It can harden within an hour and
ruin the roll.
IMPORTANT
Do NOT pick or pull heat activated adhesive off
the rolls when they are cold. You can cause
irreparable damage to the laminating rolls.
IMPORTANT
Do not use compressed air to clean the machine.
Blowing debris can be forced into places where it
will later ignite or short electric circuits.
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Maintenance and Troubleshooting
ORCA-IV Image Transfer Laminator Operation Manual
To clean beads of adhesive, dust and dirt from the
rolls:
To clean the cabinet and covers:
1. Using a damp cotton terry cloth (water only), clean
the exterior of the image transfer laminator.
1. Allow the image transfer laminator to cool slightly
to no higher than 110ºF (43ºC).
2. Set the FWD/REV switch to the REV position and
let the rolls move slowly as you clean them. Set the
Speed Control to 1.5 ft/min.
WARNING
Do not use liquid or aerosol cleaners on the image
transfer laminator. Do not spill liquid of any kind
on the image transfer laminator. You can be
severely shocked, electrocuted or cause a fire. Use
only a damp cloth for cleaning.
3. Clean the rolls using a moderate amount of 80%
isopropyl alcohol on a cotton terry cloth.
IMPORTANT
To clean the doors:
Use the minimum amount of pressure necessary
to clean the rolls. You can destroy the silicone
layer on the rolls by pressing to hard or
scrubbing too long in one spot.
1. Using a cotton terry cloth, wash the doors using a
mild soap or detergent and lukewarm water.
IMPORTANT
IMPORTANT
Do not scrub or use brushes or squeegees to clean
the doors. You can scratch the surface.
Exercise care when cleaning the rolls with 80%
isopropyl alcohol:
2. Rinse thoroughly to prevent water spotting.
3. To remove grease, rub lightly with isopropyl alco-
hol, then wash and rinse.
• Use only in a well ventilated area.
• Wear rubber gloves.
• Use only on cool rolls.
Compatible Cleaning Agents:
•
Fantastik1
Cleaning heated rolls can ignite the fumes.
•
•
Formula 4091
Hexcel, F.O. 554
Joy2
Lysol3
Mr. Clean2
•
•
IMPORTANT
Use only 80% isopropyl alcohol or a rubber
cement eraser to clean the laminating rolls.
Harsh chemicals like toluene, acetone or MEK
destroy the silicone covering of the rolls.
•
•
Neleco-Placer
•
•
PineSol4
Top Job2
•
1
Windex5
Registered Trademark of the Clorox Company.
Registered Trademarks of Procter & Gamble.
Registered Trademark of Sterling Drugs.
Registered Trademark of American Cyanamid.
Registered Trademark of the Drackett Products Company.
2
3
4
5
4-2
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ORCA-IV Image Transfer Laminator Operation Manual
Maintenance and Troubleshooting
/XEULFDWLRQ
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Occasionally, the kick cable needs adjustment to prop-
erly reset after use.
Tools required:
1
•
/ " hex wrench
8
Tools required:
•
•
•
•
High temperature grease or lithium grease
Grease gun
•
Phillips head screwdriver
To adjust the kick cable:
Heavy weight gear oil
Soft cloth
1. Remove the kick cable cover by unscrewing the
four screws and lifting the cover off.
2. Check the alignment of the internal mechanism. It
should seat squarely against the metal pin.
To lubricate the image transfer laminator:
IMPORTANT
Do not lubricate the image transfer laminator
when it is hot. You can be burned.
IMPORTANT
Figure 4-11: Kick Cable Incorrectly Set -
Mechanism Is Not Square
Unplug the image transfer laminator and lockout
power while you are performing this procedure.
You could be severely shocked, electrocuted, or
get your fingers caught in the drive mechanisms.
Mechanism correctly
seated against metal pin.
1
1. Remove the drive side cabinet cover using the / "
8
hex wrench by removing the screws holding the
cover in place.
2. Using the grease gun, lubricate each grease fitting
(shown in Figure 4-1) with one squirt of high tem-
perature grease.
3. Grease the main roll lift pins with high temperature
grease (also shown in Figure 4-1).
Figure 4-12: Kick Cable Tripped - Mechanism
Correctly Seated
4. Using heavy weight gear oil, lubricate the lift
mechanism. On a yearly basis, disassemble and
grease all the levers and pins on the lift mecha-
nism.
3. The bolts that hold the switch to the bracket are
slotted and can be used to fine tune the switch
adjustment. Loosen the bolts, tighten them until
snug, make the necessary adjustments, then lock
them down securely.
5. Lubricate the chain using a soft cloth and gear oil.
6. Replace the cabinet covers and reconnect power to
the image transfer laminator.
Note
☞
Disassembly of the laminator should be performed by a
qualified service technician.
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Maintenance and Troubleshooting
ORCA-IV Image Transfer Laminator Operation Manual
&RQWDFWLQJꢁ7HFKQLFDOꢁ6XSSRUW
For machine parts and technical service in North
America, please call: 1-608-246-8844 or fax 1-608-
246-8645. Please provide serial number when call-
ing for service. In Europe, please call: +44 (0) 1844
202 440 or fax: +44 (0) 1844 202 441.
For film and application questions in North America,
please call 1-608-246-8844 or fax 1-608-246-8645. In
Europe, please call: +44 (0) 1844 202 440 or fax: +44
(0) 1844 202 441.
4-4
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ORCA-IV Image Transfer Laminator Operation Manual
Maintenance and Troubleshooting
Grease Fitting
Grease Fitting
Grease Fitting
Keep Pins (3) Well Oiled (Monthly)
Disassemble and Grease (Yearly)
Lubricate Slides with
Grease
Pull Roll -
Grease Both
Sides, Bottom
Roll
Grease Main
Roll Bearings -
Both Sides,
Top and
Grease Fitting
Bottom Rolls
Grease Fitting
Figure 4-1: Grease Fittings
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Maintenance and Troubleshooting
ORCA-IV Image Transfer Laminator Operation Manual
2XWSXWꢁ7URXEOHVKRRWLQJꢁ*XLGH
Problem:
Problem:
Problem:
D waves in the image, not in the D waves in the laminate.
Straight waves in the output.
laminate.
Hints:
Hints:
Hints:
• Increase brake tension
on laminate.
• Decrease clutch tension.
• Check operational settings for
materials being used.
• Check paper tension.
• Check relative moisture
content of the paper.
• Check roll pressures.
• Check nip settings.
Other Common Problems:
Feed
Direction
Problem:
Blistering in the image.
Hints:
• Increase speed or lower the operating
temperature.
Problem:
Coiling of encapsulated images.
Hints:
• Balance the upper and lower unwind brake
tension. Adjust cooling fans.
Problem:
Longitudinal waves or stuttering, jerking, or
excessive noise from the drive side of the
laminator.
Problem:
Waves on only one side of the
output.
Hints:
Hints:
• Increase chain tension, decrease unwind
brake tension.
• Check nip settings.
• Check for even paper tension.
• Check for proper alignment on
initial setup.
4-6
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ORCA-IV Image Transfer Laminator Operation Manual
Maintenance and Troubleshooting
Table 4-4: Machine Troubleshooting Guide
Problem
Number
Problem
Possible Cause
Corrective Action
a. Is there power to the unit?
a. Check for power to the machine
(building circuit breaker is on,
main switch is on (|), and the
machine circuit breaker is on
(up)).
1
No display.
a. Is the machine reset?
a. Make sure all safety buttons are
released (out). Be sure all kick
cables are reset and adjusted
properly. Press the machine reset
(above main switch). See
"Machine Reset Procedure" on
page 3-3.
2
Display reads 8888.
a. Is the direction indicator (FWD/
REV) pressed?
b. Is the speed not turned up?
a. Press FWD or REV.
b. Turn up the speed control.
3
4
Display reads .0 and the
machine does not run.
a. Is there a kick cable or safety but- a. Make sure all safety buttons are
Display missing the decimal
point (e.g. -reads 30 instead
of 3.0)
ton that has not been reset?
released (out). Be sure all kick
cables are reset and adjusted
properly. Press the machine reset
(above main switch). See
"Machine Reset Procedure" on
page 3-3.
a. Is the kick cable stretched out of
adjustment?
a. Verify that the kick cable is truly
resetting (listen, look). Adjust the
kick cable. See “Adjusting the
Kick Cable” on page 4-3.
5
6
Display missing the decimal
point (e.g. -reads 30 instead
of 3.0) but the kick cables
and safety buttons have been
checked and the reset button
has been pushed.
a. Is the tension too low?
b. Does the roll lower unevenly?
c. Was there a misalignment on set
up?
d. Is there a bad roll of material?
e. Is the web loose only when first
starting or splicing?
a. Increase appropriate brake ten-
sion.
Waiver on one side of paper/
vinyl.
b. Adjust cylinder flow controls.
c. Measure from the side frame to
the edge of material in front and
back to verify that the material is
webbed through straight.
f. Is there uneven nip pressure?
d. Try a different roll.
e. Raise and lower the roll (pop up
and down) to pull the initial loose
web straight and tight.
f. Call Technical Support to disas-
semble and lubricate the cylinder
lift linkage (qualified service
technician required).
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Maintenance and Troubleshooting
ORCA-IV Image Transfer Laminator Operation Manual
Problem
Problem
Number
Possible Cause
Corrective Action
a. Was the initial material webbing
straight?
b. Is the roll telescoped?
c. Is there excessive tension?
a. Measure carefully from sideframe
and straighten webbing.
b. Use end plates on all unwinds.
c. Lower the tension.
7
8
Rewound material not even
on edge.
d. Is it a poor roll of film (soft end)? d. Try a new roll.
a. Has the slitter idler increased in
diameter at the point of contact
with the blades?
a. Sand and/or file down the higher
Plastic slitter tube has devel-
oped a larger diameter where
the round knives cut causing
paper stress lines and paper
tearing at peal idler.
spots in the plastic tube.
b. Replace the slitter tube (note: use
as little pressure on the slitter as
possible to increase the life of the
slitter tube).
a. Is the rewind engaged in the
drive?
b. Is there air pressure?
a. Line up the drive tang and side
shafts over to the drive side to
engage them.
9
Rewind is not turning
b. Check for appropriate main air
supply or increase the air pressure
to the rewind.
a. Is the pull roll up?
a. Lower the pull roll. The laminate
paper rewind will not turn and the
pressure will not increase until
the pull roll is down.
b. Stop the motor to allow the web
force to be set.
10
11
Laminate paper rewind will
not turn and/or you cannot
set the pressure.
a. Is the IR sensor blocked?
b. Is the IR sensor misaligned?
c. Is there cool air blowing on the
roll?
a. Be sure nothing ever blocks the
path of the IR sensor.
b. Align the sensor.
c. Direct the cool air away from the
roll surface.
Roll is overheating.
d. Is there an electrical problem?
d. Call Technical Support.
4-8
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ORCA-IV Image Transfer Laminator Operation Manual
Maintenance and Troubleshooting
Problem
Number
Problem
Possible Cause
Corrective Action
a. Has a speed setting been set?
b. Are the doors closed and shafts
locked in?
c. Are the e-stop buttons pressed?
Are the kick cables reset?
d. Is there decimal on display?
e. Check motor fuses on the back of
machine.
a. Press the FWD or REV arrow and
12
I pressed the motor forward
button, but the rolls would
not turn!
turn the speed control up.
b. Close the doors and lock in the
unwind/rewind shafts.
c. Make sure all safety buttons are
released (out). Be sure all kick
cables are reset and adjusted
properly. Press the machine reset
(above main switch). See
"Machine Reset Procedure" on
page 3-3. Verify that the kick
cable is truly resetting (listen,
look). Adjust the kick cable. See
“Adjusting the Kick Cable” on
page 3-3.
d. Press the machine reset (above
main switch). See "Machine
Reset Procedure" on page 3-3.
e. Remove fuses and replace, if nec-
essary. Be sure to replace with the
correct size fuses: two 6A fuses
for the motor and one 1A fuse for
the power supply.
a. see problem 12
a. See problem 12.
13
14
I pressed the motor reverse
button, but the rolls would
not turn!
a. Is there air pressure to the
machine?
b. Is there at least 20 psi on the
gauge?
a. Verify that the air supply is suffi-
cient (≤100 psi).
I pressed the main roll down
push button, but the roll did
not go down!
b. Turn up regulator for main roll
pressure.
c. Are the e-stop push buttons
pressed and the kick cables reset?
d. Is the machine reset?
c. See problem 12.
d. See problem 12.
e. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
a. Is there air pressure to the
machine?
b. Is the machine reset?
a. Verify that the air supply is suffi-
cient (≤100 psi).
15
16
I pressed the main roll up
push button, but the rolls did
not go up!
b. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
a. Is there air pressure to the
machine?
b. Is there at least 20 psi on the
gauge?
c. Is the roll hook retracted?
d. Are the e-stop push buttons
pressed and the kick cables reset?
e. Is the machine reset?
a. Verify that the air supply is suffi-
cient (≤100 psi).
I pressed the pull roll down
push button, but the rolls did
not go down!
b. Increase the pull roll air pressure.
c. Disconnect and reconnect air
pressure to the machine and
observe pull roll locking mecha-
nism.
d. See problem 12.
e. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
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Maintenance and Troubleshooting
ORCA-IV Image Transfer Laminator Operation Manual
Problem
Problem
Number
Possible Cause
Corrective Action
a. Is there air pressure to the
machine?
b. Is the machine reset?
a. Verify that the air supply is suffi-
cient (≤100 psi).
17
I pressed the pull roll up
push button, but the rolls did
not go up!
b. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
a. Are the e-stop push buttons
a. See problem 12.
18
I pressed the top roll temper-
ature control “ON” push but-
ton and nothing happens.
pressed and the kick cables reset? b. Reset the machine. See "Machine
b. Is the machine reset? Reset Procedure" on page 3-3.
c. Is there a decimal point in the dis- c. Reset the machine. See "Machine
play?
Reset Procedure" on page 3-3.
a. Is the machine reset?
a. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
19
20
The display shows unusual
numbers or characters.
a. This is normal. This shows that
you are in PREHEAT AUTO
mode.
a. If you press the preheat button
again, it will go off.
I press the preheater push
button and a “P” is displayed
on the control panel.
a. Is the cooling fan toggle switch
set correctly?
a. The cooling fan push button is a
4-way toggle switch, keep push-
ing the button until the fan goes
off. From the off position, press
once to turn only the cooling idler
on, press twice to turn the cooling
tubes only on, press a third time
to turn on both the cooling idler
and the cooling tubes, and press a
fourth time to turn the cooling
systems off.
21
I pressed the cooling fan
push button and the fan did
not turn off.
a. Are the e-stop push buttons
pressed and the kick cables reset? b. Reset the machine. See "Machine
b. Is the machine reset? Reset Procedure" on page 3-3.
a. See problem 12.
22
23
I pressed the cooling fan
push button and the fan did
not turn ON.
a. Is the proximity switch that reads a. Make adjustment and try again.
I pushed the totalizer push
button, the display changed
to read 4 characters, but the
value does not increase.
the motor sensor teeth adjusted
properly?
b. Does the input light “X1” come
on when the proximity switch
comes on?
b. If the input light comes on, go to
problem 48.
a. Is the machine reset?
a. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
24
I pressed the totalizer-reset
push button while in total-
izer mode, and it did not
reset and other buttons on
the panel do not work either.
4-10
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ORCA-IV Image Transfer Laminator Operation Manual
Maintenance and Troubleshooting
Problem
Number
Problem
Possible Cause
Corrective Action
a. Is the machine reset?
b. Is there a problem with the key-
pad?
a. Reset the machine. See "Machine
25
I pressed the totalizer-reset
push button while in total-
izer mode, and it did not
reset and other buttons on
the panel do not work either,
but the controls on the other
panel work.
Reset Procedure" on page 3-3.
b. Check/tighten the connector to
the keypad.
c. Is there a software problem?
c. Call Technical Support.
a. Has the display panel been cali-
brated?
b. Is the pressure transducer faulty?
a. Call Technical Support.
b. Call Technical Support.
26
My air supply is 100 psi, but
my control panel reads less
than 100 psi.
a. This is a normal safety function.
a. No corrective action necessary.
27
28
When I operate the machine
in reverse, an alarm goes off.
a. Main rolls are down, and the rolls a. Raise the rolls or run the machine
An alarm sounds rapidly
after a 10 second delay.
are not turning.
at a slow speed to increase the life
of the rolls.
a. The main roll is in the up position a. If you’re not using the machine,
29
After 55 minutes of no activ-
ity, a 4 beep alarm sounds,
followed by a 30 second
delay
and the temperature controller is
on.
turn the temperature controller
off, or lower the roll and run the
machine at a slow speed. Failure
to do this will reduce the life of
your rolls and may cause perma-
nent damage.
a. Is there a technical problem with a. Contact Technical Support.
the alarm?
30
31
The alarm does not come on
for the conditions outlined
above.
a. Are the e-stop push buttons
a. See problem 12.
When the rolls are stopped, I
pressed the switch to adjust
the pressure to the brakes or
clutches, and nothing hap-
pened.
pressed and the kick cables reset? b. Reset the machine. See "Machine
b. Is the machine reset?
Reset Procedure" on page 3-3.
a. This may be normal. When the
machine is running the computer
takes over the settings and adjusts
the pressure to the brakes and
clutches. The change that you
attempted to make may have been
too small to see on the gauge as a
percent allowable pressure for
that size roll.
a. Push and release button (do not
hold). Try manual mode.
32
When the rolls are moving, I
pressed the switches to
adjust the pressure to the
brakes and clutches, and
nothing happens.
In automatic mode with the motor
off, set the web force. When it
starts to run, see calculated pres-
sure sent to brake for that
required web force. Even though
you do not see a large increase in
the pressure on the display, feel
the web tension manually to see if
the brake tension has changed.
a. Are the shafts locked in?
a. Close the doors and lock in the
shafts, then try the motor.
33
I pressed the motor forward
push button and the arrow
light did not come on.
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Maintenance and Troubleshooting
ORCA-IV Image Transfer Laminator Operation Manual
Problem
Problem
Number
Possible Cause
Corrective Action
a. Are the guard doors closed?
b. Is the machine reset?
c. Are the e-stop buttons pressed
and the kick cables reset?
a. Close the doors.
34
I pressed the shaft engage
push button and the shaft did
not engage.
b. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
c. See problem 12.
a. Has the machine blown a fuse?
b. Did you activate the kick cable?
a. Check fuses on the back of the
machine.
b. Reset the kick cable.
35
36
The machine was running,
but stopped abruptly.
a. Was the e-stop pressed?
b. Did you activate the kick cable?
a. Reset the e-stop and reset the
machine. See "Machine Reset
Procedure" on page 3-3.
b. Reset the kick cable and reset the
machine. See "Machine Reset
Procedure" on page 3-3.
The machine was running,
but then the rolls went up
and the machine stopped
a. Is the machine reset?
a. Reset the machine. See "Machine
Reset Procedure" on page 3-3.
37
38
Nothing seems to work.
Slitter is not cutting.
a. Is the blade adjusted properly?
b. Is the blade dull or damaged?
c. Is the bushing that mounts the
blade worn out?
a. Check blade adjustment. “Setting
the Slitter” on page 3-12
b. Replace blade.
c. Replace the bushing.
a. Is the slitter tube enlarged?
a. The plastic slitter tube can
become enlarged from many cuts
in a close area. This causes the
edge of the paper to go around a
larger diameter at the slitter sta-
tion and causes small tears in the
paper’s edges which can lead to
the paper starting to tear all the
way across at the rear idler. The
solution is to sand/file down the
frequently used raised areas on
the slitter’s plastic tube.
39
Paper rips easily at the point
it is pulled off.
4-12
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ORCA-IV Image Transfer Laminator Operation Manual
Warranty
6HFWLRQꢁꢈꢁꢃꢁ:DUUDQW\
This warranty specifically does not cover:
/LPLWHGꢁ:DUUDQW\
1. Damage to the laminating rolls caused by knives,
razor blades, other sharp objects, or failure caused
by adhesives.
GBC Pro-Tech Engineering Company, Inc. warrants
the equipment sold is free from defects in material and
workmanship for a period of one year from the date of
delivery to the customer for parts and ninety days (90)
from the date of delivery to the customer for labor.
This warranty is the only warranty made by GBC Pro-
Tech and cannot be modified or amended.
2. Damage to the machine caused by lifting, tilting,
and/or any attempt to position the machine other
than rolling on the installed casters on even sur-
faces.
3. Improper use of the machine.
GBC Pro-Tech’s sole and exclusive liability and the
customer’s sole and exclusive remedy under this
warranty shall be, at GBC Pro-Tech’s option, to
repair or replace any such defective part or prod-
uct. These remedies are only available if GBC Pro-
Tech’s examination of the product discloses to GBC
Pro-Tech’s satisfaction that such defects actually
exist and were not caused by misuse, neglect,
attempt to repair, unauthorized alteration or modi-
fication, incorrect line voltage, contaminated air
supply, or by fire, accident, flood, or other hazard.
This warranty specifically does not cover damage to
the laminating rollers caused by knives, razor blades,
other sharp objects, failure caused by adhesives or
improper use of the machine. Warranty repair or
replacement does not extend the warranty beyond the
initial period from the date of delivery.
IMPORTANT
Unauthorized customer alterations will void this
warranty.
THE WARRANTY MADE HEREIN IS IN LIEU OF
ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING ANY WARRANTY OR
MERCHANTABILITY OR FITNESS FOR A PAR-
TICULAR PURPOSE. GBC PRO-TECH WILL NOT
BE LIABLE FOR PROPERTY DAMAGE OR PER-
SONAL INJURY (UNLESS PRIMARILY CAUSED
BY ITS NEGLIGENCE), LOSS OF PROFIT OR
OTHER INCIDENTAL OR CONSEQUENTIAL
DAMAGES ARISING OUT OF THE USE OR
INABILITY TO USE THE EQUIPMENT.
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Warranty
ORCA-IV Image Transfer Laminator Operation Manual
Blank page.
5-2
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ORCA-IV Image Transfer Laminator Operation Manual
Specifications
6HFWLRQꢁꢉꢁꢃꢁ6SHFLILFDWLRQV
Table 6-1: ORCA-IV Image Transfer Laminator
Specifications
Characteristic
Specifications
Dimensions
(L x D x H)
86" x 48" x 73"
(2.2 x 1.2 x 1.7 m)
Weight
Uncrated: 3060 lbs (1814 kg)
Main Rolls
62" (157 cm) roll face with high
release silicon rubber coating for
54" wide materials
Main Roll Open- 1.25" (3.2 cm) maximum open-
ing
ing
Material
Uses transfer materials 0 - 54"
(0 - 137.2 cm) wide. Handles
materials on 3" (7.6 cm) ID cores
with material diameters up to 15"
(38.1 cm).
Speeds
0 to 10 fpm (0 to 3.1 mpm)for
transfer process with variable
speed and 19 fpm (5.8 mpm) ,
reversible action, start and stop
controlled by the instrument
panel.
Safety Features
•
All electrical and moving
mechanical parts are located
in bolted cabinets
•
•
Emergency stop buttons with
a reset button circuit
Fully guarded with inter-
locks
•
•
Emergency stop kick cables
Preheater module
Options
Installation
Requirement
230VAC 50 or 60 Hz, three
phase, 45A per phase with pre-
heater (35A per phase without
preheater) for 4 wire delta
hookup. 40A service without the
preheater and 50A service with
the preheater is required.
Filtered air at 1.5 cubic feet per
minute (cfm), 50 liters/minute at
a pressure of 100 pounds per
square inch (psi) (700 kPa)
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Specifications
ORCA-IV Image Transfer Laminator Operation Manual
Blank page.
6-2
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ORCA-IV Image Transfer Laminator Operation Manual
,
,QGH[
Installation requirements 2-1, 6-1
International shipments 2-5
Isopropyl alcohol 4-1
1XPHULFV
3M 3-12
$
-
Accessory pack 2-4
Air supply 2-2
Audible signals 3-3
Jumper configurations 2-1
.
Kick cable 1-2, 2-6
Adjusting 4-3
&
Centering the web 3-13
Chain
/
Lubrication 4-3
Changing film and paper 3-14
Cleaning 4-1
Laminate adhesives 3-12
Leveling 2-5
Lubrication 4-3
Cabinet and covers 4-2
Doors 4-2
0
Rolls 4-1
Controls
Main roll opening 6-1
Main rolls 6-1
Maintenance schedule 4-1
Material 6-1
Front brake panel 3-6
Front control panel 3-4
Rear brake panel 3-10
Rear control panel 3-8
Motor 2-7
1
(
Nip 1-1, 1-3, 3-1
Emergency stop buttons 1-2, 2-6, 3-2
Environment 2-1
2
)
Options 6-1
Film 3-12
3
Loading 3-11
Paper 3-12
Film spacing 3-14
Front clutch/brake panel 3-6
Front control panel 3-4
FWD/REV switch 4-2
Positioning the film 3-13
Preinstallation checklist 2-1
Process control charts 3-15
5
*
Rear clutch/brake panel 3-10
Rear control panel 3-8
Recommended materials 3-12
Reset button 1-3
Reset procedure, machine 1-3
Reset, machine 3-3
Grease fittings 4-3
+
Heater 2-7
Controller 2-7
Heating 3-11
Rexam 3-12
Riggers 1-5, 2-4
Roll to roll transfer 3-15
Rubber cement eraser 4-1
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ORCA-IV Image Transfer Laminator Operation Manual
6
Safety 1-1
Safety features 6-1
Safety hazard decals 1-7
Safety information 1-1, 3-1
Safety labels 1-5
Setup 3-11
Setup procedure 2-5
Shutdown 3-16
Shutdown, machine 3-16
Slitter 3-12
Specifications
Dimensions 6-1
Installation requirements 6-1
Main roll opening 6-1
Main rolls 6-1
Material 6-1
Options 6-1
Speeds 6-1
Weight 6-1
Speeds 6-1
Splicing
Paper 3-14
Vinyl 3-14
7
Technical support
Call 1-608-246-8844 or fax 1-608-246-8645 4-4
8
Unpacking 2-4
Crate 2-4
Upper main roll 1-4
9
Vinyl transfer 3-15
Vinyl transfer and overlamination materials 3-12
:
Warnings and cautions 1-1
Warranty 5-1
Exclusions 5-1
7-2
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