GBC Laminator 80 99 User Manual

ORCA 80-99 OPERATION  
& MAINTENANCE MANUAL  
© June 2000 GBC Pro-Tech  
Do not duplicate without written permission.  
GBC Pro - Tech  
4151 Anderson Road  
DeForest, WI 53532  
Ph: ( 608 ) 246 - 8844  
Fx: ( 608 ) 246 - 8645  
Revision :  
Part number : 930 - 055  
 
Table of Contents  
Orca 80-99 Operation and Maintenance Manual  
Section 5: Operations  
Operation....................................................................................... 5 - 1  
Front control panel diagram........................................................ 5 - 2  
Rear control panel diagram......................................................... 5 - 3  
Front control panel ....................................................................... 5 - 4  
Rear control panel ........................................................................ 5 - 4  
Setup .............................................................................................. 5 - 5  
Processes ....................................................................................... 5 - 7  
Process control chart (blank) ...................................................... 5 - 10  
Process control diagram (blank) ................................................. 5 - 11  
Hot mount (Chart 2.2) .................................................................. 5 - 12  
Hot mount (Diagram 2.2) ............................................................. 5 - 13  
Hot mount/Laminate (Chart 2.3) ................................................. 5 - 14  
Hot mount/Laminate (Diagram 2.3)............................................ 5 - 15  
Page II  
© GBC Pro - Tech June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Table of Contents  
Encapsulation (Chart 2.4)............................................................ 5 - 16  
Encapsulation (Diagram 2.4)........................................................5 - 17  
Hot laminate/PSA mount (Chart 2.5)...........................................5 - 18  
Hot laminate/PSA mount (Diagram 2.5)......................................5 - 19  
Hot laminate/PSA mount (Second pass - Chart 2.6) ..................5 - 20  
Hot laminate/PSA mount (Second pass - Diagram 2.6) ............5 - 21  
Cold overlaminate/ PSA mount (Chart 2.7) ................................5 - 22  
Cold overlaminate/PSA mount (Diagram 2.7) ............................5 - 23  
Cold overlaminate/PSA mount (Second pass - Chart 2.8) .........5 - 24  
Cold overlaminate/PSA mount (Second pass - Diagram 2.8) ....5 - 25  
Cold laminate only using a sled (Chart 2.9) ................................5 - 26  
Cold laminate only using a sled (Diagram 2.9) ...........................5 - 27  
© GBC Pro - Tech June 2000  
Page III  
 
Table of Contents  
Orca 80-99 Operation and Maintenance Manual  
Section 6: Maintenence  
Daily ................................................................................................6 - 1  
Monthly ...........................................................................................6 - 1  
Six Month .......................................................................................6 - 2  
Chain Diagram...............................................................................6 - 3  
Page IV  
© GBC Pro - Tech June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Safety  
SAFETY  
10. Unplug this product from the wall outlet and refer  
servicing to qualified service personnel under the following  
conditions:  
READ THIS SECTION BEFORE  
OPERATING THE ORCA 80-99 LAMINATOR!  
A. When the power cord is damaged or frayed.  
B. If liquid has spilled into the product.  
FOR YOUR SAFETY:  
C. If the product has been exposed to rain or water.  
Your safety as well as the safety of others is important to  
GBC Pro-Tech. In this instruction and on the product  
are important safety messages. Read these messages  
carefully.  
WARNING:  
1. Read all these instructions.  
Never place fingers or arms between the rollers  
when they are turning or when the rollers are in  
the closed position.  
2. Save these instructions for later use.  
3. Follow all warning and instructions marked on the  
D. If the product does not operate normally when the  
operating instructions are followed. Adjust only those  
controls that are covered by the operating instructions  
since improper adjustment of other controls may result in  
damageandwilloftenrequireextensiveworkbyaqualified  
technician to restore the product to normal operation.  
product.  
4. Unplugthisproductfromthewalloutletbeforecleaning.  
Do not use liquid cleaners or aerosol cleaners. Use a  
damp cloth for cleaning.  
5. Do not use this product near water.  
E. If the product exhibits a distinct change in performance,  
indicating a need for service.  
6. This product should be operated from the type of  
power source indicated on the marking label. If you are  
not sure of the type of power available, consult your dealer  
or a qualified and certified electrician.  
Safety Information  
7. Do not allow anything to rest on the power cord. Do  
not locate this product where persons will walk on the  
cord.  
WARNING:  
It is vital that everyone working around the  
laminator rolls avoid wearing loose-fitting clothing,  
ties or dangling jewelry which could be caught in  
the nip.  
8. Never push objects of any kind into this  
product through any slots as they may touch dangerous  
voltage points or short out parts that could result in a risk  
of fire or electric shock. Never spill liquid of any kind on  
the product.  
The GBC Pro-Tech laminator has been designed with  
operator safety as a primary consideration. However,  
operators must become thoroughly familiar with the  
controls, and proper operation and safety features of the  
machine before starting to use the unit.  
9. Do not attempt to service this product yourself, as  
opening or removing covers may expose you to dangerous  
voltage points or other risks. Refer all servicing to service  
personnel.  
© GBC Films Group June 2000  
Page 1 - 1  
 
Safety  
Orca 80-99 Operation and Maintenance Manual  
GBC Pro-Tech laminators are powerful machines which  
are designed to accomplish specific tasks such as  
mounting, laminating and encapsulating. The forces  
required to accomplish laminating can vary from negligible  
to very large. The air-cylinder system used to provide  
downward pressure on the top roll is capable of producing  
forces greater than 1000 pounds (454 kg). This force  
can be applied to any object that may be present in the  
opening (called the nip) between the two rollers.  
machine, or by stepping on or kicking the E-Stop  
cable located at the bottom of the machine.  
Quick action in this regard can aid in preventing or  
minimizing injury or machine damage.  
Because of the electrical shock hazard and the  
chance that a person might get either fingers or  
clothing into the drive mechanism, the cabinets  
should only be opened by a qualified service person,  
after the machine is shut off and the power  
disconnected.  
As a safety measure, the laminator is equipped with a  
photoelectric eye system which stops the machine when  
objects or hands are located in the nip area. Once the  
blocking object is removed and the light beam is  
reestablished, the laminator rolls resume turning.  
Operators should use care in lowering the top laminating  
roll and know how to react quickly in an emergency. The  
laminator roll UP-DOWN switch is located on the front  
instrument panel labeled “Laminator Roll Controlson  
the left-hand side of the machine. As the name implies,  
this switch controls the up and down motion of the top  
laminator roll. Before turning this switch to the DOWN  
position, assure that nothing is in the nip area.  
Most GBC Pro-Tech machines are designed to heat the  
lamination rollers. Temperatures can be set to over 200  
degrees F (100 degrees C). Thus there is a danger of a  
severe burn if the  
rollers are touched during set-up or operation.  
The machines have steel end cabinets that are bolted  
closed. They serve to isolate the electrical- and drive-  
system components.  
WARNING:  
Please note: All persons working on or near the  
Orca 80-99 Laminator must be advised of the  
following:  
If any clothing, tools, or anything other than film  
or paper is inadvertently drawn into the nip, the  
action of the rolls may be halted immediately (and  
the top roll lifted) by pushing or striking any of the  
red E-Stop switches located at the top of the  
Page 1 - 2  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Warranty  
WARRANTY  
Limited Warranty  
CAUTION:  
Exclusions to the Warranty  
This warranty specifically does not cover:  
Unauthorized customer alterations will void this  
warranty.  
1. Damage to the laminating rollers caused by knives, razor  
blades, other sharp objects, or  
failure caused by adhesives.  
2. Damage to the machine caused by lifting, tilting, and/or  
any attempt to position the machine other than rolling on  
the installed casters.  
GBC Pro-Tech warrants the equipment sold is free from  
defects in material and workmanship for a period of one  
(1) year from the date of delivery to the customer.  
This warranty is the only warranty made by Pro-Tech  
and can not be modified or amended.  
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 product.  
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 modification,  
incorrect line voltage, contaminated air supply, or  
by fire, accident or 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 one year period  
from the date of delivery.  
THE WARRANTY MADE HEREIN IS IN LIEU  
OF ALL OTHER WARRANTIES, EXPRESS OR  
IMPLIED, INCLUDING ANY WARRANTY OR  
MERCHANTABILITY OR FITNESS FOR A  
PARTICULAR PURPOSE. GBC PRO-TECH  
WILL NOT BE LIABLE FOR PROPERTY  
DAMAGE OR PERSONAL 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.  
© GBC Films Group June 2000  
Page 2 - 1  
 
Orca 80-99 Operation and Maintenance Manual  
Specifications  
ORCA 80-99  
SPECIFICATIONS  
Laminating Material:  
Description:  
Uses heat-activated 0-74” and pressure-sensitive  
materials 0 - 80" (0- cm) wide with films on 3" (7.6  
cm.) ID core.  
Floor-standing laminator with multiple unwind  
positions for high productivity heat-activated laminating,  
encapsulating, heat transfer and mounting. The  
laminator can also be used with pressure-sensitive films  
for cold mounting and laminating applications.  
Laminating Speeds:  
0 to 30 fpm ( 0 to 9 Mpm) with variable speed,  
reversible action, START and STOP controlled via the  
front instrument-panel switch or with a foot switch.  
Includes:  
Outfeed edge slitters for in line trimming of finished  
product.  
Unwind - Rewind:  
Dimensions:  
Three unwind positions; three rewind positions  
L - 120", D - 50", H - 66" (L- 3M, D- 1.27M, H-  
1.68M)  
Safety Features:  
(1) Photo-eye motor stop, 4 emergency stop buttons  
and two kick cables to stop the machine and raise rolls.  
Weight (uncrated):  
2800 pounds (1270 kg)  
Warranty:  
One year parts warranty (except silicone roll coverings  
and table tops).  
Laminating Rolls:  
86.5" length (220 cm) roll face with thermally  
conductive silicone covered with high release silicone  
surface, upper and lower rolls internally heated.  
Temperature controlled by state of the art infrared  
sensors with closed loop digital control systems,  
independently adjustable for both top and bottom rolls.  
Electric:  
220 VAC, 50 or 60 Hz, single phase, 60-65 Amps.  
Three phase 32 Amps (Europe only).  
Compressed Air:  
Laminating Opening:  
2 CFM @ 100 PSI.  
1_” (4.75 cm) maximum opening controlled with dual  
air cylinders.  
© GBC Films Group June 2000  
Page 3 - 1  
 
Orca 80-99 Operation and Maintenance Manual  
Installation  
INSTALLATION  
Uncrating the Machine  
CAUTION:  
6. When all the accessories have been removed from the  
crate you will notice that there are two ramps that are  
bolted down to the crate bottom: these will need to be  
removed, using the phillips head screwdriver.  
When taking the top off, care should be taken so  
that the top does not fall into the crate, possibly  
damaging the laminator. It might be necessary to  
use two or three people for this task.  
The ramps must then be secured to the edge of the crate  
bottom using the screws left over from crate disassembly  
(see diagram).  
During the uncrating process make sure that the  
screws do not end up on the floor. They can cause  
problems later when trying to roll the machine into  
position.  
PLEASE NOTE: The Orca 80-99 Laminator is a  
large and heavy piece of mechanical equipment.  
Casual movement of equipment of this type can be  
hazardous to the average person; and poses the  
potential of serious damage to the machine.  
To uncrate the Orca 80-99 Laminator you will need a  
phillips head screwdriver. It helps to have a cordless drill  
with the screwdriver bit, because there are quite a few  
screws to remove throughout this procedure. In order to  
minimize the possibility of damage to your new Orca 80-  
99 Laminator, please follow this procedure exactly.  
It will be necessary to employ qualified and  
trained personnel (licensed, certified RIGGERS)  
if any movement of the machine other than rolling  
on a flat, level surface is contemplated.  
1. The top of the crate is the first piece to be removed  
(see diagram on page 4-3).  
The Orca 80-99 Laminator is not designed to be  
tipped up or sideways in anyway. Such action may  
disturb the exact alignment of the rolling parts of  
the machine and require extensive re-alignment.  
GBC Pro-Tech’s warranty does not cover  
malfunction of the equipment due to mis-handling  
and/or tipping.  
2. Next, remove one side of the crate (see diagram). At  
this point it is necessary to have someone support the  
remaining side of the crate while the remaining end is being  
removed. Maintain support of the side until all mounting  
screws are removed and the side is off the crate.  
GBC Pro-Tech bears no responsibility for parties  
who fail to follow these directions. Any injury or  
damage to the machine due to improper moving is  
the sole responsibility of the mover.  
3. Remove the end of the crate (see diagram).  
CAUTION:  
Do not use a knife or other sharp instrument to  
remove any protective covering. This could cause  
irreparable damage to the machine.  
Before the machine can be rolled off the crate, the foot  
bolts must be freed from the four shipping hold-down  
plates. Loosen the lock-nut on each of the foot bolts.  
4. Remove the shrink wrap from the machine and its  
contents.  
Unscrew the foot bolts from the hold-down plates. Raise  
but do not remove the bolts and lock nuts from the foot  
bracket. (At this time, you may wish to remove the hold-  
down plates from the crate to provide unrestricted removal  
of the machine from the crate).  
5. Once the shrink wrap is off, remove any accessories  
from the crate. While doing this, take care not to scuff  
the machine.  
© GBC Films Group June 2000  
Page 4 - 1  
 
UNCRATING DIAGRAM  
ORCA-80-99  
1
5
4
INSTALL SCREWS  
2
3
 
Orca 80-99 Operation and Maintenance Manual  
Installation  
7. Once the ramps are secured and the hold down plates  
are removed, the machine can be rolled off the crate  
bottom. Thiswillrequirefourpeoplehandlingthemachine  
and rear of the machine to insure that it has not changed.  
If it has, repeat the procedure until the machine’s front,  
on its four corners and carefully rolling the machine off the rear, and both sides are all level. Tighten the lock nuts  
crate bottom (see diagram). The machine can now be  
rolled into its final operating position.  
securely to the foot brackets.  
8. At this point a qualified electrician connects power to  
Choose a spot with sufficient space around the unit so the machine. Make sure before supply power is provided  
that there can be front and back work tables and adequate that the machine circuit breaker is in the off position. This  
space for efficient material flow. Thus, a typical room area is also the point where the appropriate supply of clean,  
requirement for the ORCA 80-99 is 20 X 24 feet (6.0 x dry compressed air is connected to the machine (see power  
7.3 Meters) to allow use of work tables in front and to  
the rear of the machine. See the suggested layout in Fig.  
1-1 (page 4-4).  
and air requirements).  
Electrical Requirements  
Once the Orca 80-99 Laminator has been placed in its  
final position, optimum performance is obtained by The ORCA 80-99 is designed to accept 220 to 240-volt  
installing the supplied leveling pads and leveling the AC, 50/60-Hz, 60 Amps, single phase 3 wire (USA).  
machine. Install one leveling pad on each foot-bolt,  
tighteningsecurely.  
The peak power required by the unit is 55 Amperes. Or,  
in Europe only 3-N phase 230/400 VAC, 50 Hz, 25  
Amps per phase.  
Lower the leveling pad to the floor by turning down the  
foot bolts. Turn all the bolts sufficiently to lift all four of  
the casters off the floor.  
Before attempting to electrically connect or operate your  
newOrca80-99Laminator, aqualified, licensedelectrician  
should be consulted to ensure that an adequate power  
supply, having the appropriate capacity, overcurrent  
protection, safety lockouts, etc., is available; and to ensure  
that the power supply of the Orca 80-99 is in accordance  
with all established national and regional electrical codes  
and standards.  
CAUTION:  
Some generation of static electricity is  
unavoidable during the laminating process due to  
the nature of the materials used. In order to avoid  
any hazard of ignition, fire or explosion due to  
static spark, it is imperative that the operating  
environment is free of dust, flammable liquids, and  
vapors.  
CAUTION:  
The air supply to the Orca must be clean and dry  
Then, face the machine and place a carpenter’s level left- or the machine will be damaged.  
to-right on one of the idlers. Adjust the bolts on the front  
two foot brackets so that the machine is level left-to-right.  
GBC Pro-Tech, will not be responsible for damage  
Then, move the level to the rear of the machine and adjust to the equipment caused by improper connection,  
the rear two leveling pads.  
incorrect power supply or other incorrect electrical  
installation.  
Next, place the level front-to-rear on one of the air cylinder  
brackets and adjust the bolts equally on the two foot  
brackets on that side. Move the level to the other air  
Before initial power is applied to the machine assure that  
all toggle switches on the front and rear control panels  
cylinder bracket and repeat the procedure for the other and the main power circuit breaker (inside/bottom of the  
side.  
left-side cabinet) are set to OFF. The AC connection is  
located on the bottom/front of the left-side cabinet.  
After both sides have been leveled front-to-back, go back  
and check the side-to-side level condition of the front  
© GBC Films Group June 2000  
Page 4 - 3  
 
Installation  
Orca 80-99 Operation and Maintenance Manual  
Work Table  
6' X 6'  
[2m x 2m]  
(on w heels)  
AIR SUPPLY  
REAR  
ELECTRICAL  
SU PPLY  
FRONT  
10' [3m]  
3'  
[1m  
]
Work Table  
6' X 6'  
[2m x 2m]  
(on w heels)  
20' [6m]  
Fig. 1-1  
SUGGESTED WORKSPACE  
LAYOUT  
ORCA 80-99  
Page 4 - 4  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Installation  
2
1
1
1
1
1
1
4
2
2
1
Additional slitter knives  
T-handle wrench, 5/16"  
T-handle wrench, 1/4"  
Masking Tape  
Tape Measure  
Rubber Cement Pick-Up  
Shim Set  
Leveling Pads  
Outfeed Slitters  
O-Rings, Brake  
Oil, Air Tool  
Air Requirements  
CAUTION:  
Do not use a knife or other sharp object to remove  
the paper coverings. This would cause irreparable  
damage to the rolls and necessitate their  
replacement.  
The Orca 80-99 laminator requires filtered air at 2 cubic  
feet per minute (CFM), (50 liters/minute) at a pressure of  
at least 100 pounds (700 kPa) per square inch (PSI).  
The air supply must be clean (free of dirt) and dry.  
Moisture will cause corrosion and particles can block  
pneumatic controls. Either can cause the laminator to  
malfunction.  
These items are needed to put the machine into operation.  
RECYCLING INSTRUCTIONS:  
The crate components can be reused for shipping  
the machine again, or may be disassembled and  
the wood and screws recycled. The shrink wrap  
however, is not recyclable so therefore must be  
discarded.  
It is the customer’s responsibility to provide appropriate  
filters and water traps for the air line before the air is routed  
to the laminator.  
GBC Pro-Tech suggests that the best approach to the air  
requirement is to provide a dedicated small compressor  
for the laminator. A standard light-duty 1/2 to 3/4  
horsepower (1 kW) electric air compressor with 1.5 to  
2.5 CFM output with a 2.5 - gallon (20 Liter) storage  
tank is appropriate.  
In order to begin operation of the machine, the Up/Down  
rates for the main and pull rolls and the nips must be set  
(see the Operation section of this manual). Once set, the  
machine is ready for operation.  
Air is fed to the machine via a 1/4-inch quick-disconnect  
male connector. This connector is located below the  
cabinet on the left side of the machine. (Once the air  
supply and electrical power are connected to the machine,  
proceed to the section on Operation in this manual).  
9. Next, remove the paper coverings from the roll. After  
the roll coverings have been removed, you will need to  
open the accessory pack. The accessory pack contains:  
Qty  
Description  
1
1
1
1
1
1
Set, Allen wrenches  
Slittingknife  
Manual  
Bottle of Isopropyl Alcohol  
100 % white cotton terry rags  
Set, spare fuses  
© GBC Films Group June 2000  
Page 4 - 5  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
OPERATION  
Safety  
5. Use a 100-percent cotton terry cloth to remove  
heat-activated laminating residue, while the rolls are hot.  
Follow this procedure every time heat-activated  
laminates are used.  
Safety is always the primary concern. If you have not  
read the safety information at the front of this manual,  
do so now. Do not attempt operation of the machine  
until you fully understand this safety information.  
WARNING:  
1. Never place fingers or arms between the  
rollers, both main and pull, or in roller slots no  
matter what the operational status the machine is  
in.  
General Precautions  
1. Keep razor blades, knives, and all other sharp  
objects away from the chrome and silicone rollers. They  
are easily damaged and very expensive to replace.  
2. It is vital that everyone working around the  
laminator rolls avoid wearing loose-fitting clothing,  
ties or dangling jewelry, which could be caught in  
the nip.  
CAUTION:  
Insert shims to keep the laminating and pull rolls  
apart when the machine is not in use. Do not rely  
on the air supply. Prolonged contact can damage  
the rolls.  
WARNING:  
Extra caution must be used when operating the  
laminator with the provided foot switch. The foot  
switch acts as an “over-ride” to the photoelectric  
eye; i.e., it allows the rolls to continue operation  
even if the photoelectric eye detects an  
obstruction near the nip.  
2. Harsh chemicals such as Toluene or MEK will  
destroy the silicone covering on the laminating rolls. The  
rolls should be cleaned daily following the procedure  
outlined in the Maintenance section of this manual.  
This function is necessary a) to allow initial hand-  
feeding of process materials to the rolls and b) to  
prevent damage to the process at the end of a  
sheet due to “curl-up” of the sheet end.  
CAUTION:  
If silicone adhesives contact the top or bottom roll,  
remove it IMMEDIATELY using isopropyl  
alcohol. It will harden within an hour.  
Operators are cautioned to use the foot switch for  
as short a time as practicable, and to exercise  
caution when doing so.  
3. Do not allow liquid silicone adhesives to contact the  
top or bottom silicone roll. These materials will bond to  
the roll in much less than one hour. If some adhesive  
does get on the roll, wipe it off IMMEDIATELY using  
isopropyl alcohol.  
4. The laminating rolls will develop flat spots if left in  
contact with each other when not in use. Always insert  
the shims when shutting off the laminator. Do not rely on  
the air supply to keep the top roller in the raised  
position, as the air supply can fail at any time.  
© GBC Films Group June 2000  
Page 5 - 1  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
A
TOP UNWINDS (3)  
ON/OFF  
AIR PRESSURE  
ADJUSTMENT  
(TOP BRAKE)  
PRESSURE  
PRESSURE  
PRESSURE  
PRESSURE  
PRESSURE  
ADJUST  
ADJUST  
ADJUST  
ADJUST  
ADJUST  
OFF  
O N  
B
C
D
TOP REWIND  
ON/OFF  
TOP BRAKE CONTROLS  
OFF  
O N  
LAMINATOR ROLL  
UP/DOWN  
TOP CLUTCH CONTROLS  
AIR PRESSURE  
GAUGE  
OFF  
O N  
BOTTOM UNWIND  
ON/OFF  
LAMINATOR ROLL CONTROLS  
OFF  
O N  
E
F
BOTTOM REWIND  
ON/OFF  
J
BOTTOM BRAKE CONTROLS  
TOP HEATER SWITCH  
ON/OFF LAMP  
OFF  
O N  
RUN/JOG  
SWITCH  
K
BOTTOM HEATER SWITCH  
ON/OFF LAMP  
BOTTOM CLUTCH CONTROLS  
Photoeye  
JOG  
RUN  
G
H
FORWARD/REVERSE  
SWITCH  
STOP  
Blocked  
REV  
FWD  
L
PHOTOEYE  
LAMP  
OFF  
ON  
LIGHTS  
SEL  
RST  
OFF  
ON  
M
SPEED CONTROL  
MAIN POWER  
ON/OFF  
POWER  
MOTOR CONTROLS  
380-3440  
PRO-TECH ENGINEERING, MADISON, WISCONSIN  
LAMP  
N
I
SPEED READOUT  
MAIN POWER  
SWITCH  
Fig. 2-1  
FRONT CONTROL PANEL  
Page 5 - 2  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
A
B
D
E
TOP HEATER  
ON/OFF  
BOTTOM HEATER  
ON/OFF  
TOP HEAT  
BOTTOM HEAT  
OFF  
ON  
OFF  
ON  
TOP HEATER  
CONTROL  
BOTTOM HEATER  
CONTROL  
C
F
BOTTOM FAN BANK  
ON/OFF  
TOP FAN BANK  
ON/OFF  
TOP COOLING FANS  
BOTTOM COOLING FANS  
OFF  
ON  
OFF  
ON  
PULL ROLL CLUTCH  
PRESSURE GAUGE  
PRESSURE  
ADJUST  
AIR PRESSURE  
ADJUSTMENT  
OFF  
ON  
G
PULL ROLL CLUTCH  
ON/OFF  
PULL ROLLER CLUTCH  
PULL ROLL  
PRESSURE GAUGE  
PRESSURE  
PRESSURE  
PRESSURE  
ADJUST  
ADJUST  
ADJUST  
AIR PRESSURE  
ADJUSTMENT  
OFF  
ON  
H
PULL ROLL  
UP/DOWN  
PULL ROLLER PRESSURE  
BOTTOM UNWIND  
TENSION PRESSURE  
GAUGE  
AIR PRESSURE  
ADJUSTMENT  
OFF  
ON  
I
BOTTOM BRAKE  
ON/OFF  
BOTTOM BRAKE  
BOTTOM REWIND  
TENSION PRESSURE  
GAUGE  
AIR PRESSURE  
ADJUSTMENT  
OFF  
ON  
J
BOTTOM CLUTCH  
ON/OFF  
BOTTOM CLUTCH  
Fig. 2-2  
REAR CONTROL PANEL  
© GBC Films Group June 2000  
Page 5 - 3  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
Operator Controls  
J. ON/OFF LAMP (Top Heater) - Denotes whether  
the top heater controller is on or off.  
The operator controls for the Orca laminator are  
K. ON/OFF LAMP (Bottom Heater) - Denotes  
operator position. See Figures 2-1 and 2-2. The names  
and functions of these controls are as follows:  
whether the bottom heater controller is on or off.  
L. PHOTO EYE LAMP - Denotes whether or not the  
PHOTO EYE is blocked.  
FRONT CONTROL PANEL  
M. MAIN POWER LAMP - Denotes whether or not  
Please note that in each of the control sections there is a  
Pressure Gauge, an On/Off switch and an Air Pressure  
Regulator. The Pressure Gauge shows the operational  
pressure. The On/Off switch turns the control function  
on or off. The Air Pressure Regulator adjusts the air  
pressure for the control function.  
the main power is on the machine.  
N. MAIN POWER SWITCH - Turns the  
main power on and off.  
A. TOP BRAKE CONTROLS - Regulation of the  
REAR CONTROL PANEL  
upper unwind shaft brakes.  
A. ON/OFF (Top Heater Controller) - Controls  
B. TOP CLUTCH CONTROLS - Front upper rewind  
whether or not the top heater controller is on or off.  
shaft clutch regulation.  
B. TOP HEATER CONTROLLER - Controls the  
upper main roll’s operational temperature and provides  
a readout of the actual temperature.  
C. LAMINATOR ROLL CONTROLS - Regulation of  
the main laminating rolls.  
D. BOTTOM BRAKE CONTROLS - Regulation of  
C. ON/OFF (Top Fan Bank) - Controls whether or  
the front lower unwind brake.  
not the top fan bank is on or off.  
E. BOTTOM CLUTCH CONTROLS - Regulation of  
D. ON/OFF (Bottom Heater Controller) - Controls  
the shaft’s lower front rewind clutch.  
whether or not the bottom heater controller is on or off.  
F. RUN/JOG SWITCH - Changes control of the  
machine drive from a foot switch operation to  
continuous run. It also allows the operator to “Jog” the  
rolls for a short period of time.  
E. BOTTOM HEATER CONTROLLER - Controls  
the lower main roll’s operational temperature and  
provides a readout of the actual temperature.  
F. ON/OFF (Bottom Fan Bank) - Controls whether or  
G. REV-FWD - This switch controls the direction of  
not the bottom fan bank is on or off.  
the drive system, forward or reverse.  
G. PULL ROLLER CLUTCH CONTROLS-  
H. SPEED CONTROL - Adjusts the speed of the  
machine from zero to maximum as the control is turned  
clockwise.  
Regulation for the bottom pull roller clutch.  
CAUTION:  
I. SPEED READOUT - Digital readout of the machine  
speed and total throughput in either metric or standard  
units.  
Use the minimum laminator roll pressure  
consistent with good results. Excess pressure can  
damage the laminating rollers.  
Page 5 - 4  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
H. PULL ROLLER PRESSURE CONTROLS -  
points to remember when loadingfilm:  
Regulation for the upper pull roll pressure and up/down.  
CAUTION:  
I. BOTTOM BRAKE CONTROL - Regulation for  
the bottom rear unwind brake.  
Assure that film is always mounted so that the  
adhesive side will face outward from the  
laminating roller.  
J. BOTTOM CLUTCH CONTROL - Regulation for  
the bottom rear rewind shaft’s clutch.  
1. The adhesive side of the film must be oriented away  
(on the outside) of the laminating roller. Otherwise it will  
immediately bond to the roller, creating a major clean-  
up project. Films have a shiny side and a dull side. The  
dull side is the one with the adhesive. Thus, the dull side  
should ALWAYS face outward from the laminating roll.  
Setup  
Set up of the Orca laminator is quick and  
straightforward when instructions are followed directly.  
When you first receive the Orca Laminator the nips  
must be set before operation. The procedures for  
setting the main and pull roll nips are on pages 8-1 and  
8-2.  
2. 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, excess glue on rolls and other assorted  
troubles will result.  
Laminator Roll Pressure:  
CAUTION:  
1. You should use only the minimum amount of roll  
pressure needed to accomplish the task. While higher  
nip pressure can make the adhesive bond faster, excess  
pressure can damage the rollers. Wrinkles, bubbles and  
such have causes that generally cannot be cured with  
more pressure.  
Unless the two films fed to the nip are carefully  
aligned, poor results will be seen.  
Positioning Film  
2. A typical roll pressure for soft substrates such as  
Foamcore or Orca-Board is between 20 to 30 pounds  
per square inch (PSI) or 32 to 205 kPa.  
The following procedure is applicable to both the top  
and the bottom feed unwinds:  
3. The range of typical values for hard substrates is 25  
to 50 PSI, 170 to 345 kPa.  
1. Remove the ball detent retaining pins and carefully  
remove the unwind/rewind shaft from its saddles. Pay  
particular attention to the drive side saddles. The drive  
side of the shafts must be oriented so as to not pry on  
the brake or clutch protrusion. To do so would  
irreparably damage both brakes and clutches.  
Loading the Film  
Film is loaded on the appropriate unwinds. Instructions  
later in this section will cover loading and aligning film.  
For applications such as encapsulation, film will be fed  
from both top and bottom unwinds.  
2. Slide the film onto the unwind shaft.  
3. Install the shaft back into its saddles again paying  
careful attention to the drive side end of the shaft.  
Return ball detent pins to secure the shaft in its saddles.  
The process of loading and aligning film is the same for  
both the top and the bottom. There are two important  
© GBC Films Group June 2000  
Page 5 - 5  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
4. Center the film by sliding it back and forth on the  
shaft until centered. As soon as the film is unwound  
from the shaft, the core support will lock the roll into  
position.  
laminating roller(s) to reach operating temperature.  
When the pre-set operating temperature has been  
reached, the machine is ready to use.  
5. Recheck the centering of the film roll with a tape  
measure.  
Cooling  
(with optional cooling fans)  
The following procedure is the fastest way to cool  
down the machine. Natural cooling can also be  
employed:  
WARNING:  
Normal operation of the Orca 80 laminator  
involves the application of large amounts of heat  
to the process materials. The surfaces of the rolls  
are at a high enough temperature to cause burns if  
they are touched.  
1. Set the heater switches to OFF.  
2. Position the two rear fan banks so that they are tilted  
to direct air flow at the rolls.  
Operators are cautioned not to touch, lean or fall  
against the rolls of an operating laminator. Do not  
become unbalanced when working near an  
operating laminator.  
3. Set the Laminator Roll Control to the DOWN  
position.  
4. Set the Forward/Reverse switch to the FORWARD  
position.  
Heating  
5. Set the speed control to 5 fpm (150 cpm).  
The following instructions should be employed when  
heating one or both of the laminating rolls. The  
procedure is the same for top and bottom:  
6. Let the machine run until the laminating rolls return to  
room temperature.  
1. Set the heater switch to ON.  
Paper Tips  
2. Adjust the temperature controller for the desired  
operating temperature using the controller push  
bottoms.  
1. Always cut the leading edge of a print straight so they  
can be fed perpendicular to the laminating rolls.  
For the Syrlec type controller use the up and down  
arrows to adjust the set point. Hold down the desired  
arrow until the correct set point is achieved.  
Process Control Charts  
Chart 2-1 and 2-1B show a blank set of process  
control charts for the ORCA 80. These charts are  
where you record the way you thread film through the  
machine’s rolls and idlers (called webbing) and the  
setting of controls and switches for each product and  
process.  
For the CAL3200 it is necessary to press the * button  
at the same time as the up or down arrow to adjust the  
set point temperature.  
3. When heating the rolls, keep the top roll down and  
turning at a moderate speed to prevent uneven heating.  
GBC Pro-Tech laminators respond in a very accurate  
and repeatable manner. The charts provide a way to set  
up each time, every time, for repeatable performance  
by assuring all controls are set to optimum.  
4. It will take approximately 25 minutes for the  
Page 5 - 6  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
B. Put a piece of contact/release paper over the print.  
Otherwise, adhesive will be applied to the laminating  
roller which can cause damage and the ink from  
electrostatic prints will be deposited on the roll.  
The process charts are also an excellent tool for training  
new operators. They provide a “road map” for correct  
machine setup and operation.  
The process control charts should be kept in this  
manual or in a book close to the Orca. Use the machine  
to encapsulate the popular charts so they can withstand  
coffee spills and will be available for ready reference.  
C. Feed the print/Orca board package though the nip.  
Mounting/Laminating  
In the rest of this section you will find completed  
process control charts for the basic operations of the  
machine. These are based on Orca-Film and Orca-  
Board and typical prints. If you have a special  
application use the blank charts to make your own  
records.  
The following procedure is for one-step mounting and  
heat-activated laminating using mounting board with one  
adhesive side such as Orca-Board.  
1. Setup:  
Information:  
A. The setup is shown in process chart 2-3 and 2-3B.  
B. Mount the film and web as shown in chart 2-3B.  
When trying new products and processes,  
remember that GBC Pro-Tech’s customer service  
technicians are only a phone call away.  
C. Shims: Set the two front shim dials to 1/32 less than  
board height.  
Mounting Only  
D. Laminator Roll Pressure: 40 PSI, 275 kPa.  
E. Speed: 3 fpm (90 cpm).  
1. Setup:  
A. See process chart 2-2 and 2-2B.  
B. Set Shims:  
F. Upper Laminator Roll Heat: 245 degrees F, 118  
degrees C.  
G. Cooling: Off.  
C. Upper Laminator Roll Pressure: 40 to 80 PSI, 275 -  
550 kPa.  
H. Film Roll Brake Pressure 20 PSI, 135 kPa.  
D. Speed: 3.  
2. Procedure:  
E. Upper Laminator Roll Heat: 245 degrees F, 118  
degrees C.  
A. Feed the Orca board dull (adhesive) side up with  
the print positioned as desired. A tack iron may be used  
to hold the leading edge of the print in place.  
Mounting Only (continued)  
2. Procedure:  
Encapsulation  
1. Setup:  
A. Lay the print on the board. Using a tack iron, tack  
the leading edge of the print down onto the board so it  
is held in place.  
A. Refer to process chart 2-4 and 2-4B for webbing  
instructions.  
© GBC Films Group June 2000  
Page 5 - 7  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
B. Trim to slightly larger than the desired finished size.  
WARNING:  
B. Shims: none.  
C. Laminating Roller Pressure: 60 PSI, 410 kPa.  
D. Pull Roller Clutch Pressure: On, 80 PSI, 550 kPa.  
E. Pull Roller: Down, 60 PSI, 410 kPa.  
F. Speed: 4 to 6 fpm  
Take care when repositioning rewind/unwind  
shafts or other heavy parts or materials, used in  
the various web-up patterns. They are heavy and  
can cause injury to fingers and/or toes if not  
handled properly.  
G. Top Roll Temperature: 220-230 degrees F (90 -  
Procedure, Pass 2:  
110 degrees C).  
A. Prepare to put the print through a second time to  
mount the print to the substrate. — anything from  
wood, to Masonite, to Gator foam. Start by setting the  
shims to the appropriate spacing for the material used.  
H. Bottom Roll Temperature: 220-230 degrees F (90 -  
110 degrees C).  
I. Cooling: Optional.  
B. Trim the board to the size of the print.  
J. Use of the rear rewind for the finished material is  
optional. It is a good procedure for long runs. If a  
rewind is used in this application the clutch pressure  
should be 15 PSI.  
C. Align the work to the board and assure an exact fit.  
Place weights on the center of the print to assure that it  
does not move relative to the board during the next  
steps.  
2. Procedure:  
D. Raise one end of the print and peel back  
approximately two inches of the liner to expose the  
adhesive that was applied to the print in pass 1. Fold it  
under. Lay the print back down evenly and extremely  
flat. From the center outward, tack the exposed  
adhesive to the substrate.  
A. Feed the work into the nip with the leading edge  
tight and entering the nip evenly from side to side. For  
thin paper from electrostatic printers in roll form, it is  
best to fold over the leading edge approximately 6  
inches to create a square leading edge.  
E. Position the piece so that the end with the liner  
peeled back is facing the nip. Insert the first one inch of  
the board into the nip.  
Two-Pass Mount and  
Laminate (Hot and Cold)  
F. Very carefully wrap the print back and over the top  
laminating roll. Be sure there are no wrinkles in the nip  
area. Carefully peel off the liner as the board progresses  
through the laminator.  
Cold/Mount Laminate  
A. See charts 2-5, 2-5B, 2-6 and 2-6B for settings.  
B. Assure that the mounting film from the bottom side  
has the sticky adhesive side riding up around the outside  
of the bottom laminating roller.  
G. Trim the piece to the finished size.  
Hot/Mount Laminate  
Procedure, Pass 1:  
A. Refer to charts 2-7, 2-7B, 2-8 and 2-8B.  
B. Encapsulate image. (see chart 2-7)  
© GBC Films Group June 2000  
A. Run the print through to apply adhesive and  
laminate.  
Page 5 - 8  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
C. Raise Main Roll (Hot).  
D. Reverse Motor.  
E. 2nd Pass: Set Nip Height and tack leading edge.  
Run through as liner is being pulled off.  
Cold Overlamination (Using a Sled)  
1. Setup:  
A. Refer to charts 2-9 and 2-9B  
B. Set main roll shims to 3/16"  
2. Procedure:  
A. Use a starter board to get the film started and  
feeding without wrinkles.  
B. Lay image on the sled and place it up against the  
leader board.  
C. Feed image through the nip following the leader  
board into the nip. Maintain paper tension on the image  
until it is through the nip.  
D. Cut around the image with a sharp knife to remove  
it from the leader board.  
© GBC Films Group June 2000  
Page 5 - 9  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-1  
Process:  
Materials (top/bottom):  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
Top Heat  
Top Clutch  
Bottom Heat  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
Top Cooling Fans  
Bottom Cooling Fans  
Pull Roller Clutch  
Pull Roller Pressure  
Bottom Brake (rear)  
Bottom Clutch (rear)  
Pull Roller Shims  
Laminator Roller Shims  
Helpful Hints/Notes:  
Page 5 - 10  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
(I) REMOVABLE IDLER  
U
(F) FIXED IDLER  
(U) UNWIND SHAFT  
(R) REWIND  
(M) MAIN ROLL  
(P) PULL ROLL  
R
OUTFEED  
SLITTER  
F
M
P
I
F
F
F
F
P
M
U
R
R
U
Chart 2-1B  
IDENTIFICATION DIAGRAM  
© GBC Films Group June 2000  
Page 5 - 11  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-2  
Process: Hot Mount, One Pass  
Materials (top/bottom): /3/16" thick Hot tissue coated board  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
OFF / NA Top Heat  
ON / 245o F (118o C)  
OFF / NA  
OFF  
Top Clutch  
OFF / NA Bottom Heat  
ON / 40 p.s.i. Top Cooling Fans  
OFF / NA Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
2 - 3 f.p.m. Bottom Brake (rear)  
3/16" Bottom Clutch (rear)  
Pull Roller Shims  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
OFF  
OFF / NA  
OFF / NA  
OFF / NA  
OFF / NA  
NA  
Laminator Roller Shims  
Helpful Hints/Notes:  
Lay the image to be mounted on the board and push the board into the nip while the rolls are not  
turning. Then, quickly, depress the foot switch to turn the rolls. Make sure to maintain good  
paper tension while mounting the image.  
Page 5 - 12  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
IMAGE  
245 °F  
118 °C  
COLD  
CHART 2-2B  
ONE PASS HOT MOUNT  
© GBC Films Group June 2000  
Page 5 - 13  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-3  
Process: Hot Mount and Laminate, One Pass  
Materials (top/bottom): / 3/16" thick Hot tissue board  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
ON / 20 p.s.i. Top Heat  
ON / 245o F (118o C)  
OFF / NA  
OFF  
Top Clutch  
OFF / NA Bottom Heat  
ON / 40 p.s.i. Top Cooling Fans  
OFF / NA Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
2 - 3 f.p.m. Bottom Brake (rear)  
3/16" Bottom Clutch (rear)  
Pull Roller Shims  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
OFF  
OFF / NA  
OFF / NA  
OFF / NA  
OFF / NA  
NA  
Laminator Roller Shims  
Helpful Hints/Notes:  
Start the overlaminate with a leader board the same thickness as the board being mounted to.  
While maintaining paper tension, lay the image to be mounted on the board and follow the leader  
board into the nip.  
Page 5 - 14  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
IMAGE  
245  
1°1F8  
°C  
COLD  
CHART 2-3B  
ONE PASS HOT MOUNT AND LAMINATE  
© GBC Films Group June 2000  
Page 5 - 15  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-4  
Process: Encapsulation  
Materials (top/bottom): 3 mil Gloss / 3mil Gloss  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
ON / 20 p.s.i. Top Heat  
ON / 230o F (110oC)  
ON / 230o F (110oC)  
ON  
Top Clutch  
ON / 20 p.s.i. Bottom Heat  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
ON / 60 p.s.i. Top Cooling Fans  
ON / 20 p.s.i. Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
4 - 6 f.p.m. Bottom Brake (rear)  
ON  
ON / 80 p.s.i.  
ON / 60 p.s.i.  
OFF / NA  
OFF / NA  
0
Laminator Roller Shims  
0
Bottom Clutch (rear)  
Pull Roller Shims  
Helpful Hints/Notes:  
Page 5 - 16  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
UNW IND  
230  
1F0  
°C  
230  
1F0  
°C  
Chart 2-4B  
ENCAPSULATION  
© GBC Films Group June 2000  
Page 5 - 17  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-5  
Process: Hot Overlaminate with Pressure Sensitive Mount Adhesive  
Materials (top/bottom): 3 mil Gloss / Mount Adhesive  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
ON / 20 p.s.i. Top Heat  
ON / 230o F (110oC)  
OFF / NA  
OFF  
Top Clutch  
OFF / NA Bottom Heat  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
ON / 60 p.s.i. Top Cooling Fans  
ON / 20 p.s.i. Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
4 - 6 f.p.m. Bottom Brake (rear)  
OFF  
ON / 80 p.s.i.  
ON / 60 p.s.i.  
OFF / NA  
OFF / NA  
0
Laminator Roller Shims  
0
Bottom Clutch (rear)  
Pull Roller Shims  
Helpful Hints/Notes:  
The encapsulated image will have waves running 90 degrees to the feed of the film. This is due  
to the moisture in the mount adhesive’s release liner. Once mounted the waves disappear.  
Page 5 - 18  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
UNW IND  
230 °F  
110 °C  
COLD  
UNW IND  
Chart 2-  
5B  
TWO PASS HOT OVERLAMINATE  
WITH PRESSURE SENSITIVE MOUNT ADHESIVE  
FIRST PASS  
© GBC Films Group June 2000  
Page 5 - 19  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-6  
Process: Hot overlaminate with Pressure Sensitive Mount Adhesive (Second Pass)  
Materials (top/bottom): / 3/16" Foamcore  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
OFF / NA Top Heat  
OFF / NA  
OFF / NA  
OFF  
Top Clutch  
OFF / NA Bottom Heat  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
OFF / NA Top Cooling Fans  
OFF / NA Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
REVERSE Pull Roller Pressure  
2 - 3 f.p.m. Bottom Brake (rear)  
N/A Bottom Clutch (rear)  
Pull Roller Shims  
OFF  
ON / 40 p.s.i.  
ON / 30 p.s.i.  
OFF / NA  
OFF / NA  
3/16"  
Laminator Roller Shims  
Helpful Hints/Notes:  
When mounting keep an even wrap around the upper pull roll to eliminate any wrinkles due to  
uneven feed of the image. During the mounting process, it is also helpful to have a table the  
same height as the pull roller nip to help feed the board and image into the pull rollers.  
Page 5 - 20  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
RELEASE  
LINER  
COLD  
COLD  
Chart 2-6B  
TWO PASS HOT OVERLAMINATE  
WITH PRESSURE SENSITIVE MOUNT ADHESIVE  
SECOND PASS  
© GBC Films Group June 2000  
Page 5 - 21  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-7  
Process: Cold overlaminate with pressure sensitive mount adhesive  
Materials (top/bottom): PSA Laminate/ PSA Mount Adhesive  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
ON / 40 p.s.i. Top Heat  
ON / 115° F (46oC)  
OFF / NA  
OFF  
Top Clutch  
ON / 20 p.s.i. Bottom Heat  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
ON / 40 p.s.i. Top Cooling Fans  
ON / 20 p.s.i. Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
4 - 6 f.p.m. Bottom Brake (rear)  
OFF  
ON / 60 p.s.i.  
ON / 60 p.s.i.  
OFF / NA  
OFF / NA  
0
Laminator Roller Shims  
0
Bottom Clutch (rear)  
Pull Roller Shims  
Helpful Hints/Notes:  
Page 5 - 22  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
UNW IND  
RELEASE  
PAPER  
REW IND  
115 °F  
46 °C  
COLD  
MOUNT  
ADHESIVE  
UNW IND  
Chart 2-7B  
TWO PASS COLD OVERLAMINATE  
WITH PRESSURE SENSITIVE MOUNT ADHESIVE  
FIRST PASS  
© GBC Films Group June 2000  
Page 5 - 23  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-8  
Process: Cold overlaminate with pressure sensitive mount adhesive (second pass)  
Materials (top/bottom): / 3/16" Foamcore  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
OFF / NA Top Heat  
OFF / NA  
OFF / NA  
OFF  
Top Clutch  
OFF / NA Bottom Heat  
ON / 30 p.s.i. Top Cooling Fans  
OFF / NA Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
2 - 3 f.p.m. Bottom Brake (rear)  
3/16" Bottom Clutch (rear)  
Pull Roller Shims  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
OFF  
OFF / NA  
OFF / NA  
OFF / NA  
OFF / NA  
N/A  
Laminator Roller Shims  
Helpful Hints/Notes:  
When mounting keep an even wrap around the upper main roll to eliminate any wrinkles due to  
uneven image feed.  
Page 5 - 24  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
115  
46  
°F  
RELEASE  
LINER  
°C  
COLD  
Chart 2-8B  
TWO PASS COLD OVERLAMINATE  
WITH PRESSURE SENSITIVE MOUNT ADHESIVE  
SECOND PASS  
© GBC Films Group June 2000  
Page 5 - 25  
 
Operations  
Orca 80-99 Operation and Maintenance Manual  
PROCESS CONTROL CHART 2-9  
Process: Cold Overlam only (using a sled)  
Materials (top/bottom): Pro-Gloss / 3/16" board (to be used for the sled)  
Front Control Panel  
Adjustments  
Rear Control Panel  
Adjustments  
Top Brake  
ON / 40 p.s.i. Top Heat  
ON / 115o F (46oC)  
OFF / NA  
OFF  
Top Clutch  
ON / 20 p.s.i. Bottom Heat  
ON / 40 p.s.i. Top Cooling Fans  
OFF / NA Bottom Cooling Fans  
OFF / NA Pull Roller Clutch  
FORWARD Pull Roller Pressure  
4 - 6 f.p.m. Bottom Brake (rear)  
3/16" Bottom Clutch (rear)  
Pull Roller Shims  
Laminator Roller  
Bottom Brake (front)  
Bottom Clutch (front)  
Forward/Reverse  
Speed  
OFF  
OFF / NA  
OFF / NA  
OFF / NA  
OFF / NA  
NA  
Laminator Roller Shims  
Helpful Hints/Notes:  
Use a starter board of the same thickness as the sled being used to start the laminate into the nip.  
Lay the image on the sled and follow the leader board into the nip while maintaining paper  
tension on the image being overlaminated.  
Page 5 - 26  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Operations  
UNW IND  
RELEASE  
PAPER  
REW IND  
3/16"STARTER  
BOARD  
3/16" FOAMBOARD  
IMAGE  
115 °F  
46 °C  
COLD  
Chart 2-9B  
COLD OVERLAMINATE  
© GBC Films Group June 2000  
Page 5 - 27  
 
Orca 80-99 Operation and Maintenance Manual  
Maintenance  
MAINTENANCE  
Monthly  
Introduction  
Setting the Nip:  
WARNING:  
The gap between the two laminator rolls and the  
secondary drive rollers is called the nip or roll nip. It  
should be checked once a month. They should be  
adjusted according to the following procedures.  
Some maintenance procedures require opening the  
cabinets while the power and air are still  
connected to the machine.  
Because of the potential for electrical shock from  
wiring and crushing of fingers or arms in rotating  
apparatus, only properly trained personnel should  
perform these tasks.  
Main Roll Nip Setting Procedure:  
1. Make sure that the machine has both power and air.  
It is also necessary to make sure that the up/down rates  
of the upper main roll are even prior to setting the nip; if  
not follow the rate adjusting procedure on page 4-2.  
Please note that the main rolls have to be cold (room  
temperature) when performing this procedure.  
CAUTION:  
Never attempt maintenance on an operating  
machine unless the instructions specifically call for  
it.  
2. Remove the shims and set the main roll pressure to  
40 psi. Note that this must be done with the upper  
main roll in its fully up position.  
GBC Pro-Tech laminators require minimal  
maintenance. However, regular maintenance is  
essential to keep any piece of precision machinery  
at peak performance. The following procedures  
are segmented into daily, monthly, biannual, and  
as-required procedures.  
3. Loosen main roll air cylinder caps and spin them to  
their fully up position.  
4. Lower the upper main roll and spin down the main  
roll air cylinder caps until they are finger tight and  
secure.  
Daily  
1. Clean the Laminating Rolls:  
5. Raise the upper main roll. The main roll nip is now  
set.  
The silicone laminating rolls can be cleaned of dust and  
dirt by passing an adhesive-coated board through the  
nip. (Of course, the nip should be set for the thickness  
of the board used). A mild dishwashing detergent can  
also be used to clean the rolls. However a better  
procedure is to use isopropyl alcohol and a 100-  
percent cotton terry rag.  
Pull Roll Nip Setting Procedure:  
1. Make sure that the machine has both power and air  
and that both cabinets are open. It is also necessary to  
make sure that the up/down rates of the upper pull roll  
are even prior to setting the nip; if not follow the rate  
adjusting procedure on the adjacent column.  
Samples of these two items were supplied in the  
accessory kit shipped with the machine.  
2. Remove the shims and set the pull roll pressure to  
40 psi. The upper pull roll should be in the fully up  
position when making these adjustments.  
© GBC Films Group June 2000  
Page 6 - 1  
 
Maintenance  
Orca 80-99 Operation and Maintenance Manual  
3. Loosen both pull roll air cylinder caps and spin them  
As Needed  
to their fully up position.  
Chain Tensioning:  
4. Lower the upper pull roll and spin down the pull roll  
air cylinder caps until they are finger tight and secure  
them. The pull roll nip is now set.  
1. Make sure that the machine has air only, no power,  
and that the right (drive side) cabinet is open (see the  
diagram on page 8-3).  
Cylinder Up/Down Rate Adjustment:  
2. Using a large adjustable wrench turn the appropriate  
chain tensioner until the desired chain tension is  
achieved. Make sure that the chain tension of each of  
the three chains is fairly close. If not it might cause  
stuttering in the feed of the laminator.  
If the upper laminating roll or upper pull roll moves up  
or down unevenly, the cylinder flow controls need to be  
adjusted.  
Turn them clockwise to slow the up/down rate and  
counter-clockwise to increase the up/down rate. To  
correct for uneven motion, when the roll is going up,  
adjust the flow controls at the top of the air cylinders.  
To adjust for uneven lowering, set the air pressure on  
the laminating roll regulator at 100 pounds per square  
inch (PSI), 690 kPa, and make the necessary  
adjustments to the flow controls on the bottom of the air  
cylinders.  
Six Months  
1. Lubrication:  
Disconnect the power and air supply to the machine.  
Then, remove the end panels.  
Lubricate the bearings on the ends of each laminating  
roll (two per roll) with a high temperature grade of  
bearing grease, such as Lubriplate 930-2 or equivalent  
from a standard grease gun. Also lubricate the flange  
bearing on the bottom secondary drive roll (pull roller).  
Lubricate by hand the slots that both the upper main  
and pull rolls slide up and down in.  
Complete the lubrication by wiping the entire length of  
the chain with an oily rag. It is also important to note  
that over-lubrication of bearings is a leading cause of  
bearing failure. Close the side panels, and reconnect the  
electrical power and air supply.  
Page 6 - 2  
© GBC Films Group June 2000  
 
Orca 80-99 Operation and Maintenance Manual  
Maintenance  
PRIMARY  
SECONDARY  
CHAIN 3  
CHAIN  
TENSIONERS  
CHAIN 4  
CHAIN TENSION  
DIAGRAM  
© GBC Films Group June 2000  
Page 6 - 3  
 

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