25&$ ,9 ,PDJH 7UDQVIHU /DPLQDWRU 2SHUDWLRQ 0DQXDO N G E CY S T O P AR 'UR N T O TD RE S AU EME R © 1998 GBC Pro-Tech Do not duplicate without written permission N G E CE % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 PROTECH WAR AC NING HT UN MIS G E EN N G E CY S T O P AR 'UR N T O TD RE S AU EME R GA RD E N G E CE psi 100 90 kPa 80 700 70 630 60 50 40 30 20 10 CA 560 490 420 350 280 CAL
ORCA-IV Image Transfer Laminator Operation Manual The information in this publication is provided for reference and is believed to be accurate and complete. GBC Pro-Tech is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication, including, but not limited to, any implied warranty of fitness or merchantability for any particular use.
ORCA-IV Image Transfer Laminator Operation Manual 7DEOH RI &RQWHQWV 6HFWLRQ 6DIHW\ Caution/Warning Label Locations .................................................................................... 1-5 6HFWLRQ ,QVWDOODWLRQ Preinstallation Checklist........................................................................
ORCA-IV Image Transfer Laminator Operation Manual 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Cleaning .......................................................................................................................... 4-1 Lubrication ....................................................................................................................... 4-3 Adjusting the Kick Cable........................................................................
ORCA-IV Image Transfer Laminator Operation Manual 6HFWLRQ 6DIHW\ DO NOT ATTEMPT TO OPERATE YOUR ORCA-IV IMAGE TRANSFER LAMINATOR UNTIL YOU HAVE READ THIS SECTION CAREFULLY! Your safety, as well as the safety of others, is important to GBC Pro-Tech. This section contains important safety information. The following symbols are used throughout this manual to indicate warnings and cautions. DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
ORCA-IV Image Transfer Laminator Operation Manual N GE CY S TO R ET AR N D' UR OT S AU EM E R FRONT P 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 emergency stop buttons must be in the out position and you must perform the Machine Reset Procedure. See “Machine Reset Procedure” on page 1-3.
ORCA-IV Image Transfer Laminator Operation Manual Safety N G E CY S TO P T D' U R RE AR N T O S AU EM E R Kick Cable Reset Button N G E CE % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 PRO -TEC H Figure 1-3: Kick Cable Reset Button Reset Button Power Switch w/ Lock 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.
Safety ORCA-IV Image Transfer Laminator Operation Manual IMPORTANT Do not operate the image transfer laminator near water. You can be severely shocked, electrocuted or cause a fire. DANGER Remove and lockout power from the image transfer laminator before servicing. You can be severely shocked, electrocuted or cause a fire. 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.
ORCA-IV Image Transfer Laminator Operation Manual 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. 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.
Safety ORCA-IV Image Transfer Laminator Operation Manual Located Inside ACHTUNG Cabinet WARNING One Located At Each Roll Load Point (7 Total) 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. N G E CY S Located Inside Cabinet TO OT N D'U R RET AR S AU P E ME R ©1994 Hazard Communication Systems, Inc. 800-748-0241 N G E CE ER LL y elr area. D RO .
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 (“Meaning” column) of each decal. Decal Meaning WARNING! WARNING ACHTUNG Moving parts can crush and cut. MISE EN GARDE Do not operate with guard or door open. Decal Meaning WARNING! SAFETY INSTRUCTIONS SICHERHEITSRICHTLINIEN 1. 2. CONSIGNES DE SÉCURITÉ 3. 4.
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ORCA-IV Image Transfer Laminator Operation Manual Installation 6HFWLRQ ,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. Before an ORCA-IV Image Transfer Laminator can be installed there are a few requirements that must be met.
Installation ORCA-IV Image Transfer Laminator Operation Manual ❏ Is there an appropriate filtered dry air supply available? 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.
ORCA-IV Image Transfer Laminator Operation Manual Installation 4' x 6' (1.2m x 2m) Work Table on Wheels Rear Electrical Supply (Standard Inlet on Bottom of Machine) 38.4" (.98m) 50" (1.27m) Air Supply (On Bottom of Machine) 24' (7.3m) 85" (2.16m) Front 153" (3.89m) 4' x 6' (1.
Installation ORCA-IV Image Transfer Laminator Operation Manual 8QSDFNLQJ ☞ NOTE ALL SHIPMENTS ARE EX- WORKS. At our dock title passes to the buyer Please review your insurance coverage 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 applicable, you should make a note of this on the Bill of Lading.
ORCA-IV Image Transfer Laminator Operation Manual ☞ NOTE A word about international shipments: As these are heavy pieces of equipment, GBC Pro-Tech takes every precaution to ensure that our image transfer laminators are properly crated to the highest standards. Before machines leave our loading dock, they are pretreated with a VCI protective film to provide total corrosion protection. This protective film is wrapped around the machine and completely sealed.
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 following checklist to confirm that the unit is operating properly and that all safety mechanisms are functioning. Startup Checklist Start the image transfer laminator and go through the following checklist. Figure 2-8: Leveling Side to Side 6.
ORCA-IV Image Transfer Laminator Operation Manual ❏ 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 doors open. You should not be able to increase the speed of the machine above 3.0 ft/min (1 m/min). ☞ Note The speed control works best with a slow, gradual increase or decrease of the speed control knob. IMPORTANT Installation CAUTION Never allow loose objects (pens, knife blades, jewelry, etc.
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ORCA-IV Image Transfer Laminator Operation Manual Operation 6HFWLRQ 2SHUDWLRQ 6DIHW\ The ORCA-IV Image Transfer Laminator has been designed with safety as a primary consideration. However, 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.
ORCA-IV Image Transfer Laminator Operation Manual N GE CY S TO R ET AR N D' UR OT S AU EM E R FRONT P 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 emergency stop buttons must be in the up position and you must perform the Machine Reset Procedure. See “Machine Reset Procedure” on page 3-3.
ORCA-IV Image Transfer Laminator Operation Manual Operation 6. Start the motor and increase the speed. N G E CY S TO P T D' U R RE AR N T O S AU EM E R Kick Cable Reset Button N G E CE % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 % 100 90 80 70 60 50 40 30 20 10 PRO -TEC H Figure 3-3: Kick Cable 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. 1.
Operation ORCA-IV Image Transfer Laminator Operation Manual 2SHUDWRU &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.
ORCA-IV Image Transfer Laminator Operation Manual Operation 8. ROLL TEMPERATURE - Provides a readout of the temperature of the upper main roll and the setpoint 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 controller 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.
Operation ORCA-IV Image Transfer Laminator Operation Manual )URQW &OXWFK %UDNH 3DQHO % 100 90 Upper Middle Clutch (Rewind) Percent Web Force 1 2 80 70 60 50 40 30 3 20 10 % 100 5 90 Upper Front Clutch (Rewind) Percent Web Force 4 80 70 60 50 40 6 30 20 10 % 100 90 8 80 Middle Front Brake Percent Web Force 7 70 60 50 40 30 9 20 10 % 100 Unwind/Rewind Shaft Locking System ON/OFF Lowerr Front Brake Percent Braking Force 10 90 12 80 70 60 50 40 11 30 20 10 PRO-TECH 13 Upper M
ORCA-IV Image Transfer Laminator Operation Manual Operation 11. LOWER FRONT BRAKE PERCENT BRAKING 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 tension you set.
Operation ORCA-IV Image Transfer Laminator Operation Manual 5HDU &RQWURO 3DQHO Pull Roll 1 Pressure Display 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 Main Roll 2 UP/DOWN 3 Pull Roll Pressure Adjustment 4 GBC Logo Automatic/Manual Mode Control 5 Speed/ Accumulator Display Speed Adjustment 6 7 Pull Roll Torque ON/OFF 8 Roll Pull Force Adjustment/Display 9 Pull Roll UP/DOWN 10 11
ORCA-IV Image Transfer Laminator Operation Manual Operation 12. ACCUMULATOR RESET - Resets the accumulator. 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.
Operation ORCA-IV Image Transfer Laminator Operation Manual 5HDU &OXWFK %UDNH 3DQHO % 100 90 Upper Rear Brake Percent Web Force 1 2 80 70 60 50 40 30 3 20 10 % 100 5 90 Middle Rear Clutch Percent Web Force 4 80 70 60 50 40 6 30 20 10 % 100 90 8 80 Lower Rear Clutch Percent Web Force 7 70 60 50 40 30 9 20 10 Unwind/Rewind Shaft Locking System ON/OFF Upper Rear Brake Pressure Upper Rear Brake Indicator Middle Rear Clutch Pressure Middle Rear Clutch Indicator Lower Rear Clutch Pressu
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 followed exactly. Use the following instructions when heating the upper main roll. /RDGLQJ WKH )LOP 2. Adjust the temperature controller for the desired operating temperature using the temperature controller set point adjustment.
Operation ORCA-IV Image Transfer Laminator Operation Manual 5HFRPPHQGHG 0DWHULDOV 6HWWLQJ WKH 6OLWWHU )LOPV ([FOXGLQJ 9LQ\O 7UDQVIHU DQG 1. Turn the thumbscrew on the slitter counterclockwise until it stops. 2YHUODPLQDWLRQ The ORCA IV image transfer laminator is capable of processing a wide range of pressure sensitive and thermal laminates onto an equally wide range of image materials. The primary considerations are: • Laminate adhesives are compatible with image materials.
ORCA-IV Image Transfer Laminator Operation Manual 3RVLWLRQLQJ WKH )LOP DQG &HQWHULQJ WKH :HE Tools required: • 1 • Tape measure /4" T-handle wrench 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.
Operation ORCA-IV Image Transfer Laminator Operation Manual )LOP 6SDFLQJ To advance the vinyl without the paper: Table 3-2: Film Spacing Film Size 54" (137.16 cm) Distance From End of Shaft to Material Side Plate Distance From Machine Side to Material Side Plate 7-15/16" (20.16 cm) 7-1/2" (19.05 cm) 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.
ORCA-IV Image Transfer Laminator Operation Manual 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. 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.
Operation ORCA-IV Image Transfer Laminator Operation Manual 3URFHGXUH 1. See process chart 3-1 and diagram 3-1a for material mounting instructions and machine adjustments. 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.
ORCA-IV Image Transfer Laminator Operation Manual Operation 352&(66 &21752/ &+$57 WEB FORCE SUGGESTED VALUES Main Product Rewind (Finished Graphic) 20 WF Transfer Media, 3M 8601i 15 WF Marking Film (Vinyl) Like 3M (8620, 8640, etc.) 20 WF Overlaminate Unwind 50 WF Used Transfer Media (Rewind) 20WF Strip Release Liner (Laminate) 30 WF 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 (.
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ORCA-IV Image Transfer Laminator Operation Manual 6HFWLRQ 0DLQWHQDQFH DQG 7URXEOHVKRRWLQJ Performing regular maintenance on the ORCA-IV Image Transfer Laminator is critical to the proper operation of the machine. A maintenance schedule and a section of procedures for disassembling and reassembling the serviceable areas of the image transfer laminator are included in this section.
Maintenance and Troubleshooting ORCA-IV Image Transfer Laminator Operation Manual To clean beads of adhesive, dust and dirt from the rolls: 1. Allow the image transfer laminator to cool slightly to no higher than 110ºF (43ºC). To clean the cabinet and covers: 1. Using a damp cotton terry cloth (water only), clean the exterior of the image transfer laminator. 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.
ORCA-IV Image Transfer Laminator Operation Manual Maintenance and Troubleshooting /XEULFDWLRQ $GMXVWLQJ WKH .LFN &DEOH Tools required: Occasionally, the kick cable needs adjustment to properly reset after use. • 1/ " 8 • High temperature grease or lithium grease • Grease gun • Heavy weight gear oil • Soft cloth hex wrench Tools required: To lubricate the image transfer laminator: • Phillips head screwdriver To adjust the kick cable: 1.
Maintenance and Troubleshooting ORCA-IV Image Transfer Laminator Operation Manual &RQWDFWLQJ 7HFKQLFDO 6XSSRUW For machine parts and technical service in North America, please call: 1-608-246-8844 or fax 1-608246-8645. Please provide serial number when calling 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.
ORCA-IV Image Transfer Laminator Operation Manual Maintenance and Troubleshooting Grease Fitting Grease Fitting Keep Pins (3) Well Oiled (Monthly) Disassemble and Grease (Yearly) Grease Fitting Lubricate Slides with Grease Pull Roll Grease Both Sides, Bottom Roll Grease Main Roll Bearings Both Sides, Top and Bottom Rolls Grease Fitting Grease Fitting Figure 4-1: Grease Fittings © GBC Pro-Tech 1998 October 4-5
Maintenance and Troubleshooting ORCA-IV Image Transfer Laminator Operation Manual 2XWSXW 7URXEOHVKRRWLQJ *XLGH Problem: D waves in the image, not in the laminate. Problem: D waves in the laminate. Problem: Straight waves in the output. Hints: • Check paper tension. • Check relative moisture content of the paper. Hints: • Increase brake tension on laminate. • Check roll pressures. • Check nip settings. Hints: • Decrease clutch tension. • Check operational settings for materials being used.
ORCA-IV Image Transfer Laminator Operation Manual Maintenance and Troubleshooting Table 4-4: Machine Troubleshooting Guide Problem Number Problem Possible Cause Corrective Action 1 No display. 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)). 2 Display reads 8888. a. Is the machine reset? a. Make sure all safety buttons are released (out).
Maintenance and Troubleshooting Problem Number 4-8 ORCA-IV Image Transfer Laminator Operation Manual Problem Possible Cause Corrective Action 7 Rewound material not even on edge. a. Was the initial material webbing straight? b. Is the roll telescoped? c. Is there excessive tension? d. Is it a poor roll of film (soft end)? a. Measure carefully from sideframe and straighten webbing. b. Use end plates on all unwinds. c. Lower the tension. d. Try a new roll.
ORCA-IV Image Transfer Laminator Operation Manual Problem Number Maintenance and Troubleshooting Problem Possible Cause Corrective Action 12 I pressed the motor forward button, but the rolls would not turn! 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 turn the speed control up. b.
Maintenance and Troubleshooting Problem Number 4-10 Problem ORCA-IV Image Transfer Laminator Operation Manual Possible Cause Corrective Action 17 I pressed the pull roll up push button, but the rolls did not go up! a. Is there air pressure to the machine? b. Is the machine reset? a. Verify that the air supply is sufficient (≤100 psi). b. Reset the machine. See "Machine Reset Procedure" on page 3-3. 18 I pressed the top roll temperature control “ON” push button and nothing happens. a.
ORCA-IV Image Transfer Laminator Operation Manual Problem Number Problem Maintenance and Troubleshooting Possible Cause Corrective Action 25 I pressed the totalizer-reset push button while in totalizer mode, and it did not reset and other buttons on the panel do not work either, but the controls on the other panel work. a. Is the machine reset? b. Is there a problem with the keypad? c. Is there a software problem? a. Reset the machine. See "Machine Reset Procedure" on page 3-3. b.
Maintenance and Troubleshooting Problem Number 4-12 Problem ORCA-IV Image Transfer Laminator Operation Manual Possible Cause Corrective Action 34 I pressed the shaft engage push button and the shaft did not engage. 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. b. Reset the machine. See "Machine Reset Procedure" on page 3-3. c. See problem 12. 35 The machine was running, but stopped abruptly. a.
ORCA-IV Image Transfer Laminator Operation Manual 6HFWLRQ :DUUDQW\ /LPLWHG :DUUDQW\ 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 ProTech and cannot be modified or amended.
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ORCA-IV Image Transfer Laminator Operation Manual Specifications 6HFWLRQ 6SHFLILFDWLRQV Table 6-1: ORCA-IV Image Transfer Laminator Specifications Characteristic Dimensions (L x D x H) Weight Main Rolls Main Roll Opening Material Speeds Safety Features Options Installation Requirement Specifications 86" x 48" x 73" (2.2 x 1.2 x 1.7 m) Uncrated: 3060 lbs (1814 kg) 62" (157 cm) roll face with high release silicon rubber coating for 54" wide materials 1.25" (3.
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ORCA-IV Image Transfer Laminator Operation Manual ,QGH[ , 1XPHULFV 3M 3-12 Installation requirements 2-1, 6-1 International shipments 2-5 Isopropyl alcohol 4-1 $ - 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 Cabinet and covers 4-2 Doors 4-2 Rolls 4-1 Controls Front brake panel 3-6 Front control panel 3-4 Rear brake panel 3-10 Rear control pa
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