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GBC 80-99 - page 1
GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645 ORCA 80-99 OPER ATION & MAINTENANCE MANUAL © June 2000 GBC Pro- Tech Do not duplicate without written permission. Part number : 930 - 055 ...
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GBC 80-99 - page 2
Page I Table of Contents Orca 80-99 Operation and Maintenance Manual © GBC Pro - Tech June 2000 Table of Contents Section 1: Safety Safety features .............................................................................. 1 - 1 Section 2: Warranty Limited warranty information ..................................................... 2 - 1 Exclusi ...
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GBC 80-99 - page 3
Page II Table of Contents Orca 80-99 Operation and Maintenance Manual © GBC Pro - Tech June 2000 Section 5: Operations Operation ....................................................................................... 5 - 1 Front control panel diagram ........................................................ 5 - 2 Rear control panel diagram ........ ...
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GBC 80-99 - page 4
Page III Table of Contents Orca 80-99 Operation and Maintenance Manual © GBC Pro - Tech June 2000 Encapsulation (Chart 2.4) ............................................................ 5 - 16 Encapsulation (Diagram 2.4) ........................................................ 5 - 17 Hot laminate/PSA mount (Chart 2.5) .............................. ...
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GBC 80-99 - page 5
Page IV Table of Contents Orca 80-99 Operation and Maintenance Manual © GBC Pro - Tech June 2000 Section 6: Maintenence Daily ................................................................................................ 6 - 1 Monthly ........................................................................................... 6 - 1 Six Month .... ...
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GBC 80-99 - page 6
Page 1 - 1 Safety Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 SAFETY READ THIS SECTION BEFORE OPER ATING THE ORCA 80-99 LAMIN AT OR! FOR YOUR SAFET Y: Y our 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 care ...
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GBC 80-99 - page 7
Page 1 - 2 Safety Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 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 ...
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GBC 80-99 - page 8
Page 2 - 1 Warranty Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 WARRANTY Limited Warranty CAUTION: Unauthorized customer alterations will void this warrant y. GBC Pro- T ech 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 custome ...
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GBC 80-99 - page 9
Page 3 - 1 Specifications Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 ORCA 80-99 SPECIFIC ATIONS Description: 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 fo ...
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GBC 80-99 - page 10
Page 4 - 1 Installation Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 INS TALLATION Uncrating the Machine CAUTION: When taking the top off, care should be taken so that the top does not fall into the crate, possibly damaging the laminato r . It might be necessary to use two or three people for this task. During the uncrat ...
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GBC 80-99 - page 11
Page 4 - 2 Installation © GBC Films Group June 2000 Orca 80-99 Operation and Maintenance Manual 23 i n. [59 cm] 3 2 IN STALL SCREWS UNCRAT ING DIAGRAM 5 ORC A-80-99 1 4 ...
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GBC 80-99 - page 12
Page 4 - 3 Installation Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 7. Once the ramps are secured and the hold down plates are removed, the machine can be rolled off the crate bottom. This will require four people handling the machine on its four corners and carefully rolling the machine off the crate bottom (see diagra ...
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GBC 80-99 - page 13
Page 4 - 4 Installation © GBC Films Group June 2000 Orca 80-99 Operation and Maintenance Manual SUGG ESTED WOR KSPACE LAY OUT F i g . 1-1 AIR SUPPLY ELECTRICAL S U PPLY 20 ' [6m] 24' [7.3 m] 10' [3 m] 4' [1.2 m] 10 ' [3m] 3' [1m ] ORC A 80-99 FRONT REAR Work Tab le 6' X 6' [2m x 2 m] (on w hee l s) Work Tab ...
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GBC 80-99 - page 14
Page 4 - 5 Installation Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 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 minu ...
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GBC 80-99 - page 15
Page 5 - 1 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 OPER ATION Safety Safety is always the primary concern. If you have not read the safety information at the front of this manual, do so no w . Do not attempt operation of the machine until you fully understand this safety information. General Precautions 1 ...
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GBC 80-99 - page 16
Page 5 - 2 Operations © GBC Films Group June 2000 Orca 80-99 Operation and Maintenance Manual ON TOP CLUTCH CONTROLS LAMINATOR ROLL CONTROLS BOTTOM BRAKE CONTROLS BOTTOM CLUTCH CONTROLS TOP BRAKE CONTROLS PRO-TECH ENGINEERING, MADISON, WISCONSIN 380-3440 POWER OFF ON OFF ON LIGHTS PRESSURE PRESSURE OFF OFF PRESSURE PRESSURE OFF OFF PRESSURE OFF S ...
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GBC 80-99 - page 17
Page 5 - 3 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 ADJUST PRESSURE BOTTOM CLUTCH OFF ON BOTTOM COOLING FANS TOP COOLING FANS BOTTOM HEAT OFF TOP HEAT ON BOTTOM BRAKE PULL ROLLER PRESSURE PULL ROLLER CLUTCH ADJUST PRESSURE ADJUST PRESSURE ADJUST PRESSURE ON OFF ON OFF OFF ON ON OFF ON OFF ON OFF REAR CONTR ...
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GBC 80-99 - page 18
Page 5 - 4 Operations © GBC Films Group June 2000 Orca 80-99 Operation and Maintenance Manual Operator Controls The operator controls for the Orca laminator are operator position. See Figures 2-1 and 2-2. The names and functions of these controls are as follows: FRONT CONTROL PANEL Please note that in each of the control sections there is a Pressu ...
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GBC 80-99 - page 19
Page 5 - 5 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 H. PULL ROLLER PRESSURE CONTROLS - Regulation for the upper pull roll pressure and up/down. I. BOTTOM BRAKE CONTROL - Regulation for the bottom rear unwind brake. J. BOTTOM CLUTCH CONTROL - Regulation for the bottom rear rewind shaft ’s clutch. Setup Se ...
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GBC 80-99 - page 20
Page 5 - 6 Operations © GBC Films Group June 2000 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. 5. Recheck the centering of the film roll with a tape measure. WARNING: Normal o ...
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GBC 80-99 - page 21
Page 5 - 7 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 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 en ...
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GBC 80-99 - page 22
Page 5 - 8 Operations © GBC Films Group June 2000 Orca 80-99 Operation and Maintenance Manual 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 G. Top Roll T emperature: 220-230 degrees F (90 - 110 degrees C). H. Bottom Ro ...
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GBC 80-99 - page 23
Page 5 - 9 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 C. Raise Main Roll (Hot). D. Reverse Moto r. 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. ...
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GBC 80-99 - page 24
Page 5 - 10 Operations © GBC Films Group June 2000 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 Top Cooling Fans Bottom Brake (front) Bottom Cooling Fans Bottom Clutch ( ...
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GBC 80-99 - page 25
Page 5 - 11 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 (I) REMO VABLE I DLER (F) FIXED IDLER (U) UN WIND S HA FT (R) REWIND (M) M A IN ROLL (P) P ULL ROLL U U U F F F F F I R R R M M P P OUTFEED SLI TT ER IDENTIFICATION DIAGRAM Chart 2-1B ...
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GBC 80-99 - page 26
Page 5 - 12 Operations © GBC Films Group June 2000 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 / 245 o F (118 o C) Top Clutch O FF / N ...
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GBC 80-99 - page 27
Page 5 - 13 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 245 °F COLD ONE PASS HOT MO UNT 118 °C IMAGE CHAR T 2-2B ...
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GBC 80-99 - page 28
Page 5 - 14 Operations © GBC Films Group June 2000 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 / 245 o F (118 o C) Top Cl ...
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GBC 80-99 - page 29
Page 5 - 15 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 245 °F COLD ONE PASS HOT MO UNT AND LAMINATE 118 °C IMAGE CH ART 2-3B ...
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GBC 80-99 - page 30
Page 5 - 16 Operations © GBC Films Group June 2000 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 / 230 o F (110 o C) Top Clutch ON / 20 p.s.i. Bottom Hea ...
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GBC 80-99 - page 31
Page 5 - 17 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 230 °F UN W IND ENCAPS UL AT ION 230 °F Cha r t 2-4B 110 °C 110 °C ...
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GBC 80-99 - page 32
Page 5 - 18 Operations © GBC Films Group June 2000 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 O N / 230 o F ...
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GBC 80-99 - page 33
Page 5 - 19 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 230 °F UN W IND TWO PASS HOT O VERLAMINATE COLD W IT H PRESSURE SENS ITIV E MOUN T A DHES IVE FIRST PASS Chart 2- 5B 110 °C UN W IND ...
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GBC 80-99 - page 34
Page 5 - 20 Operations © GBC Films Group June 2000 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 Top ...
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GBC 80-99 - page 35
Page 5 - 21 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 COLD COLD W IT H PRESSURE SENS ITIV E MOUN T A DHES IVE SECOND PASS TWO PASS HOT O VERLAMINATE RELEASE LINER Chart 2-6B ...
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GBC 80-99 - page 36
Page 5 - 22 Operations © GBC Films Group June 2000 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 ...
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GBC 80-99 - page 37
Page 5 - 23 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 RE W IND PAPER RELEASE 46 °C COLD UN W IND W IT H PRESSURE SENS ITIV E MOUN T A DHES IVE FIRST PASS TWO PASS CO LD OVERLAMINATE MOUNT ADHESIVE UN W IND Cha r t 2-7B 115 °F ...
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GBC 80-99 - page 38
Page 5 - 24 Operations © GBC Films Group June 2000 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 To ...
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GBC 80-99 - page 39
Page 5 - 25 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 46 °C COLD W IT H PRESSURE SENS ITIV E MOUN T A DHES IVE SECOND PASS TWO PASS CO LD OVERLAMINATE RELEASE LINER Cha r t 2-8B 115 °F ...
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GBC 80-99 - page 40
Page 5 - 26 Operations © GBC Films Group June 2000 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 / 115 o ...
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GBC 80-99 - page 41
Page 5 - 27 Operations Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 RE W IND PAPER RELEASE 115 °F COLD UN W IND IMAGE 3/16" FOAMBOARD 3/16"S TARTER BOARD CO LD OVER LA M INATE Chart 2-9B 46 °C ...
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GBC 80-99 - page 42
Page 6 - 1 Maintenance Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 MAINTENANCE Introduction WARNING: 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 a ...
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GBC 80-99 - page 43
Page 6 - 2 Maintenance © GBC Films Group June 2000 Orca 80-99 Operation and Maintenance Manual 3. Loosen both pull roll air cylinder caps and spin them to their fully up position. 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. Cylinder Up/Down Ra ...
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GBC 80-99 - page 44
Page 6 - 3 Maintenance Orca 80-99 Operation and Maintenance Manual © GBC Films Group June 2000 CH AI N T ENS ION D IA GR AM PR IMA RY SECO NDARY CHA IN 3 CHA IN 4 CHA IN TENS I ONERS ...
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