GBC Orca 1600 User manual

GBCPro-Tech
4151AndersonRoad
DeForest, WI 53532
Revision : A Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
ORCA 1600 OPERATION &
MAINTENANCE MANUAL
©February2001GBCFilms Group
Do not duplicate without written permission.
Partnumber: 930 -061
ORCA 1600
GBC
Pro - Tech

Read me fileOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
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Page I
Table ofContentsOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
Table of Contents
Section 1.0 Safety
1.1 Symbols ......................................................................................................1 - 1
1.2 Pneumatic safety ........................................................................................1 - 2
1.3 Safety features ............................................................................................1 - 2
1.4 Mechanical safety ......................................................................................1 - 4
1.5 Heating safety .............................................................................................1 - 4
1.6 Maintenance safety ....................................................................................1 - 5
1.7 Installation ..................................................................................................1 - 5
1.8 Operation ...................................................................................................1 - 8
1.9 Applications ...............................................................................................1 - 10
1.10 Troubleshooting .......................................................................................1 - 12
1.11 Maintenance ............................................................................................1 - 12
1.12 Label Explanation ....................................................................................1 - 14
Figure 1.12.1 Label Location ....................................................1 - 16

Page II
Table ofContents Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
Section 2.0 Warranty
2.1 Limited warranty information ....................................................................2 - 1
2.2 Exclusions to the warranty ........................................................................2 - 1
Section 3.0 Specifications
3.1 General .......................................................................................................3 -1
3.2 Consumables................................................................................................3 - 2
3.3 Function ......................................................................................................3 - 3
3.4 Electrical ....................................................................................................3 - 4
3.5 Dimensions .................................................................................................3 - 5
Section 4.0 Installation
4.1 Pre-installation check list ..........................................................................4 - 1
Figure 4.1.1 Suggested floor layout ..............................................4 - 3
4.2 Know your machine ...................................................................................4 - 4

Page III
Table ofContentsOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
4.3 Unpacking ..................................................................................................4 - 5
4.4 Shrink wrap ..............................................................................................4 - 5
4.5 Crated .........................................................................................................4 - 6
4.6 Accessory pack ..........................................................................................4 - 9
4.7 Electrical connection ..................................................................................4 - 9
4.8 Air connection ............................................................................................4 - 11
4.9 Installing levelers .......................................................................................4 - 12
4.10 Leveling ...................................................................................................4 - 13
4.11 Calibrations .............................................................................................4 - 14
Section 5.0 Operations
5.1 Power ON/ OFF .........................................................................................5 - 1
5.2 Front control panel ....................................................................................5 - 2
Figure 5.2.1 Front control panel ............................................................5 - 4

Page IV
Table ofContents Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
5.3 Rear control panel ......................................................................................5 - 5
Figure 5.3.1 Rear control panel ............................................................5 - 7
5.4 Setting temperature ....................................................................................5 - 8
5.5 In case of an emergency .............................................................................5 - 9
5.6 Film loading/ unloading ...........................................................................5 - 10
5.7 Main roller nip ..........................................................................................5 - 11
5.8 Pull roller nip ............................................................................................5 - 12
5.9 Shutdown procedure ..................................................................................5 - 12
Section 6.0 Applications
6.1 Temperature chart .....................................................................................6 - 1
6.2 Helpful hints ...............................................................................................6 - 2
6.3 Temp conversion chart ...............................................................................6 - 3
Figure 6.3.1 Temperature conversion chart .................................6 - 4

Page V
Table ofContentsOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
6.4 Charts and diagrams .................................................................................6 - 5
Chart - 0 ( blank chart ) ..........................................................................6 - 6
Diagram - 0 .............................................................................................6 - 7
Chart - 1 ( 1 pass mounting ) ...................................................................6 - 8
Diagram - 1 .............................................................................................6 - 9
Chart - 2 ( PSA decaling ) .....................................................................6 - 10
Diagram - 2 ............................................................................................6 - 11
Chart - 3 (Mounting a PSA decal ) ........................................................6 - 12
Diagram - 3 ............................................................................................6 - 13
Chart - 4 ( Thermal decal ) ...................................................................6 - 14
Diagram - 4 ............................................................................................6 - 15
Chart - 5 ( Mounting a thermal decal ) .................................................6 - 16
Diagram - 5 ............................................................................................6 - 17
Chart - 6 ( Thermal encapsulation ) ......................................................6 - 18
Diagram - 6 ............................................................................................6 - 19

Page VI
Table ofContents Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
Section 7.0 Troubleshooting
7.1 Wave problems ..........................................................................................7 - 1
7.2 Film problems .............................................................................................7 - 3
7.3 Machine problems .....................................................................................7 - 4
7.4 Glossary ......................................................................................................7 - 5
Section 8.0 Maintenance
8.1 Maintenance schedule ...............................................................................8 - 1
8.2 Cleaning the rollers ..................................................................................8 - 2
8.3 Dust - Pre-coated boards ............................................................................8 - 3
8.4 Dirt and PSA adhesive - Alcohol and cloth ...............................................8 - 3
8.5 Thermal adhesive .......................................................................................8 - 4
8.6 Clean the laminator ....................................................................................8 - 5
8.7 Clean the control panels .............................................................................8 - 6

Page 1 - 1
SafetyOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
1.0 Safety
CAUTION
Do not attempt to operate your ORCA 1600
laminator until you have read this
section carefully!
Your safety, as well as the safety of others, is
important to GBC Films Group. This section contains
important safety information.
The following symbols are used throughout
this manual to indicate Information, Caution,
Warning, Danger and Electrical Shock conditions.
1.1 Symbols
INFORMATION
Indicates helpful information that should be
considered before, during, or after an
action, step or procedure is given.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, could result in minor
or moderate injury, or alerts against unsafe
practices or alerts against actions which
could damage the product.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result
in serious injury.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, could result in death
or serious injury.
ELECTRICAL
SHOCK
Indicates an electrical shock situation which,
if not avoided, could result in serious
paralyzation of the body or death.

Page 1 - 2
Safety Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
1.2 Pneumatic safety
The Orca 1600 laminator has been designed
with safety as a primary consideration; however, you
must become thoroughly familiar with the controls,
properoperation,proper service proceduresandsafety
features of the laminator before using or servicing the
unit.
The pneumatic system used to provide down-
ward pressure on the top main roller and the top pull
roller is capable of producing great amount of forces.
This force is applied to any object presented in the
opening (called the nip) between the two rollers.
CAUTION
Objects other than media, film or approved
substrates, will cause irreparable damage
to the rollers if caught in the nip.
Use care in lowering the top main and/ or pull
rollers. Know how to react quickly in an emergency.
The top main laminator roller UP-DOWN switch is
located on the front control panel. The top pull roller
UP-DOWNswitch is locatedon the rearcontrol panel.
This switch controls the up and down motion of the
top pull roller.
Before pressing either of these switches to the
DOWN position, ensure that nothing is in the nip ar-
eas. If any problem or danger should occur, depress-
ing any of the emergency stop push buttons or engag-
ing the emergency cables, described in Section 1.3,
stops the rollers from closing and raises them com-
pletely.
1.3 Safety features
Important safety features of the Orca 1600
laminator are the emergency stop push buttons ( E-
STOP), the emergency stop cables ( E-CABLE) and
the photo electric sensors ( PHOTO-EYE ). It is
recommended that you become thoroughly familiar
with each of these safety features purpose and how to
use them in the event of an emergency.
E- STOP
To engage any oneof the four E-STOPs, press
the push button down. Any one of these, when
engaged, removes power to the motor and opens the
main roller and pull roller nips.
E
M
E
R
G
E
NC
Y
S
T
O
P
Disengaged
Turn
E
M
E
R
G
E
NC
Y
S
T
O
P
Engaged
Push
To continue operation, all E-STOPS must be
in the up position. To reset the E-STOP, twist the
button 1/4 turn counter clockwise and reset the main
roller UP-DOWN switch to UP.

Page 1 - 3
SafetyOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
E- CABLE
To engage the front or rear E-CABLE, push
in on the cable using your foot. Either cable, when
engaged, removes power to the motor and opens the
main roller and pull roller nips. The E-CABLE are
provided in the event you are unable to reach one of
the four E-STOPs.
Press in or down
ORCA1600
GBC
Pro-Tech
To continue operation, reset the main roller
UP-DOWN switch to UP and continue on with
operation. The E-CABLE automatically resets itself
when the cable springs back to it’s original position.
All E-STOPs must be in the unlatched position as
well.
The E-CABLE may be adjusted if you feel
the cable is too sensitive or too loose. Contact your
local service representative for this adjustment.
PHOTO-EYE
The Orca 1600 is equipped with three sets of
PHOTO-EYEs, one atthe main roller nip,onebehind
the pull roller nip and one in front of the pull roller
nip. The PHOTO-EYEs, when blocked by an object,
stop the rollers from turning and will resume turning
when the sensor is no longer blocked.
This safety feature not only protects the
operator but also protects objects from entering the
rollers nip causing damage. The PHOTO-EYEs are
calibrated at time of installation.
With the FWD/ REV switch in the FWD
position, the PHOTO-EYE at the front of the main
roller nip (1) and the rear of the pull roller nip (3) are
engaged.
( 1 ) Main roller
photo-eye
( 2 ) Front pull roller
photo-eye
( 3 ) Rear pull roller photo-eye
With the FWD/ REV switch in the REV
position, the PHOTO-EYE at the front of the pull
roller nip (2) is engaged only.

Page 1 - 4
Safety Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
1.4 Mechanical safety
WARNING
Never remove or open any guarding or
covers from the machine. These are
placed for you protection as well as
the protection of the machine.
WARNING
Never place hands, fingers or objects
through any opening of the side frame. Your
hand or fingers may be pinched or crushed
or you may cause damge to the machine.
WARNING
When swinging out or in an unwind,
keep hands and fingers away from
the pivot end. Your hand or
fingers may be pinched.
WARNING
Keep hands and fingers away from the
ends of the removable idlers when
removing or installing them at
various locations on the machine.
1.5 Heating safety
The heating components of the Orca 1600 can
reach temperatures of over 200 oF ( 100 oC ).
DANGER
At these temperatures there is a danger of
severe burn if the rolls are touched during
setup, operation or servicing.
In the event of a run away heat failure, the
machine is equipped with a thermal cut off switch.
This switch will remove power to the heating system
before any damage can be caused by the run away
heat failure.
If run away heat failure occurs, call
your local service representative
before using the machine again.
INFORMATION
CAUTION
Never leave the roller in the down position
without rolling when the rollers are heated.
This will cause damage to the rollers.

Page 1 - 5
SafetyOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
1.6 Maintenance safety
Any maintenance requiring the cabinets to be
openedwith electrical powerconnected should beonly
performed by a qualified service technician.
INFORMATION
Only a qualified service technician should
perform any procedure requiring the
cabinet doors to be opened.
The word qualified is defined as;
Qualified ;
• Any engineer that has experience with
electrical and mechanical design of lamination
equipment. The engineers should be fully aware of
all aspects of safety with regards to lamination
equipment.
•Anycommissioning or serviceengineermust
be of competent nature, trained and qualified to GBC
Films Group standards to fulfill that job. This person
will have completed and passed the full service
training course from GBC Films Group.
• Any GBC Technician, GBC Specialist, and /
orGBCFilms Group Technician that hasbeen through
the GBC Pro-Tech service training course.
1.7 Installation
The following symbols are positioned at
various points in Section 4 Installation.
CAUTION
Failure to follow the pre-installation check
list can result in damage to the laminator.
WARNING
The operating environment must be free of
dust, flammable liquids and vapors. You can
be injured by inhaling chemical vapors.
WARNING
Vapor build up or stored flammable liquids
can cause a fire. Excessive dust can damage
the laminator.
CAUTION
Do not locate the laminator where air is
blowing directly on the machine. The air
flow can cool the rolls unevenly and result
in poor output quality.

Page 1 - 6
Safety Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
WARNING
The Orca 1600 Laminator is a large and
heavy piece of equipment. It is necessary to
employ LICENSED RIGGERS ONLY to
move the laminator. The laminator is not
designed to be tipped up or sideways in any
way. Such action disturbs the exact
alignment of the rolling parts of the machine
and requires extensive realignment. You can
be crushed or seriously injured.
INFORMATION
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.
INFORMATION
Before signing the Bill of Lading, you
should be sure to inspect the crate
and / or pallet for signs of damage or
missing items; if applicable, make
note of this on the Bill of Lading.
WARNING
The unpacking process requires at least two
people. You can be severely injured, crushed
or cause damage to the laminator.
INFORMATION
Depending on the destination and customer
preference, your machine may be shipped in
various ways. The laminator may arrive
shrink wrapped or in a plywood crate on a
skid. Please follow the unpacking procedure
that pertains to your method of shipment.
CAUTION
Do not use a knife or other sharp object to
remove the shrink wrap from around the
laminator. You can cause irreparable
damage to the rollers.
WARNING
Do not attempt to move the laminator across
anything other than a flat level surface
without trained and qualified riggers. You
can be crushed or seriously injured.
GBC Film Group's warranty does not
cover malfunction of the equipment due to
mishandling and / or tipping. GBC Films
Group bears no responsibility for personal
injury or damage due to moving the
laminator improperly.
INFORMATION

Page 1 - 7
SafetyOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
CAUTION
Do not allow the top to fall into the crate. It
can damage the laminator.
INFORMATION
Do not put packing screws on the floor.
They can cause problems when trying to roll
the laminator into position or you can
become injured if stepped on.
CAUTION
A second person must support the side
labeled 5 in Figure 4.5.1 It can fall and
damage the laminator or cause harm to you
and others.
WARNING
Do not attempt to use the ramps if they are
not secured to the pallet. Ensure the pallet is
on a flat even surface before attempting to
roll the machine off.
About recycling: The crate components can
be reused for shipping the laminator again
or can be disassembled and the wood and
screws recycled. The shrink wrap is not
recyclable, so it must be discarded.
INFORMATION
Ensure sufficient space for opening of the
cabinets for maintenance and servicing.
INFORMATION
ELECTRICAL
SHOCK
Only a qualified electrician should connect
power to the laminator. You can be severely
shocked, electrocuted or cause a fire if
power is improperly applied.
ELECTRICAL
SHOCK
Only a qualified electrician should verify
the voltage. You can be severely shocked,
electrocuted or cause a fire.

Page 1 - 8
Safety Orca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
WARNING
Do not operate the machine with the
control side or drive side cabinet
in the open position.
ELECTRICAL
SHOCK
Do not operate the laminator if the power
cord is damaged or frayed. You can be
severely shocked, electrocuted or cause a
fire. Contact a qualified electrician to
replace the cord.
The upper main roller and the upper pull
roller should be in the raised position.
INFORMATION
ELECTRICAL
SHOCK
These calibrations require the laminator
to be powered up while the cabinets
are opened.
1.8 Operation
The following symbols are positioned at
various points in Section 5 Operation.
WARNING
Do not wear ties, loose fit clothing or
dangling jewelry while operating or
servicing the laminator. These items can get
caught in the nip and choke you or you can
be crushed or burned.
WARNING
When the laminator rollers are in
motion, keep hands and fingers
away from the nip of the rollers.
You may be CRUSHED or BURNED!
The laminator will only turn on if
all E-STOPs are unlatched.
INFORMATION
The center position is to prevent jamming
of the motor when changing directions
INFORMATION

Page 1 - 9
SafetyOrca 1600 Operation and Maintenance Manual
© GBC Films Group February 2001
Top temperature control unit on/ off
switch must be on to turn the lower
temperature control unit to on.
INFORMATION
When decreasing pressure, allow the
pressure guage to drop below the desired
value, then increase pressure to the set
pressure desired. This allows for a more
accurate pressure reading.
INFORMATION
When an emergency stop feature is activated
and the main roll is in the up position, the
pull roll will only stay in the up position
until the emergency stop feature is
deactivated.
INFORMATION
The motor must be engaged for the cooling
fans to turn on. If the fan switch is in the
"on" position, the fans will automatically
turn on when the motor is engaged.
INFORMATION
INFORMATION
When requiring top and bottom heat, it is
recommended to set both temperatures to
the same set point.
The maximum set point temperature
is 270 oF ( 132 oC ).
INFORMATION
The minimum set point temperature
is 32 oF ( 0 oC ).
INFORMATION
When a safety feature is engaged, the
upper rollers raise and power to
the drive motor is removed.
INFORMATION
The upper main roller UP/ DOWN switch
resets the main roller to the correct position.
INFORMATION