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Orbit Manufacturing 2000 Printer User Manual

1. GBC Films Group January 2001 Page 7 3 Troubleshooting Orbit 2000 Operation and Maintenance Manual 7 2 Wave pattern troubleshooting Waves or ripples in laminated images can be caused by paper tension laminating temperature incorrect nip clutch tension binding of film core on brakes or core ends and cooling Below is a description of some common waves Please refer to the wave illustration associated with each description Paper tension Wave 1 Cause These waves visible in the finished image are caused by uneven paper tension across the width of the image often called D Waves This can occur due to improper handling of the paper at the laminator Prior to entering the nip the middle of the image becomes baggy and eventually folds on itself Solution To remove these waves check that the feed head is feeding the images smoothly and or check the nip pressure of the laminating rollers Laminating temperature Wave 2 Cause These are caused by the different rates of expansion and contraction of laminates and papers specifically coated ink jet and photographic papers during lamination The waves are induced when the laminate and paper are both heated and then cooled causing stress due to different rates of cooling between the film and the paper Solution To eliminate the waves you may either decrease the laminating temperature or increase the speed Nip Wave 3 Cause These waves are seen on one side
2. s008 1 24 1 13 Safety Rules for the feeder table ccccsssssssscsccssssssssccescsssssseeees 1 26 GBC Films Group January 2001 Page I Table of Contents Orbit 2000 Operation and Maintenance Manual 1 14 Safety Rules for the central drive maintenance sccccssssssrcssseees 1 27 1 15 Safety Rules for snapping assembly chain belt drive maintnenance 1 28 1 16 Safety Rules for maintenance replacement of the twin knife 1 29 Section 2 Warranty 2 1 Terms and conditions eeooooooesossssssossossssssssssececccccceceecosoecessssessssssssssssssse 2 1 2 2 Limited period of warranty ssessesseesesssscocooceccesesossoococececeesosooesocecesssssossoe 2 2 2 3 Limited warranty conditions sssssseseoococccccesececccccccsesssssesssoocsscoososssseeeesese 2 2 Section 3 Specifications 3 0 Specific dimensions and weight of the equipment illustration 3 1 3 1 Dimensions and weight of the equipment e essssocsessssoocccesssscocecsssooccecessosoe 3 1 3 2 Shipping crate dimensions sssssssssssococeococcocecececececcssssesssssssosooossssssseesse 3 2 3 3 Basic technical data cae cccsussa us cedccssnocessosdeecasevesdavacssdassececaunesayaccesosssvesatanseys 3 2 Page II GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Table of Contents Section 4 Installation 4 0 Installation precautions iccccccc
3. 10 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting 7 5 Web troubleshooting A stripe appears across the laminated paper sheets Cause The stripe is caused by the decurling bar Solution This may be corrected by turning the bar over to a larger radius described in Section 5 and or increasing pressure on the pull rollers described in Section 5 When using polypropylene film GBC 8300 the sheets separate between the laminating section and the separator Cause The tension between the laminating rollers and the pull rollers is too great for the film Solution Decrease the paper pull adjustment on the pull rollers described in Section 5 The sheets are cut from the side by the twin knives Cause The gap between the knife s sharp edge and the leading pin is too small mn WARNING WARNING Do not place your fingers or objects under the plastic guard unless the equipment is disconnected from the power supply and the emergency stop switch is depressed Solution Turn the knife farther away from the pin and or insert the shims GBC Films Group January 2001 Page 7 11 Troubleshooting Orbit 2000 Operation and Maintenance Manual 7 6 Machine troubleshooting UN ATTENTION At no time should a guard panel cabinet door or cover be removed by an operator for troubleshooting purpose not even trained operators Only qualified GBC service tech
4. ORBIT 2000 OPERATION amp MAINTENANCE MANUAL January 2001 GBC Films Group Do not duplicate without written permission GBC Pro Tech 4151 Anderson Road DeForest WI 53532 Revision Ph 608 246 8844 Part number 930 051 Fx 608 246 8645 Orbit 2000 Operation and Maintenance Manual Read me file Read Me File The information in this publication is provided for reference and is believed to be accu rate and complete GBC Films Group 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 GBC Films Group reserves the right to make changes to this publication and to the products described in it without notice All specifications and information concerning products are subject to change without notice Reference in this publication to information or products protected by copyright or patent does not convey any license under the rights of GBC Films Group or others GBC Films Group assumes no liability arising from infringements of patents or any other rights of third parties This publication is copyrighted 2000 by GBC Films Group All rights reserved The information contained in this publication is proprietary and may not be reproduced stored transmitted or transferred in
5. Repeat as necessary AN WARNING 4 WARNING Hot surface Exercise extreme caution when cleaning the chrome roller Surface temperatures may be upwards of 248 F to 275 F 120 135 C AN ATTENTION 5 Always use cotton or Nomex gloves when cleaning the chrome roller AN WARNING 6 CAUTION Do not use aggressive solvents that could cause damage to the rubber rollers Use only Mineral Spirits AN WARNING WARNING Crush hazard exists near any rollers Do not press Pressure Up Pressure 7 Roll Close switch when your hands or fingers are near the pressure roller arms A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death Page 8 6 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Maintenance 8 2 2 Safety Rules for maintenance replacement of the twin knife The twin knife is very sharp and extreme caution should be exercised when working in its vicinity For safe work the following safety rules should be followed AN WARNING 1 WARNING Knife has sharp edges Do not touch the sharp edges of the knives AN WARNING zJ WARNING For safe knife adjustment use a 4 mm allen wrench only The allen wrench can be inserted through the oval shaped openings in the upper section of the plastic guard of the twin knife AN WARNING 3J WARNING Do n
6. 3 Lamination section The lamination section consists mainly of the spool arbor heating controls laminating rollers and the spreader roller The laminator serves the purpose of unwind the spool of film via the spool arbor activating the thermal adhesive via the chrome roller laying it on the fed sheets via the laminating rollers and decurling the sheets for flat separation via the decurling bar 5 3 1 Film roll positioning AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film Use the following instructions to load a roll of film and to properly position it 1 Set the lateral film adjust nut a so that the face is in line with the marker b on the thread of the spool arbor c This provides acenter point in which you can adjust the film shaft left or right to fine tune the film lay down on the sheets GBC Films Group January 2001 Page 5 23 Operations Orbit 2000 Operation and Maintenance Manual 2 Lower the spool arbor support arm d by pressing down on the latch e and pull towards you from the control side YOUR MACHINE MAY OR MAY NOT HAVE A SUPPORT ARM 3 Loosen the 8 mm screw to the control side conical cone f and slide it off of the spool arbor c 4 Loosen the nut g on the drive side conical cone h and leave loose measurement purposes Page 5 2
7. Additional comments GBC Films Group January 2001 Read me file Orbit 2000 Operation and Maintenance Manual This page intentionally left blank GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Table of Contents Table of Contents Section 1 Safety 1 1 Safety Complete equipment ccccoccccoococscocccccccccccescscscecsosscssssssseesessesese 1 1 1 2 Safety Rules for loading paper ssccesssssscccecesssooocecesesssoooccecssssssooseeessssoo 1 4 1 3 Safety Rules for handling the feeding head sssoooecsssssececssooocsssssosoeeee 1 5 1 4 Safety Rules for setting up the rollers and the hinged stops s000 1 7 1 5 Safety Rules for set up of the adjustable guide plates ccssssssseees 1 9 1 6 Safety Rules for the chrome and pressure rollers sccsessososssosesooseesse 1 10 1 7 Safety Rules for the snap roller area seccccsssssocccsssooccesessoocesssssooceessoo 1 14 1 8 Safety Rules for the use of the twin knife sscosesssoccccsssseocecssoseccesssooe 1 17 1 9 Safety Rules for the position adjustment of the decurling bar 1 19 1 10 Safety Rules for electrical installation ssssssoooecessssoooeesssssssoooeesssee 1 20 1 11 Safety Rules for machine cleaning eeeesssosooeocesessssocoececsssssssocoeceesssso 1 22 1 12 Safety Rules for machine maintenance and adjustments
8. GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Installation 4 0 Installation Precautions AN WARNING WARNING To avoid injury to yourself or damage to the equipment please read and understand the instructions in this manual before you attempt to install operate or service the laminator 1 The GBC Orbit 2000 System may be installed only by a qualified as defined below GBC employed technician 2 Any moving or un installing of the equipment may also only be done by a qualified as defined below GBC employed technician 3 Once the machine is installed all cables remaining on the floor from the electrical cabinet to the machine must be covered to avoid any accidents Qualified e 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 e Any commissioning or service engineer must be of competent nature trained and qualified to GBC Pro Tech standards to fulfill that job This person will have completed and passed the full service training course from GBC Pro Tech e Any GBC Technician GBC Specialist and or GBC Pro Tech Technician that has been through the GBC Pro Tech service training course GBC Films Group January 2001 Page 4 1 Installation Orbit 2000 Operation and Maintenance Manual 4 1 Pre installation checklist The ins
9. been switched off two 2 minutes has expired form an idle state You can reengage the pressure rollers by pressing the pressure roller selector switch to Close Up position Ol PRESSURE ROLL oT di UP lt ___ New overlay DOWN DOWN Original overlay a The up indicator is illuminated when the pressure roller is up immediately after an emergency stop push button has been depressed immediately after power has been removed or turned off GBC Films Group January 2001 Page 5 31 Operations Orbit 2000 Operation and Maintenance Manual 5 3 4 Spreader roller option INFORMATION The following information is for those machines that are euipped with the optional spreader roller The spreader roller a is designed to adjust so the laminate is evenly applied across the chrome roller The adjustment is located on the operator side of the machine Follow the steps below to adjust the spreader roller 1 Loosen the lock nut b 2 Turn the adjustment knob c Clockwise to raise the control side of the spreader roller Counterclockwise to lower the control side of the spreader roller 3 Tighten the lock nut b Page 5 32 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 4 Separator section This section consists of the decurling bar pull roller twin knives snapping assembly and t
10. may be performed only by person s trained in all aspects of the equipment 1 The table move is sluggish even without paper load CAUTION Depress the emergency stop button before checking for chain tension AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught by moving parts while performing tasks Check the tension of each chain and adjust properly Clean or lubricate leading spindles 2 The automatic operation is not consistent AN WARNING CAUTION Only a qualified service technician may correct this fault Check the micro switch inside the feeder check for loose wires and the contactor in the electrical cabinet GBC Films Group January 2001 Page 7 9 Troubleshooting Orbit 2000 Operation and Maintenance Manual 7 4 Misfed sheets troubleshooting AN WARNING WARNING Only person s trained in all aspects of the equipment may perform any troubleshooting procedures PROBLEM FIX e Paper is not acclimatized Feed at lower speed e Incorrect vacuum or pressure Adjust vacuum amp or pressure WARNING Press the stop button before performing any troubleshooting PROBLEM FIX e Sheets are sticking Ream needs fanning e Side stacker plates are tight Adjust for a slight gap e Suctions cups are plugged Clean the suction cups e Suction cups are not picking up Replace the dry or worn the sheets suction cup s Page 7
11. or the other of the laminated image They are generally caused by uneven settings of either the laminating rollers or the pull rollers causing uneven tension between the laminating rollers and the pull rollers Solution Check the paper pull adjustment laminating roller pressure and or the spreader roller if equipped adjustment Page 7 4 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting Paper pull tension Wave 2 amp 4 Cause These patterns are caused by too little Wave 2 or too much Wave 4 tension of the laminated material between the laminating rollers and the pull rollers Solution To remove these waves adjust the paper pull adjustment and or laminating roller pressure Brake tension Wave 5 Cause These are straight bands across the image usually at uneven intervals and are usually minimal to excessive This intermittent tension is caused by binding of the film core on the brake or core end inserts Solution Ream out the core Cooling brake tension Wave 6 Cause These waves may have no particular pattern and may manifest themselves in a wavy rather than flat finished product They are caused by stresses or unevenness in the laminate or the image Solution To prevent this type of waving reduce the tension on the film If this proves to be ineffective check for gauging uneven thickness across the width in the laminate Wrinkles on both e
12. plates The guiding plates form paper before it enters into the chrome roller Their position must be adjusted for different paper weights For a safe adjustment of plates follow these safety rules AN ATTENTION 1 The plate s position may be adjusted while the equipment is running by using the set up screw This may only be performed by a trained operator AN WARNING 2 CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught by the hinged stops or the feed rollers AN ATTENTION 3 The chrome roller guard must be in the fully closed position Chrome roller guard Chrome roller Paper amp film stock Pressure roller GBC Films Group January 2001 Page 1 9 Safety Orbit 2000 Operation and Maintenance Manual 1 6 Safety Rules for the chrome and pressure rollers The working temperature of the chrome roller is 120 to 135 deg C Because of the machine function it is not possible to cover the area around the chrome and pressure rollers completely Near the contact area of the rollers there is a very dangerous zone Because of that and the high temperature the following safety rules must be complied with AN WARNING 1 WARNING The chrome roller may be hot Contact will result in severe burns AN WARNING 2 WARNING Keep fingers hands and other body parts away from the rollers AN WARNING 3 CAUTION Never clean the surfa
13. sheets before continuing with the adjustments The variator has a slight delay Page 5 20 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 2 6 Second gate AN WARNING CAUTION Only a qualified service technician may adjust the second gate The second gate a rigisters the sheet and drops out of the way releasing the sheet so that the overlap of the individual sheets are within the required limits of 1 5 mm Position of the second gate The top edge of the second gate a must exceed the height of the guide plate b by 2 3 to 2 7 2 3 2 7 mm b lt 4 GBC Films Group January 2001 Page 5 21 Operations Orbit 2000 Operation and Maintenance Manual 5 2 7 Adjustable guide plates Sliding plates a guide the sheets into the pressure area helping to minimize wrinkles of the sheets They form the sheet before it enters the laminating rollers The plates position is adjusted by turning screw b and nut c When working with heavy paper adjust the plates so the sheet is guided into roller 1 8 in 3 17 mm below chrome roller and pressure roller nip When working with light paper adjust the plates so the sheet is guided into roller 1 4 in 6 35 mm below chrome roller and pressure roller nip Page 5 22 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5
14. smallest effective diameter of the protective conductor in the tested branch of the protective circuit c Voltage checks from fused disconnect 240 VAC 10 3 phase with ground Check each leg A B nad C to ground for proper voltage drop Check main line voltage to locking plug connection on the Orbit 2000 Connect plug from Orbit 2000 to electrical supply d Performa safety check of all emergency stops safety latches and lockouts Emergency stop buttons Safety shields Power on off lockout Table limit switches Feeder head protect from pile up table e Power up the Orbit 2000 and confirm that the temperature contoller is illuminated If the temperature controller is not illuminated check the E Stops safety latches or lockouts for activation f Check all roatations of motors Feeder Pile up Feeder pile down main drive and compressor feeder Page 4 10 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Installation g Perform a function check of the control panel switches h Ensureall guides move correctly i Install the stacking table GBC Films Group January 2001 Page 4 11 Installation Orbit 2000 Operation and Maintenance Manual This page intentionally left blank Page 4 12 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 0 Operation AN WARNING WARN
15. to connect an additional conductor for the inter connection since the value of leakage currents from noise suppression elements is higher than 3 5 mA AC This terminal for the additional interconnection can be located on the bar between the side plates when the lower cover on the operator s side has been opened The additional interconnecting conductor is to be attached to this terminal A 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 A ELECTRICAL SHOCK Do not allow anything to rest on the power cord Do not locate the cord where people can walk on it You or others can be severely shocked electrocuted or cause a fire GBC Films Group January 2001 Page 4 3 Orbit 2000 Operation and Maintenance Manual Installation 4 2 Suggested floor layout N Pa uoneado 5 uien uoneiado uoneiado E Asepuosas a gt Aiepuosas a m 2 gt aad A n J E ea Q Ra amp e lt t wet UN w p O UIN CHIZ UIIN ASaszZ vL jiii Joss rdwo 1a4990qg Page 4 4 Orbit 2000 Operation and Maintenance Manual Installation 4 3 Shipping damage inspection INFORMATION Before signing the Bill of Lading youshould inspect the crate and or palletfor signs of damage or missing items ifapplicabl
16. troubleshooting cccccccccccccssssssssssssssssssssssssssssssssssees 7 10 7 5 Web troubleshooting ssssssseoseeeseocccccececececceccecssessssesesssoocosososossooessesesesesese 7 11 7 6 Machine troubleshooting seecccooooeeeeececesessssesssssssssocccocccccecececccessssssssesssoo 7 12 Section 8 Maintenance 8 1 Maintenance schedule sosssssoesesesesssssssoceceesosssssssssoecssssssssssosoessesssssssssoe 8 2 8 2 Operators Maintenance 22 6cescccccccssscssecccces coe descsectededescevaccccecetenccessctvedss 8 5 8 2 1 Safety Rules for machine cleaning ccssccccssssssssrcccssssssscoees 8 5 8 2 2 Safety Rules for maintenance replacement of the twin knife 8 7 8 2 3 Feed table chain tensioning cccccccsssssssssssssssssssssssssssssssscees 8 9 Page VI GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 0 Safety regulations 1 1 Safety Complete equipment AN ATTENTION Do not operate this equipment unless you have read and understand this 1 operator manual and have been fully trained in its operation by a qualified GBC service technician AN ATTENTION The operator may use the Orbit 2000 only for the lamination of paper sheets The equipment may not be used for any other type of work The type of paper 2 and film must comply with conditions of Section 2 of the Technical Specifications The equipment is provided with means
17. whole or in part in any form without the prior and express written permission of GBC Films Group The following information will explain how to move around within the electronic version of this publication The hand will change to a pointer finger identifying hyperlinked areas When moving from page to page use 14 to return to the first PAGE use gt to advance to the last PAGE use 4 to go back one PAGE and use gt to advance one PAGE When moving from view to view use lt 4 to return to a previous VIEW and use gt gt to advance to the next VIEW Should you find an error within this publication or would like to make a suggestion please utilize the fax correspondence sheet following this read me file and fax it to the number provided Your comments and help will ensure up to date information Thank you GBC Films Group January 2001 Read me file Orbit 2000 Operation and Maintenance Manual This page intentionally left blank GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Read me file Fax Correspondence Fax number 608 246 8645 Date To Sean Flood at GBC Pro Tech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re Orbit 2000 Operations and Maintenance Manual 930051 Section Page Correction s
18. 4 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 Position the roll of film on the spool arbor c with respect to the adhesive side Poly in or Poly out Refer to Section 6 Applications 6 Replace the control side conical cone f on the operator s side and leave the 8 mm screw loose for movemt 7 Measure from operators side side frame to paper pile left margin a Always add 1 8 in 3 17 mm to this measurement Use the measurement just obtained with the 1 8 in 3 17 mm addition to measure the edge of the film b on the spool arbor to the operators side side frame GBC Films Group January 2001 Page 5 25 Operations Orbit 2000 Operation and Maintenance Manual 8 Tighten the 8 mm screws on both conical cones and tighten the nut g on the drive side conical cone h to secure the roll of film to the spool arbor c 9 Use the lateral film adjust nut a to fine tune the positioning of the spool arbor with respect to the pile stack and use the unwind brake nut i to apply tension to film roll on shaft Page 5 26 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 3 2 Heating AN WARNING WARNING The chrome roller can become extremely hot Contact will result in severe burns AN WARNING WARNING Keep fingers hands and other body parts away from the rollers Heat
19. CAUTION Do not place your fingers or any other part of your body near the plastic guard while the machine is running AN WARNING 2 WARNING Do not place your fingers or objects under the plastic guard unless the equipment is disconnected from the power supply and the emergency stop switch is depressed WARNING Sharp knife can cut you Remove power and depress emergency stop switch before woking in this vicinity GBC Films Group January 2001 Page 1 17 Safety Orbit 2000 Operation and Maintenance Manual AN WARNING WARNING For safe knife adjustment use a 4 mm allen wrench only The allen 3 wrench can be inserted through the oval shaped openings in the upper section of the plastic guard of the twin knife AN WARNING 4 WARNING Disconnect power to the equipment before performing any task in the vicinity of the twin knife requiring the removal of the cover A ATTENTION 5 Do not operate the laminator unless the plastic guard is in place above the twin knife AN WARNING 6 i CAUTION Do not place any objects on the plastic knife guard A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death Page 1 18 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 9 Safety Rules for the position adjustment of the decurling bar During la
20. HONI INIH Y W JAINA dn NMOG 437104 11Nd YOLOW das ASYHSASY oor o N Z 06 e a oL og 0z Woe Z gt t LAF VN 09 os i ISINdNI dYNS G34dS das HOLVHVd4aS AONSOYSWNS Original overlay a NOILO3S ONILVNIWV1 6 D i ap GBC Films Group January 2001 Page 5 4 Operations l O A Nad MOTS 1 amd MOIS E a wo l VIIN ey O Luvs dols ka a X Z A e 06 er oL i os oz oozL v 7 N on 4 Noe of A NMOG Nmoa 19 zi i HOLOW dYNS X Luvis lt gt 4 aynLYYadWaL T 431108 71nd 3S1NdWi dYNS i 6666 Y O 4 an 8 5 aaaasin g 8 f 18 Q l X doLs AoNa9YINwI aol 8 y Orbit 2000 Operation and Maintenance Manual 0 eL l 5s 38079 f Nado l a3ads dYNS HOLVNIWVIG 303343 YOLYNINYI l soivyvdas J c O ow New overlay Page 5 5 GBC Films Group January 2001 Operations Orbit 2000 Operation and Maintenance Manual 5 2 Feeder Section The feeding mechanism consists mainly of the assembly for the lowering and lifting of the feeding table In addition there are the feeding table the feeding h
21. ING Only person s trained in all aspects of safety and operations may use this equipment AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught by the hinged stops or the feed rollers This section describes in detail each part of the four areas on the Orbit 2000 The four areas consist of 1 5 1 General information 2 5 2 The Feeder Section 3 5 3 The Lamination Section 4 5 4 The Separator Section AN ATTENTION Do not operate this equipment unless you have read and understand this operator manual and have been fully trained in its operation by a qualified GBC service technician GBC Films Group January 2001 Page 5 1 Operations Orbit 2000 Operation and Maintenance Manual 5 1 General information Under this section you will find an illustration of the main and secondary operator positions the control panel legend and an illustration of the control panel with the original overlay and the new overlay 5 1 1 The main and secondary operator positions Becker Compressor T4 25DSK Secondary L Secondary Operation Operation Main Operation Page 5 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 1 2 The control panel Legend 1 Push button start 2 Push button stop 3 Speed indicator 4 Potentiometer speed adjustment b
22. ION 1 PAPER SPECIFICATION Max paper size 14 x 20 360 x 520 mm Min paper size 8 x 8 200 x 200 mm Smallest paper size 70 lb 24 pt 115 350 g m 2 FILM SPECIFICATIONS Types of useable films Polypropylene Polyester Nylon film Film gauge 1 0 1 7 mil 1 0 1 7 mil Inside film roll diameter 21 4 3 57 77 mm Outside film roll diameter 7 4 190mm Length of rolled film 1700 ft520m 3 MACHINE PARAMETER Speed 65 ft min 20 m min Feeder pile height 25 635 mm 4 ACOUSTIC NOISE DATA Equivalent noise level L AEG 75 3 dB A 75 3 dB A Maximum noise level L Aeg max 79 8 dB A 79 8 dB A Level of the acoustic output L WA 87 7 dB A 87 7 dB A Page3 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Specifications US VERSION EU VERSION 5 ELECTRICAL CIRCUIT Power input 5kVA 10 5 kVA 10 Basic voltage requirements 3 phase 230 V 60 Hz 3 phase 400 V 50 with ground Hz with ground Nominal current 30A 30A 6 PNEUMATIC CIRCUIT Pressure in the machine circuit 90 psi 4 CFM 0 6 MPa 113 l min The feeder pneumatic circuit vacuum 0 6 Bar 0 6 Bar pressure 0 6 Bar 0 6 Bar 7 MIN MAX 1ft min 65ft min 3 m min 20 m min Slow Forward Variable speed Variable speed Slow Reverse Variable speed Variable speed GBC Films Group January 2001 Page 3 3 Specifications Orbit 2000 Operation and Maintenance Manual This page intentionally left blank Page 3 4
23. NG 1 WARNING Shut off the compressed air intake before setting up the second hinged end stops and pressure rollers AN WARNING 2 WARNING Only person s trained in all aspects of the equipment may operate the central drive A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 1 27 Safety Orbit 2000 Operation and Maintenance Manual 1 15 Safety Rules for Snapping assembly chain belt drive maintenance The chain and belt drives are protected by a fixed cover and is located on the opposite side from the operator For safe work the following safety rules should be followed AN WARNING 1 P WARNING Turn power off at the main breaker before tentioning the chains or belts A ATTENTION 2 Operator maintenance for the chains and belts are limited to lubrication and tentioning All other work must be performed by a qualified technician A ELECTRICAL SHOCK 3 Do not modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death Page 1 28 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 16 Safety Rules for maintenance replacement of the twin knife The twin knife is very sharp and extreme caution should be exercised when wo
24. ONTHLY Tighten and grease all roller chains ANNUALLY Cleaning of the electrical assembly ELECTRICAL SHOCK WARNING Power must be disconnected to machine at fused disconnect Dust can be removed by vacuuming the cabinet with a soft brush wand AN WARNING WARNING Never use compressed air to remove dust from the inside of the electrical cabinet Inspection of the electrical assembly Tightness of terminals Circuit breaker wires Loose wires Protective Circuit inspection Check whether protective connectors are tight Tighten loose connections The safety of protective circuits may be checked by feeding a current of at least 10 A 50 Hz from the PELYV source for at least 10 seconds The test is done between the PE terminal and various points that are part of the protective circuit See EN 60204 1 article 20 2 GBC Films Group January 2001 Page 8 3 Maintenance Orbit 2000 Operation and Maintenance Manual The voltage measured between the terminal PE and the test points may not exceed U 3 3V for S 1 0 square millimeters U 2 6V for S 1 5 sq millimeters U 1 9V for S 2 5 sq millimeters Where U is the largest drop in voltage and S is the smallest effective diameter of the protective conductor in the tested branch of the protective circuit The number of measurements of the protective circuit link is given by the requirements of particular regulations
25. Operator maintenance and operator adjustments may be performed only by person s trained in all aspects of the equipment A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 1 25 Safety Orbit 2000 Operation and Maintenance Manual 1 13 Safety Rules for the feeder table During the automated run the feeder table moves upward in steps When a new ream of paper is loaded the table must be moved down To ensure your safety the following safety rules should be followed AN WARNING 1 WARNING Operation of the feeder table may be performed only by person s trained in all aspects of the equipment UN ATTENTION 2 Use the Pile Stack Up or Pile Stack Down push buttons to move the feeder table A ELECTRICAL SHOCK 3 Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death Page 1 26 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 14 Safety Rules for the central drive maintenance The main motor drives the feeding head the feeding roller and the chrome roller It is located on the opposite side from the operator and protected by a fixed cover For safe work the following safety rules should be followed AN WARNI
26. Sliding pin Sliding pin Page 5 40 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Positioning of the knife assembly with respect to sheet edge Knife 1 Knife 2 5 6 mm p Positioning of the knife assembly with respect to sheet weight Heavier paper may require shims under the twin knifes to achieve a clean cut of the film To add shims remove the four screws from the knife cover Remove the the four metric allen screws fro mthe twin knifes and insert one shim under each knife Reassemble the twin knife assembly and adjust the position of the knives Thin paper Heavier paper Face a of knife close to guide bar b Face a of knife open to guide bar b GBC Films Group January 2001 Page 5 41 Operations Orbit 2000 Operation and Maintenance Manual 5 4 4 Snapping assembly AN WARNING WARNING Keep fingers hands and other body parts away from the rollers AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film The snapping assembly separates webbed overlapped sheets after the overlap has been knicked by the twin knives The snapping roller a separates the sheets from the web by moving downward toward the idler roller underneath The sheets pass between the snapping rollers and idler roller and at a set separation po
27. ance Manual 7 1 Lamination troubleshooting Blistering Cause Solution A condition where the paper coating is bubbled up from the image paper causing a blister It is created by using excessive heat during the lamination process Blistering is most commonly found with photographic and ink jet media Blistering can be avoided by ensuring you are using the correct operating parameters for the media type and film type being used Bond strength Cause Solution Refers to one of three conditions 1 the anchor strength of adhesive to laminate substrate 2 the anchor strength of the laminating film to the product that has been laminated or 3 when two layers of film are laminated together the strength of the adhesive to adhesive bond Bond strength can be ensured by using the correct amount of air pressure on the pressure roller as well correct chrome roller temperature and machine speed Coiling curling Cause Solution The finished image curls or rolls up on itself This is generally caused by improper decurling bar adjustment and or improper setting braking of film tension Adjust the decurling bar properly as described in Section 5 Adjust braking if film tension is tight Page 7 2 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting Delamination Cause Solution Refers to either one of two conditions 1 the adhesive separating fr
28. and standards valid in the user s country MAIN DRIVE AND FEED TABLE GEAR DRIVE Running in 300 hrs oil PP 90 H Normal operation 400 hrs oil PP 90 H In case of higher demands the ecologically acceptable oil TOP BLEND may be used TOP BLEND allows for up to 10 000 operation hours between changes VARIATOR Running in 10 000hrs oil OTK 8 to 10 Normal operation 10 000hrs oil OTK 8to10 Page 8 4 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Maintenance 8 2 Operators Maintenance AN WARNING WARNING Always exercise Lock out Tag out procedures when performing any type of maintenance to avoid injury to yourself others and to the equipment 8 2 1 Safety Rules for machine cleaning AN WARNING 1 WARNING Do not clean any part of the machine while the laminator is in operation AN WARNING y CAUTION Never clean the surface of the rollers while the machine is running Use the Slow FWD and Slow Reverse to change the exposed area for cleaning Use the sequence described below a Press the Inch Slow FWD or Reverse Slow Reverse b Release the perspective push button and wait for the machine to stop AN WARNING WARNING The chrome roller is hot Contact will result in severe burns GBC Films Group January 2001 Page 8 5 Maintenance Orbit 2000 Operation and Maintenance Manual c Clean the exposed area of the rollers d
29. art button if not start at that symptom A sheet of paper switched off the microswitch on the feeding head The machine was running suddenly stopped and cannot be restarted again The red LED located in the electrical cabinet is not illuminated The paper pile moved upwards causing the emergency microswitch on the feeding head to be depressed When the sheet size is changed the feeding head feeds the sheets irregularly or the sheet stays on the paper pile The reason for this may be the suction cups that overlap the paper width and suck air from where there is no paper By turning the cup the suction orifice in the suction bar is closed Check vacuum on the manometer above the feeding head GBC Films Group January 2001 Page 7 13 Troubleshooting Orbit 2000 Operation and Maintenance Manual 6 Symptom Large variations in the sheet overlap Possible causes The sheets may slip under the rolls during feeding of heavy paper without weights in the gravity rollers Add weights to the gravity rollers The sheets are pressed excessively against the gates during feeding of very light paper if the weights in the gravity rollers are to large Remove the weights 7 Symptom The upper snapping roller was turning and stopped suddenly while the machine was running Possible cause The reasons may be too small of a gap between the upper snapping roller Because of the roller friction against pap
30. c Lay Flat Aggressive adhesive 8500 30u 1 2 mil Lay Flat EVA adhesive GBC Films Group January 2001 Page 6 1 Applications Orbit 2000 Operation and Maintenance Manual 6 2 General threading procedure AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film AN WARNING WARNING Keep fingers hands and other body parts away from the rollers AN WARNING WARNING The chrome roller may be hot Contact will result in severe burns Once you have become trained in all aspects of the Orbit 2000 explained in Section 5 Operations and the safety rules explained in Section 1 Safety you may use this general threading procedure to web your machine 1 Set the heat required for the type of film being used Described in Section 5 2 Load the roll of film onto the film unwind arbor with respect to the adhesive side Described in Section 5 Page 6 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Applications 3 4 5 6 7 8 9 10 11 12 Load the sheet stack on the feed table Described in Section 5 Adhere one sheet of the same width as the sheets in the feeder to start the film web Switch the compressor on and push the start button at it s slowest speed Stop the machine at the instant the first sheet passes under the chro
31. ce of the rollers while the machine is running Use the Slow FWD and Slow Reverse to change the exposed area for cleaning AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film Page 1 10 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety AN WARNING 5 CAUTION Do not use any tools for cleaning or removing remnants of films from the rollers while the machine is in operation A ELECTRICAL SHOCK 6 Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death AN WARNING 7 sak CAUTION Do not cover the chrome roller guard ventilation holes AN ATTENTION 8 ce When cleaning follow the rules for Safety Rules for cleaning in Section 3 10 AN WARNING WARNING Keep hands and fingers away from the pressure chrome roller when using Pressure Roll Up Close and Down Open push buttons GBC Films Group January 2001 Page1 11 Safety Orbit 2000 Operation and Maintenance Manual AN WARNING 10 WARNING Depress the laminator Stop button before attempting to perform any web up procedure on the laminator AN ATTENTION 11 Always ensure the adhesive is facing away from the chrome roller when loading film AN WARNING 12 CAUTION Open the plastic chrome roller guar
32. cescscesdcccccecdsscscescedestccadedsccusceceeteadesdecseccossssenesss 4 1 4 1 Pre installation check list sccssccssessscoussassssesenssnsseveonssssesesatsowessveoswassoseenenssacs 4 2 4 2 Suggested floor layout eccscccccccccccccccccccecccccccesssssssssssssssssssssssssessssssesssssee 4 4 4 3 Shipping damage inspection sssssssssescecescccccessssssssssssssosoossccsssososeeesseesessss 4 5 4 4 Transporting of the machine sssssooooccscccecccesecesecccesssessssssosoossssssssesesssee 4 6 4 5 Electrical installation sseosssessssosoeesssssssosossssssssoesessssssssoesessssssssoessssssooo 4 7 4 6 Becker T4 25 DSK compressor installation sssssooooosoescccecssssessosososesse 4 8 4 7 Initial inspection sccccocoossssssssseseseccececceececososssosssssssssseccececeesesssessesssssssss 4 9 Section 5 Operations 5 0 Operations ssisesssscrscoseioseosisorissesossssessusnuosassssisossuan esiti ai steet ciseus nnec ese seisis 5 1 5 1 General information eeoooeoessosooosossssssessssssececccecceecececocecossessssssssssssssssssse 5 2 5 1 1 Main and secondary operator position sccccsssssssccccsssssssscees 5 2 GBC Films Group January 2001 Page III Table of Contents Orbit 2000 Operation and Maintenance Manual 5 1 2 The control panel ssssssssssssssssssssssssssesesssssssssscescsssessscssssesscsessssee 5 3 Original overlay illustration ssscococeccccssssssosssocococesececsssss
33. d fully to prevent to accidental closing onto your hands and fingers AN WARNING WARNING Hot surface Ensure the chrome roller is below 122 F 50 C 13 before servicing or adjusting Check the temperature on the temperature control display or by using an external temperature sensor or wait 60 minutes from the time the machine has been turned off Page 1 12 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety AN WARNING 14 WARNING Avoid making contact with any of the hot surface areas Avoid all pinch points and crush hazard areas as illustrated below Side view a DANGER High temperature roller surface area b DANGER Pinch Crush point area Rear view WARNING Hot surface area WARNING Crush hazard area GBC Films Group January 2001 Page 1 13 Safety Orbit 2000 Operation and Maintenance Manual 1 7 Safety Rules for the snap roller area It is not possible to cover the entire zone around the snapping roller because of the operation of the machine It is therefore necessary to observe the following safety rules A WARNING CAUTION Do not adjust the regulating screws of the snapping roller while the 1 laminator is in operation During operation the regulating screw handle is moving and your fingers may be crushed between the regulating screws and the Plexi Glass cover AN WARNING 2 CAUTION Do not place your fingers
34. dges after the pressure roller Wave 7 Cause Excessive film tension may be applied to the roll of film Solution To prevent this type of waving check the film tension as film rides around the chrome roller Minimum film tesion should be achieved Adjusting the spreader roller may also assist with this type of wave form Wrinkles from center to edge after pressure roller Wave 8 Cause Pressure roller air pressure may be to great or moisture in the paper may contribute to this type of wrinkle Solution To prevent this type of waving adjust the amount of air pressure applied tothe pressure roller It may be necessary to set the air pressure below 20 psi Store paper in a dry enviroment GBC Films Group January 2001 Page 7 5 Troubleshooting Orbit 2000 Operation and Maintenance Manual Wrinkles on either edge after the pressure roller Wave 9 Cause Air pressure on the pressure roller from side to side may require off setting Solution To prevent this type of waving off set the pressure roller by adjusting the air regulators on the pressure rollers No pattern wrinkles after the pressure roller Wave 10 Cause Excessive film tension may be applied to the web of film traveling around the chrome roller Solution To prevent this type of waving check the film tension as film rides around the chrome roller Minimum film tesion should be achieved Adjusting the spreader roller may also assist with this type o
35. e make note of this on theBill of Lading INFORMATION ALL SHIPMENTS ARE EX WORKS At ourdock title passes to the buyer Please review your insurance coverage prior to shipment as you are responsible for all subsequent freight charges and risks AN WARNING The Orbit 2000 is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The machine is not designed to be tipped up or sideways in any way Such action disturbs the exact alignment of moving parts on the machine and requires extensive realignment You can be crushedor seriously injured AN WARNING GBC Pro Tech 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 machine improperly GBC Films Group January 2001 Page 4 5 Installation Orbit 2000 Operation and Maintenance Manual 4 4 Transporting of the machine The machine is shipped from the factory bolted to a wooden shipping pallet frame Note the position of the machine on the pallet frame as illustrated to the right Moving the machine on the pallet frame can only be accomplished with a lift truck or a pallet wagon The forks of the lift truck pallet wagon must be long enough to reach past the transport supports on the farthest side from the lift truck pallet wagon To remo
36. e sensor follow the procedure below 1 Take a single sheet of paper insert it under the sensor 1 2 Block the sensor repeatedly by sliding the sheet of paper in and out from under the sensor 3 The proper function is signaled by the sensor LED which lights up accordingly WARNING CAUTION Only a qualified service technician may repair the sheet overlap sensor GBC Films Group January 2001 Page 5 19 Operations Orbit 2000 Operation and Maintenance Manual Overlap adjustment AN WARNING WARNING Only person s trained in all aspects of the equipment may perform any operator adjustments AN WARNING CAUTION NEVER TURN THE DIAL t WHEN THE MACHINE IS STOPPED For each paper size the speed of the feeding head must be adjusted This is done by manually turning the dial pointer u located below the control panel Steps ag 7 1 Set the machine to its lowest running speed er gi Sin a a os Se 2 Start the machine 3 Set the dial pointer u to a value just short of the sheet length ie a 17 in sheet set the dial to 16 5 in 4 Check the overlap 5 Should you require a shorter overlap turn the dial pointer u slightly toward the larger sheet size direction 6 Should you require a longer overlap turn the dial pointer u slightly toward the shorter sheet size direction 7 After turning the dial pointer u always wait for 2 to 4
37. ead fixed face stops first gate side stackers feeding roller and the second gate The feeder serves the purpose of stacking paper sheets and is operated by roller chains guided by two leading spindles The sheets are taken from the table and inserted into the machine by means of the feeding head During lamination the paper is removed from the pile The feeding head feeler controls the height of the pile and the lifting of the table The feed table is lifted automatically as the paper is removed One step of lift equals 2 to 3 mm independently of the amount of paper The table lift is either automatically controlled by the feeding head feeler or manually by means of push buttons on the control panel PILE UP 5 the table lifts PILE DOWN 6 the table lowers New overlay Oroginal overlay Page 5 6 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 2 1 Sheet stacking Face stacking The correct face position of the paper stack on the feeding table is provided by the face stackers a and the first gate b The sheets must be pushed tight against the surface of the face stackers One should make sure that the paper doesn t bend which can cause problems in the feeding process GBC Films Group January 2001 Page 5 7 Operations Orbit 2000 Operation and Maintenance Manual Side stacking The collation of paper pile on the sides is done by side stacker
38. eets via the transport suction cups by turning the regulator on the Becker compressor The amount of vacuum can be observed on the manometer h 5 The proper air pressure required to feather the paper is set up by means of regulators i and j Page 5 12 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 6 Adjust air blowing tubes k by turning the nut 1 so that 10 20 sheets at the top of the stack are feathered 7 Regulator m sets up the stack height GBC Films Group January 2001 Page 5 13 Operations Orbit 2000 Operation and Maintenance Manual Feeding small sheet sizes AN WARNING WARNING Press the stop button before performing the following set up procedure To feed small sizes of paper sheets less than the distance between the outside suction cups n you must loosen the screw o and rotate the two outside suction cups n 90 degrees forward then secure in place by tightening the screws o This is necessary to prevent the outside suction cups n from colliding with the side stacker guides and to not waste vacuum power on suction cups not in contact with the paper pile Page 5 14 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 2 4 First gate AN WARNING CAUTION Only a qualified service technician may adjust the first gate The first gate assembly is cal
39. er the motor overheated and the fuse tripped Reset the fuse in the distributor Service technician repair only 8 Symptom The feeding table does not rise automatically Possible causes The reason may be while the paper pile was moved into its working position the table rise wasn t switched off by the sensor which is located on the roll bar in the center of the machine The sensor in the feeding head didn t switch on due to the adjustment knob on the feeding head was turned completely to the right 9 Symptom The snapping assembly operates correctly at low speeds but loses its efficiency at higher speeds Possible causes Low air pressure and flow in the pneumatic circuit of the laminator Ensure the air pressure source is adequate Increase the air hose diameter from the air source Page 7 14 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting 9 Symptom continued Possible causes 10 Symptom Possible causes 11 Symptom Possible causes 12 Symptom Possible causes Adjust for snapping separation moves under actual snapping roller Adjust snapping position backward towards tension roller The upper snapping roller doesn t move up or down Check main air to machine The snapping roller ON OFF switch is not functioning Service technician repair only Check air cylinder solenoid The snap
40. f wave form Wrinkles appear after the pull roller Wave 11 Cause Overlap may be set incorrectly for the weight of paper being used Pull roller tension may require adjustments Solution To prevent this type of waving check the overlap setting for the sheets Thinner 60 Ib to 80 lb weighted sheets bend under the decurling bar and can cause wrinkles after the pull roller Shorten overlap to 1 8 in 3 17 mm if possible You may also have to adjust the pull roller tension as well Wrinkles appear after the snapping roller Wave 12 Cause Incorrect angle may be set on the snapping roller Solution To prevent this type of waving adjust the angle of the snapping roller Ensure that proper angle is maintained All wave patterns are illustrated on page 7 7 and 7 8 Page 7 6 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting Wave patterns 1 6 oes AE ee a Go aS Wave 1 Wave 2 Wave 3 Wave 4 ia ne _ Wave 5 Wave 6 GBC Films Group January 2001 Page 7 7 Troubleshooting Orbit 2000 Operation and Maintenance Manual Wave patterns 7 12 s fe X N rg x fe N A a ve ye 3 s ia hes fF i a 7 k a Wave 11 Wave 12 Page 7 8 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting 7 3 Feeder troubleshooting AN WARNING WARNING Operator maintenance and operator adjustments
41. fety Orbit 2000 Operation and Maintenance Manual 1 11 Safety Rules for machine cleaning AN WARNING 1 WARNING Do not clean any part of the machine while the laminator is in operation AN WARNING zJ CAUTION Never clean the surface of the rollers while the machine is running Use the Slow FWD and Slow Reverse to change the exposed area for cleaning Use the sequence described below a Press and hold the Inch Slow FWD or Reverse Slow Reverse push button b Release the perspective push button and wait for the machine to stop AN WARNING WARNING The chrome roller is hot Contact will result in severe burns c Clean the exposed area of the rollers d Repeat as necessary Page 1 22 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety AN WARNING 3 WARNING Hot surface Exercise extreme caution when cleaning the chrome roller Surface temperatures may be upwards of 248 F to 275 F 120 135 C A ATTENTION 4 Always use cotton or Nomex gloves when cleaning the chrome roller AN WARNING 5 CAUTION Do not use aggressive solvents that could cause damage to the rubber rollers Use only Mineral Spirits AN WARNING 6 WARNING Crush hazard exists near any rollers Do not press Pressure Up Pressure Roll Close switch when your hands or fingers are near the pressure roller arms A ELECTRICAL SHOCK Do not remove or modify any guard
42. he stacking table The separator section runs in conjunction with the laminator and feeder sections AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film 5 4 1 The decurling bar AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film The decurling bar applies or removes curl from the paper sheet following the lamination of AN WARNING WARNING The chrome roller may be hot Contact will result in severe burns film on the paper by the chrome roller GBC Films Group January 2001 Page 5 33 Operations Orbit 2000 Operation and Maintenance Manual Position of the decurling bar The position of the decurling bar is dependent of the paper thickness For thin paper 60 Ib to 100 Ib the decurling bar effects the web path Thin paper Chrome roller TNA Decurling bar For thicker papers 12 pt to 18 pt the decurling bar should not effect the web path Thick paper Chrome roller Decurling bar Page 5 34 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Adjusting the decurling bar AN WARNING WARNING Keep fingers hands and other body parts away from the rollers Follow the steps below to adjust the decurling bar 1 Loose
43. horized alteration or modification incorrect line voltage fire accident flood or other hazards 2 1 Terms and conditions 2 1 1 GBC Films Group warrants that the laminating machine ORBIT 2000 except as noted below is free from defects in material and workmanship for a period of 3 three months from the date of installation 2 1 2 The warranty shall be limited to repairs adjustments and or replacement as deemed necessary by GBC Films Group 2 1 3 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 FILMS GROUP 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 January 2001 Page 2 1 Warranty Orbit 2000 Operation and Maintenance Manual 2 2 Limited period of warranty Consumption replacement parts are warranted to be free from defects and workmanship for a period of 60 sixty days from date of installation and include Nip rollers Snapping rollers and Pull rollers All rubber made rollers e All belts e Feeder suction cups Warranty repair or replacement does not extend the warranty beyond the initial 60 day period from the date of installation 2 3 Limited warranty conditions The warranty becomes vo
44. ibrated at the factory and may be field calibrated by a qualified service technician only Refer to Section 8 Maintenance Function of the first gate The first gate a positions the paper ream so that the front is always vertical While the head is moving forward the first gate will tip so as to not interfere with the paper feeding GBC Films Group January 2001 Page 5 15 Operations Orbit 2000 Operation and Maintenance Manual 5 2 5 Feed roller assembly The assembly consists of gravity rollers a accelerating rollers b plate holders c and the sheet overlap sensor d Gravity rollers The gravity rollers are always touching the paper pressing it against the feed rollers The position is factory set and remains unchanged for all sizes of paper For higher paper weights the pressure has to be increased For this purpose a set of weights e is supplied as accessories The weight is simply pulled out or inserted Page 5 16 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Accelerating rollers AN WARNING CAUTION The position of the rollers are set at the factory and does not require changing regardless of sheet size Accelerating rollers increase the pressure on the feeding roller at the moment the second gate drops out of the way Allowing equal pressure to feed paper stock evenly to the chrome roller and pressure roller area The mome
45. id in the event of mishandling tampering incorrect use of films not compatible with our equipment or use contrary to the applicable instruction materials shipping damage or repair performed by other than a qualified service personnel authorized by GBC Routine maintenance cleaning adjustments normal cosmetic and mechanical wear or deterioration due to extreme conditions are not covered by this warranty Page 2 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Warranty 2 3 1 Warranty is not applicable to the following conditions 1 2 3 4 5 6 Damage to the chrome laminating roller rubberized feeding rollers pressure rollers pull rollers and snapping rollers if caused by knives razor blades or any other type of sharp tool Damage to the chrome laminating roller rubberized feeding rollers pressure rollers pull rollers and snapping rollers if caused by any object falling into the working area of the machine cleaning the rollers using solutions or material that could harm the surface Refer to Section 8 Maintenance under cleaning the rollers for suitable cleaners Damage to the Plexi Glass panels or air regulator glass caused mechanically by using cleaners that would harm the Plexi Glass covers Damage to the exterior finish caused mechanically by using cleaning solvents that would harm the finish Refer to Section 8 Maintenance under clean
46. ing is controlled by two means 1 by using the temperature controller and 2 by using the heat width selection Heat is delivered from the chrome roll of the laminating rollers Temperature adjustment Adjust the chrome roller temperature for good lamination by pressing or on the temperature controller Actual temperature Green numbers Set temperature Red numbers Decrease set point Increase set point GBC Films Group January 2001 Page 5 27 Operations Orbit 2000 Operation and Maintenance Manual Heat width selection For sheet width size between 8 11 in 200 280 mm set the heater switch a to 8 11 Ss AN HEATERS STOP Ag HEATER OFF 8 11 12 14 Original overlay AN N New overlay N N 12 14 in 305 356 mm For sheet width size between 12 14 in 305 356 mm set the heater switch a to 12 14 A N HEATERS STOP HEATER OFF 8 11 12 14 Original overlay AN N New overlay KA SA 8 11 in 200 280 mm Page 5 28 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 3 3 Laminating rollers AN WARNING WARNING Keep fingers hands and other body parts away from the rollers The upper chrome roller combined with the lower pressure roller make up the laminating rollers The laminating rollers function is
47. ing the exterior for suitable cleaners Damage to the feeding head by incompetent handling or adjusting Damage to the machine caused by moving installation performed by any person other than a qualified GBC service technician Operation of the equipment by person s not fully trained in all aspects of the machine GBC Films Group January 2001 Page 2 3 Warranty Orbit 2000 Operation and Maintenance Manual This page intentionally left blank Page 2 4 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Specifications 3 0 Specific dimensions and weight of the equipment 1956 mm __ gt 1010 mm 1325 mm 1010 mm 1210 mm lt 718 gt lt 1025 mm 3 1 DIMENSIONS AND WEIGHT OF THE EQUIPMENT US VERSION EU VERSION Machine dimensions 77 x 39 76 x 47 64 1956 x 1010 x 1210 mm length x width x height length x width x height Base dimensions 3 3 x 6 4 1 01 x 1 96 m Floor area 21 3 ft 1 98 m Weight of the Machine 1543 Ib 700 kg GBC Films Group January 2001 Page 3 1 Specifications Orbit 2000 Operation and Maintenance Manual 3 2 SHIPPING CRATE DIMENSIONS AND WEIGHT US VERSION EU VERSION Dimensions of the crate with machine 59 1 x 47 3 x 56 7 1500 x 1200 x 1440 mm length x width x height length x width x height Weight of the Machine with the crate 1676 lb 760 kg 3 3 BASIC TECHNICAL DATA US VERSION EU VERS
48. lectrical installation has been designed manufactured and tested according to EN 60204 1 1992 Standard and is shown on electrical installation schematic diagram BJ 41 110 to BJ 41 118 description BJ 41 211 to BJ 41 212 and lay out BJ 41 200 to BJ 41 203 The manufacturer of ORBIT 2000 guarantees that the machine complies with interference elimination to a level specified by EN 500081 1 part 1 in residential business and light industry zones Repairs setup and maintenance may be performed by a technically trained or sufficiently experienced person who knows how to avoid dangers involved in manipulations with electricity as stated in EN 60204 1 article 3 55 GBC Films Group January 2001 Page 4 7 Installation Orbit 2000 Operation and Maintenance Manual 4 6 Becker T4 25 DSK Compressor installation AN WARNING WARNING Do not place the compressor near machines that have exhaust air containing oil The machine includes a compressor with its own original technical description It is the rotary wing type Becker T4 25 DSK compressor operating without the use of oil It may not suck in any moisture oil or any other fluid When the compressor has been attached to the machine check the vacuum which should be 0 4 Bar 11 81 inHg Adjust the compressor for correct vacuum gauge a indication The compressor may be switched on and off by means of the switch b while the machine is being adjusted The press
49. ller option cccsssccsocssssssssseccccsccsssssssccsesssseccccecs 5 32 5 4 Separator Section sssssescccccsoosseeceesssssosscccesessssssscccccessssscssssocessssseeseesssso 5 33 5 4 1 The decurling Dart s ssisisssssisisscssiseisessissisesssossesi ssessisisssosiss sessssssssss 5 33 SAsZ PUM K I O E T 5 37 543 Twin MNES cesses sas ciis cz sawacauaceewsseuesseiise douse wavesosssbsadectessonsaccuacseasteane 5 40 5 4 4 Snapping assembly sssssssssssssesesesssssessssessssesesesssessseceeeceeeeeesesssese 5 42 5 4 5 Stacking table siiisssiisissssssiscissassnsssssosssssssossoscsisoscsisssnssosoiisnssaiisansine 5 45 Section 6 Applications GA Recommended film types ssscsssssssecccesesssssseccssssssssssssoocococsossseseeseeesessssssse 6 1 6 2 General threading procedure sssssssssssssssococccccocccccoeeeecececeseceossssssssssessee 6 2 6 3 Film threading diagram cscscosseosccccecesssssscessssssssssssooccocccooeeeeeseseesssssssssee 6 5 GBC Films Group January 2001 Page V Table of Contents Orbit 2000 Operation and Maintenance Manual Section 7 Troubleshooting 7 1 Lamination troubleshooting cccccccccccssscccscssscscscssssssssssssssssssssssssees 7 2 7 2 Wave pattern troubleshooting cccccssssssssssssssssssssscccccssssssssssssssssseseees 7 4 7 3 Feeder troubleshooting ssssssssseseeeccccoosssssssececececceesosssosssssseceececoesessssssssee 7 9 7 4 Misfed sheets
50. me roller and the leading edge of the paper appears to be at least 8 in 200 mm past the contact area between the laminating rollers Press the pressure up button At the slowest speed of the machine allow 2 3 sheets pass through the laminating rollers so you can thread the web through the snapping section Feed the web through the decurling bar Feed the web through the pull rollers Described in Section 5 Feed the web through the twin knife assembly Described in Section 5 Feed the web through the snap rollers Described in Section 5 GBC Films Group January 2001 Page 6 3 Applications Orbit 2000 Operation and Maintenance Manual 13 Grab the web beyond the snapping rollers and pull straight and tight ensuring the web is properly under the twin knives for knicking 14 Apply air to the pull roller so that the web is held tightly 15 Adjust the stack table guides and slope as necessary Described in Section 5 INFORMATION You may use an alternate method for webbing that is more comforatable to you It is strongly advised that all safety rules apply to your alternate method at all times Page 6 4 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Applications 6 3 Film threading diagram Film roll i Chrome roller Film arbor Snap rollers Decurling bar Pull rollers Sheets Stack table Po Poly in Poly out
51. mination internal stress develops between paper and the chrome roller The decurling bar straightens the sheets before they exit the lamination section During adjustment of the bar the following safety rules must be observed AN WARNING CAUTION Exercise caution while loosening the decurling bar handle 1 The securing screw and the edge of the groove on the regulating wheel may collide during sudden loosening 2J CAUTION Exercise caution while adjusting the control lever position During sudden change in the position of the control lever the set up lever of the decurling bar may be hit AN WARNING 3 CAUTION Do not place your fingers near the groove on the regulating wheel while changing the position of the decurling bar UN WARNING CAUTION Due to heat eminating from the chrome roller and pressure roller area avoid contact with the decurling bar GBC Films Group January 2001 Page 1 19 Safety Orbit 2000 Operation and Maintenance Manual 1 10 Safety Rules for electrical installation AN WARNING CAUTION Repairs adjustments and or maintenance may be performed 1 by a qualified technician excludes any operator maintenance and operator adjustments The word qualified is decribed below Qualified e 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 equi
52. n the locking lever b 2 Tumthe decurling bar adjustment lever a with respect to the paper thickness 3 Secure the decurling bar in position by tightening the locking lever b For thin paper radius R3 c may required if a line is caused by the decurling bar on the laminated sheets GBC Films Group January 2001 Page 5 35 Operations Orbit 2000 Operation and Maintenance Manual To change the from R2 to R3 and vice versa follow the steps below 1 Remove the four 8 mm bolts a 2 Turn the decurling bar b with the desired radius up 3 Replace the four 8 mm bolts a Effects of the decurling bar The sheets should lay flat when exiting the snapping rollers and are collected on the stacking table Correctly decurled sheets Incorrectly decurled sheets Io a LSS Stacking table Stacking table Page 5 36 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 4 2 Pull rollers AN WARNING WARNING Keep fingers hands and other body parts away from the rollers AN WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film The pull rollers a provide pull on the paper between the laminating section and the snapping rollers to achieve straight sheets on the decurling bar GBC Films Group January 2001 Page 5 37 Opera
53. nicians may perform any troubleshooting where internal components must be checked AN WARNING WARNING Always exercise Lock out Tag out procedures when performing any type of troubleshooting to avoid injury to yourself others and to the equipment A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death 1 Symptom The machine cannot be started with the START button Possible causes Check whether the main switch is in the ON position on the distributor Check for red and green digits on the temperature regulator indicating correct power Check for a green light in the start button Page 7 12 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting 2 Symptom Possible causes 3 Symptom Possible causes 4 Symptom Possible causes 5 Symptom Possible cause The light in the start button is off Check the Lucite cover over the chrome roller is closed Check the Lucite cover over the separator is closed Check the side door under the control panel is closed Check all emergency push buttons are in the released up position Check that the paper in the feeder is not too high where the microswitch is pressed The machine is running then suddenly stops Check for a green light in the st
54. ning is done by means of turning the bolts where the chain connects to the feeding table bolt AN WARNING WARNING Overturning of the bolt can result in disconnection of Tentioning the chain to the feeding table GBC Films Group January 2001 Page 8 9 Maintenance Orbit 2000 Operation and Maintenance Manual 8 2 4 Paper release adjustment AN WARNING CAUTION Only a qualified service technician may perform this set up AN WARNING WARNING Press the stop button before performing the following set up procedure Proper feeding is obtained by setting the lift and release of the paper for correct timing For correct feeding the instant of paper release and the instant of suction must be adjusted precisely The adjustment is done by turning the slide valve p The instant of release must be 1 5 to 2 mm before top dead center suction is adjusted simultaneously At the moment of suction the cups are in the rear position and start dropping The correct position of the slide valve q is factory adjusted and is marked by a paint filled drilled hole Page 8 10 GBC Films Group January 2001
55. nt of pressure is controlled by the control system and has been factory set The spring g determines the pressure GBC Films Group January 2001 Page 5 17 Operations Orbit 2000 Operation and Maintenance Manual Plate holders The plate holders keeps the paper sheet on the lower guiding plate to prevent it from jumping over the second gate Positioning The machine has three hold down fingers in total The position of the middle one does not change and is factory set The position of the extreme two change with respect to the size of sheet and is adjusted to be about 10 mm distant from the edge of paper after the screw h has been loosened Be sure to tighten the screw h after positioning the hold down fingers Adjusting Pressure is adjusted by moving the holder i which is held by screw j Follow the procedure below 1 Loosen the screw h i 2 Insert one sheet of paper of the same specific weight to be laminated 4 Pressure area 3 Adjust the holders so the finger k touches the paper without bending k O NU Feeder gt TS gt 4 Tighten the screw h Page 5 18 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Sheet misfeed sensor The sheet misfeed sensor protects the supporting laminating roller from the laminating adhesive Check its function daily To check th
56. obs carefully and with only one hand while the machine is running Only trained operators may use the machine Do not wear ties loose fit clothing or dangling jewelry while operating the machine 6 Turning knobs Page1 6 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 4 Safety Rules for setting up the rollers and the hinged stops AN ATTENTION 1 i l ais Do not touch the rollers or hinged stops while the machine is running AN WARNING 2 WARNING The chrome roller may be hot Contact will result in severe burns AN ATTENTION 3 The insertion or removal of any weights is permissable only when the machine is idle GBC Films Group January 2001 Page 1 7 Safety Orbit 2000 Operation and Maintenance Manual AN WARNING 4 Caution Excercise extreme caution when adjusting the rollers to avoid pinching by the loading roller A ATTENTION 5 Handle the rollers only when the Plexi glass cover of the chrome roller is closed AN ATTENTION 6 Keep fingers hands and clothing clear away from the rollers while the machine is in operation UN WARNING 7 WARNING Do not be startled by the pressure roller dropping approximately two minutes after the laminator has been stopped Page 1 8 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 5 Safety Rules for setup of the adjustable guide
57. om the laminate substrate or 2 the laminate separating from the product being laminated Delamination is eliminated by using the correct type of film for the type of media being used and setting the machine to the optimal operating parameters Out gassing Cause Solution The term that describes the phenomenon where the heat from the laminating process turns components of the printed media into a gas This is seen as a cloudy or murky finished image It can also be caused by a chemical incompatibility between the overlaminate s adhesive and the printed media Heat related out gassing may be eliminated by reducing the operating temperature or increasing the speed If out gassing is due to incompatibility it will be necessary to change film or media Silvering Cause Solution A term used to describe one of two occurrences 1 air bubbles trapped between the product and a thermal laminate generally caused by insufficient heat being applied to the laminator or 2 the adhesive not fully activated in a pressure sensitive film which will disappear once the adhesive is fully activated This activation process can be sped up if a small amount of heat is applied during the application Ensure your set point for the type of film being used is correct You may also decrease the speed which will increase the dwell time in the laminating rollers nip time which allows the film more time to absorb the heat to activate the adhesive
58. oosooeee 5 4 New overlay illustration sssccccccccccccssssssssssesessssessosossoosssssssssosoo 5 5 5 2 Feeder section s2cccsccnseaseaseeacuctsscaadeensusateseecdedoscansesbadacesdseusesoscessansewacs Cesasears 5 6 5 2 1 Sheet stacking lt csscstivcccsecccucce cts cased ces ce ececeet ce deateuscosaats suave cotentce 5 7 5 2 2 Feeder table positioning cccccccccccccccccsssssssssssssssssssssssssssssssssees 5 9 5 2 3 The feeding head scice cscs ve ceiet essa ce reeset ve en cee bcbiet eoueence vee seeetuous 5 10 5 2 4 First Gate sssvssscesssavscsouswasiswesvancessovectswassnsssuasasoassvasvaccdavesetiaesaveatess 5 15 5 2 5 Feed roller assembly essesssoseeseeceeeeeeececeeeecscssssssssssssssesssssssssssssso 5 16 5 2 6 Second gate ssisisiissssssssssssssssssss cssssssosss sss ssos nisss s sicdc e ni bassi o siosssss 5 21 5 2 7 Adjustable guide plates ssssssssssssscccccccccccececceccecesssssssssssosssso 5 22 5 3 L mina tion Section sieis ie aiai assasi 5 23 5 3 1 Film roll positioning sssssssssssssseocccoccccccecccececcccssssssssessssossoso 5 23 5 3 2 Heating stssce sees crc etec ae cee seccs asa sch a da cocasncdacadiceusczeucesssvaccunsdeneccdszecees 5 27 Page IV GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Table of Contents 5 3 3 Laminating rollers secococcccccsssesssssssocccoceececesssessssssecccosececessssssso 5 29 5 3 4 Spreader ro
59. or any other part of your body near the contact point between the upper and lower snap rollers A ATTENTION 3 During operation the plastic cover must remain in the fully closed position AN WARNING CAUTION Open the plastic snap roller guard fully to prevent accidental closing onto your hands or fingers Page 1 14 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety AN WARNING 5 CAUTION Do not place any objects on the plastic snap roller guard A ELECTRICAL SHOCK 6 Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death The snap roller side view DANGER Crush point by CAUTION Keep fingers clear during Regulating Screws machine operation Top Adjusting regulating screws WARNING Pinch hazard area Bottom GBC Films Group January 2001 Page 1 15 Safety Orbit 2000 Operation and Maintenance Manual Regulating screw view from the stacking table Rear view of the Snap Roller Guard Cover Page 1 16 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 8 Safety Rules for the use of the twin knife The cutting knives are covered by plastic guards from the top and side Because of the sharpness and speed with which the knives move it is necessary to observe the following safety rules A WARNING 1
60. ot place your fingers or objects under the plastic guard unless the equipment is disconnected from the power supply and the emergency stop switch is depressed A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 8 7 Maintenance Orbit 2000 Operation and Maintenance Manual 4 a b c e AN WARNING WARNING Always exercise Lock out Tag out procedures when performing any type of maintenance to avoid injury to yourself others and to the equipment Raise the snapping section safety shield Remove the lock down thumb screw With a 3 flat tip screwdriver remove the four flat head shoulder bolts securing the twin knife safety cover Replace the lock down thumb screw This will prevent the twin knife assembly from sliding Use a 4 mm allen wrench to remove the two hex bolts securing the blade you are replacing Replace the knife Secure the knife reusing the same bolts and a 4 mm allen wrench Remove the lock down thumb screw Replace the twin knife safety cover and secure in place using the same flat head shoulder bolts and a 3 flat tip screwdriver Replace the lock down thumb screw Page 8 8 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Maintenance 8 2 3 Feed table chain tensioning a Tensio
61. own push button CAUTION Avoid bumping your head on the feeder when loading paper AN WARNING Do not touch the stack pile table or chains with your fingers or other body parts when the table is moving or the laminator is running 2 Page1 4 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety 1 3 Safety Rules for handling the feeding head The feeding head grabs the paper sheet and inserts it into the pull rollers When changing paper size the position of the feeding head must also be changed For safe adjustments the following safety rules apply AN WARNING 1 Do not touch the feeder head while the machine is running The moving suction cups may hurt your hands or fingers AN ATTENTION 2 Do not adjust the feeding head while the machine is running with the exception of the control buttons described in Section 5 0 AN ATTENTION 3 To move the head loosen the clamp on the locating bar then slide the head by grabbing the upper handle bar and gently pull or push Handle bar Locating bar a Clamp GBC Films Group January 2001 Page1 5 Safety Orbit 2000 Operation and Maintenance Manual UN ATTENTION 4 Do not place any objects on the upper surface of the feeding head or feeder table AN ATTENTION 5 Do not remove covers fixed cover of the feeding head and or the protective rubber cover AN ATTENTION Operate the turning kn
62. ping roller moves up and down only when the snapping roller drive motor is in the ON position The snap roller push button was not pushed enough to engage the relay If the button is not illuminated the relay is not engaged Push the snap roller push button again The machine doesn t run when the main breaker is switched to ON The machine doesn t run after it was stopped by the emergency push button and the emergency push button was released The START button has not been pushed to activate the control system Push the Start button GBC Films Group January 2001 Page 7 15 Troubleshooting Orbit 2000 Operation and Maintenance Manual This page intentionally left blank Page 7 16 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Maintenance 8 0 Maintenance AN WARNING WARNING To avoid injury to yourself or damage to the equipment please read and understand the instructions in this manual before you attempt to install operate or service the laminator This section explains maintenance for operator and service Operator Maintenance Operator maintenance is limited to that described in this manual Operator maintenance may only be performed by person s fully trained in all aspects of the equipment Service maintenance Service maintenance may only be performed by a qualified GBC service technician Described in the Orbit 2000 Ser
63. pment e Any commissioning or service engineer must be of competent nature trained and qualified to GBC Pro Tech standards to fulfill that job This person will have completed and passed the full service training course from GBC Pro Tech e Any GBC Technician GBC Specialist and or GBC Pro Tech Technician that has been through the GBC Pro Tech service training course AN WARNING WARNING Operator maintenance and operator adjustments may be performed only by person s trained in all aspects of the equipment Page 1 20 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety AN WARNING 3 WARNING At no time should you attempt to overide by pass and safety shield safety switches or safety device located on this equipment A ELECTRICAL SHOCK 4 WARNING Do not modify any part of the circuitry at any time or for any reason AN WARNING 5 WARNING All guards and covers must be returned to their original position after any repairs adjustments and or maintenance has been completed AN WARNING 6 WARNING At least 1 ft 1 meter of free space is required in front of the machine to allow for safe access for work on the machine electrical system A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 1 21 Sa
64. rking in its vicinity For safe work the following safety rules should be followed AN WARNING 1 WARNING Knife has sharp edges Do not touch the sharp edges of the knives AN WARNING 2J WARNING For safe knife adjustment use a 4 mm allen wrench only The allen wrench can be inserted through the oval shaped openings in the upper section of the plastic guard of the twin knife AN WARNING 3 WARNING Do not place your fingers or objects under the plastic guard unless the equipment is disconnected from the power supply and the emergency stop switch is depressed A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 1 29 Safety Orbit 2000 Operation and Maintenance Manual This page intentionally left blank Page 1 30 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Warranty 2 0 Warranty GBC Films Group s sole and exclusive liability and the customer s sole and exclusive remedy under this warranty shall be at GBC Films Group s option to repair or replace any such defective part or product These remedies are only available if GBC Films Group s examination of the product discloses to GBC Films Group s satisfaction that such defects actually exist and were not caused by misuse neglect attempt to repair unaut
65. rocedure Feeding head setup Loosen the clamp a using the handle bar b Push the head to its back position away from the machine Press the button FEEDER STA CK PILE UP until the paper pile stops at the Paper Pile Height Sensor d The feeder foot e now assumes control and lift the table with paper stack on to its working position Move the head so that the rear stops c touch gently the rear side of the paper stack and tighten the clamp Page 5 10 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations The separating elements setup 1 The foot of the d feeler touches the top of the paper stack Move the strip e to the stack so that its front edge is 5 to 7 mm within the paper and 4 to 6 mm above it For various paper weights e must be set to provide for correct paper sheets separation 4 6mm 2 Brushes f should overlap the paper edge by 2 to 3 mm and touch the paper very lightly and not interfere with paper sheets feathering For heavier paper use only brushes instead of strips Page 5 11 GBC Films Group January 2001 Operations Orbit 2000 Operation and Maintenance Manual 3 Set up the center suction cups g by adjusting strips e so the paper sheets between the cups are tight 4 Depending on the paper type adjust vacuum as needed to lift the sh
66. s c which are placed symmetrically A slight play must be allowed between the ledges and the paper pile to prevent damage to the paper and improper feeding The side stackers are controlled by the knob d on the operator s side The arrow indicates e the direction of turning for the changing of sheet size Smaller size in the direction larger size in the direction CAUTION Ensure the path of the side stackers are clear before making any adjustments Page 5 8 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 2 2 Feeder table positioning When the paper pile has been loaded press the FEEDER STACK PILE UP button The table starts lifting and its top position is determined by the Paper Pile Height Sensor g adjust so that the first gate exceeds the height of the paper by 6 mm AN ATTENTION The capacity sensor may be adjusted by a qualified service technician only 5 First gate n GBC Films Group January 2001 Page 5 9 Operations Orbit 2000 Operation and Maintenance Manual 5 2 3 The feeding head AN WARNING WARNING Press the stop button before performing the following set up p
67. s covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 1 23 Safety Orbit 2000 Operation and Maintenance Manual 1 12 Safety Rules for machine maintenance and adjustments AN WARNING 1 WARNING Do not remove any covers or guards while the machine is in operation AN WARNING 2 WARNING Do not start the machine with the guards or covers removed AN WARNING 3 WARNING Shut off and lock the electric supply circuit breaker before performing any operator maintenance or operator adjustments AN WARNING WARNING Hot surface Ensure the chrome roller temperature is below 122 F 50 C before servicing or adjusting Page 1 24 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety A WARNING WARNING Check the temperature on the temperature control display if power 5 is ON or by using an external temperature sensor or wait 60 minutes from the time the machine has been turned off before performing any operator maintenance operator adjustments or set up AN WARNING 6 CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught by moving parts while performing tasks AN WARNING 7 CAUTION Always wear safety glasses when changing the springs Uncontrolled springs can damage your eyes AN WARNING 8 WARNING
68. sition are burst from the web into single sheets Page 5 42 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Upper snap roller positioning with respect to sheet weight With respect to the type of laminating film and paper weight adjusting of the upper snap roller a angle may be necessary The idler roller b is not adjustable Thin paper Heavy paper OPP Film Polyester Nylon Film a GBC Films Group January 2001 Page 5 43 Operations Orbit 2000 Operation and Maintenance Manual Adjusting the upper snap roller Angling of the upper snap roller is achieved by turning the regulating bolts b To adjust the angle of the upper snap roller use the following steps 1 Loosen the locking nut c 2 Turn the regulating bolt d 3 Tighten the locking nut c Direction of Direction of the roller the roller Direction of the Direction of the regulating bolt regulating bolt Page 5 44 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations 5 4 5 Stacking table MAX MIN The stacking table stacks the laminated sheets once the snap rollers have separated them a The stacking table guides a should be adjusted to accommodate the sheet size Table slope adjustment The table slope may be adjusted by changing the length of the adjustable legs There are six possible positions Both sides m
69. tallation of the machine the start up of operation and training must be provided by a qualified GBC Films Group service technician or another authorized organization C Prior to the machine installation it is necessary to provide an even floor of 2500 kg sq meter minimal load factor 36 165 lb sq ft a connection to air pressure of 0 6 Mpa 113L min 90 PSI 4 CFM for the pneumatic circuit a fused dicconnect a connection of 3 phase with ground 400 230VAC 10 50 Hz 30 amps EU Version for the electrical circuit a connection of 3 phase with ground 230VAC 10 60Hz 30 amps US Version for the electrical circuit C Becker Compressor The Becker compressor supplies air to the feeding assembly and is connected by means of a plug to the machine C Machine position The machine must be placed so that space of at least 40 cm 1 3 ft is available between the stacking table and the wall or any other fixed object space of at least 80 cm 2 6 ft is available on the drive side between the covers and the wall or any other fixed object another machine etc Page 4 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Installation C The Floor The machine must be placed on a firm and reasonably even floor capable of supporting a load of 2500 kg square meter 36165 lb sq ft C Note The machine is also provided with a terminal
70. the rollers Page1 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Safety AN ATTENTION 10 Never perform adjustments while the machine is running The machine must first be stopped adjusted and then restarted Except When Adjusting Lap For Sheet Size AN ATTENTION 11 Excercise caution when working around the feeder table control panel and stacking tray to avoid bumping you head AN ATTENTION 12 The equipment must be fixed positioned on a firm and even floor The working station of the operator must be at the same level AN ATTENTION 13 cau The operator shall provide adequate lighting suitable for the given task A ELECTRICAL SHOCK 14 Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death GBC Films Group January 2001 Page 1 3 Safety Orbit 2000 Operation and Maintenance Manual 1 2 Safety Rules for loading paper The normal function of the equipment is to insert paper and laminate it For a safe loading of paper it is necessary to follow these safety rules AN ATTENTION 1 Do not attempt to load paper while the machine is running Your fingers couldbe hurt during the automatic insertion of paper AN WARNING Ensure the feeder stack pile is in the bottom position before loading paper To move into that position press the Pile Stack d
71. tions Orbit 2000 Operation and Maintenance Manual PAPER PULL ADJUSTMENT To adjust the paper pull force use the following steps 1 Loosen the locking nut b 2 Turn the regulating bolt c 3 The setting is indicated by the white marker of the control device d with respect to the upper roller position scale e 4 Tighten the locking nut b to secure the regulating bolt c Page 5 38 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Paper pull adjustment with regards to sheet weight q lt Heavy pull WY GBC Films Group January 2001 Page 5 39 Operations Orbit 2000 Operation and Maintenance Manual 5 4 3 Twin knives UN ATTENTION Do not operate the laminator unless the plastic guard is in place above the twin knife AN WARNING CAUTION Do not place your fingers or any other part of your body near the plastic guard while the machine is running The twin knives slit the web of sheets for separation by the snapping assembly Due to the machines capability of operating at high speeds an oscillating knife assembly is used to maintain a consistant film cut Positioning of the knife assembly with respect to sheet width Position fixing bolt Position fixing bolt 12 14
72. to control lamination functions The controls as set up by the factory may not be modified or altered AN ATTENTION 3 Do not operate adjust service or repair the Orbit 2000 if you are under the influence of alcohol drugs or medication AN ATTENTION 4 Do not operate the Orbit 2000 if you are ill or tired GBC Films Group January 2001 Page 1 1 Safety Orbit 2000 Operation and Maintenance Manual AN ATTENTION 5 All safety covers must be in place during operation The equipment must not be started and used if all covers are not in place and safety switches are not operational UN ATTENTION Test all three interlocked safety guards each day the chrome roller guard snap roller guard and the guard under the laminating and snap ARGAs and 6 the two emergency stop switches one on the control panel and one on the drive side of the feeder and the pile up safety switch on the feeder table guide rails to ensure that they function properly AN ATTENTION 7 Exercise extreme caution when working with sheets to avoid paper cuts AN ATTENTION 8 Never clean any rollers while the equipment is running If needed turn the rollers for cleaning or testing by using the slow forward or slow reverse push buttons AN ATTENTION When using the slow forward and slow reverse push buttons push and release the buttons and wait for the machine to stop before cleaning the exposed area of
73. to press the adhesive and the film onto the surface of the sheets Pressure is regulated by turning the right side regulator a and or left side regulator b Independent control of the left and right side pressure enables the operator to control the amount of pressure applied to the sheets Equal pressure should be applied for good clear lamination with no wrinkling on the paper Off setting pressures on controls can help with minor wrinkling problems GBC Films Group January 2001 Page 5 29 Operations Orbit 2000 Operation and Maintenance Manual Adjusting pressure UN WARNING WARNING Do not remove any covers or guards while the machine is in operation Pressure may be adjusted by two air regulators One for each side of the pull rollers To adjust follow the procedure below 1 Pull up on the outer part of the regulator knob to unlock 2 Turn clockwise to increase pressure and or counterclockwise to decrease pressure 3 Push the outer part of the regulator knob down to lock Page 5 30 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Operations Automatic pressure cancellation The closure of the pressure rollers is controlled by the PLC The PLC will open the pressure rollers two minutes after the laminator stops to prevent damage to the rubber roller surface Automatic pressure cancellation occurs when two 2 minutes has expired after the machine has
74. ure and the vacuum valves are adjusted as needed for the operation When the valves are completely closed the compressor has the highest output electric power is unnecessarily wasted and wear and tear are increased Page 4 8 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Installation 4 7 Initial inspection A ELECTRICAL SHOCK Remove power to the laminator before performing step a below Contact with electrical components while power is supplied can result in injury or death a Electrical assembly inspection Component mounting Terminal security Wire tightness Circuit breaker wires A ELECTRICAL SHOCK Electrical troubleshooting should be left to qualified GBC service technicians Electrical shock hazard b Protective circuit inspection The safety of protective circuits may be checked by feeding a current of at least 10 A 50 Hz from the PELV source for at least 10 seconds The test is done between the PE terminal and various points that are part of the protective circuit See EN 60204 1 article 20 2 GBC Films Group January 2001 Page 4 9 Installation Orbit 2000 Operation and Maintenance Manual The voltage measured between the terminal PE and the test points may not exceed U 3 3V for S 1 0 square millimeters U 2 6V for S 1 5 sq millimeters U 1 9V for S 2 5 sq millimeters U is the largest drop in voltage and S is the
75. ust be in the same position when adjusting Largest slope Smallest slope Y GBC Films Group January 2001 Page 5 45 Operations Orbit 2000 Operation and Maintenance Manual Blower angle adjustment The blower angle may be adjusted to assist the sheet for stacking Turn the blower angle handle a to the desired position Blower pressure adjustment The blower pressure can be adjusted with respect to the paper weight To adjust the amount of air flow follow the procedure below 1 Loosen the locking nut b 2 Turn the regulating dial c clockwise or counterclockwise 3 Tighten the locking nut b Page 5 46 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Applications 6 0 Applications AN ATTENTION Do not operate this equipment unless you have read and understand this operator manual and have been fully trained in its operation by a qualified GBC service technician This section will illustrate the recommended types of films general threading procedure and film threading diagram 6 1 Recommended types of film for your Obit 2000 machine Polyester PET 1 7 mil 43u Hi Tac film Aggressive adhesive 8200 clear 30u 1 2 mil film EVA adhesive 1 7 mil 43u Nap Lam II film EVA adhesive Polypropylene OPP 8300 clear 33u 1 3 mil film EVA adhesive 1 2 mil 47u Nap Lam III film EVA adhesive GBC Lay Flat film nylon 1 7 mil 43u Hi Ta
76. ve the machine from the pallet frame remove the shipping bolts drive the lift truck pallet wagon between the pallet frame and the machine frame slowly raise the machine from the pallet frame Replace the shipping angle irons with the leveling feet before final placement The shift of the machine from the frame to the floor is shown on the picture Page 4 6 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Installation 4 5 Electrical installation The main plug may be inserted only into a fixed electrical distribution socket regularly inspected according to appropriate national standards Prior to the start up the initial inspection of the machine electrical equipment must be done according to IEC 364 6 61 standard which includes the fixed power input if the machine is not connected by a flexible cable The machine may be started only when all electrical requirements have been complied with according to appropriate national standards for printing machines During the entire time of operation the user is obligated to comply with the requirements of applicable national standards for printing machines and their electrical wiring EU VERSION US VERSION Nominal voltage 3 NPE 400 V 230 V 50 Hz 3 Phase with ground 230 10 VAC 60 Hz Operating voltage 24 VDC 24 VDC Power input 5 kVA 5 kVA Nominal current 30 Amps 30 Amps Recommended fuses 25AgTF 500V 25AgTF 500V E
77. vice Manual A ELECTRICAL SHOCK Do not modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death AN WARNING WARNING Always exercise Lock out Tag out procedures when performing any type of maintenance to avoid injury to yourself others and to the equipment GBC Films Group January 2001 Page 8 1 Maintenance Orbit 2000 Operation and Maintenance Manual 8 1 Maintenance schedule It is necessary to lubricate and inspect individual parts at regular intervals to prolong the life and ensure the correct functioning of the machine Safety as described in Section 1 of this manual must be followed when performing any type of maintenance DAILY Check the quantity of condensed water in the air treatment unit If the amount in the vessel is higher than 20 mm release the fluid Check the presence of covers and bolts Check the correct function of sensors end switches of the feeding table capacity sensor sensor protecting the feeding head control sensors of removable covers emergency stop push button Cleaning of the rollers and machine EVERY TWO WEEKS Lubricate and grease with oil or spray all sliders and leading spindles Clean the cam and grease Clean and grease guiding rollers Page 8 2 GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual Maintenance M
78. webbing diagram Poly out Poly in Film roll Film roll Chrome Chrome roller roller GBC Films Group January 2001 Page 6 5 Applications Orbit 2000 Operation and Maintenance Manual This page intentionally left blank Page 6 6 GBC Films Group January 2001 Obit 2000 Operation and Maintenance Manual Troubleshooting 7 0 Troubleshooting A WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film A ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death AN WARNING WARNING Always exercise Lock out Tag out procedures when performing any type of troubleshooting to avoid injury to yourself others and to the equipment As an operator you may correct minor problems by performing some simple checks At no time should you attempt to remove or bypass and safety device on the machine Always pay careful attention to warnings placed throughout this section All safety rules from Section 1 apply Within this section you will find Lamination troubleshooting Wave pattern troubleshooting Feeder troubleshooting Misfeed troubleshooting Web troubleshooting and Machine troubleshooting GBC Films Group January 2001 Page 7 1 Troubleshooting Orbit 2000 Operation and Mainten
79. y means of the main motor 5 Push button feeder table UP 6 Push button feeder table DOWN Ta Push button pressure roller UP 8 Push button pressure roller DOWN 9 Laminated sheets counter 10 Temperature regulator of the chrome roller deg C deg F 11 Indicator of missing sheets 12 Switch for changing heating zones on the chrome roller 13 The pulling roller switch UP DOWN 14 The cutter drive switch ON OFF 15 Push button for pulsing the snapping assembly 16 Snapping drive switch 17 Potentiometer snapping drive speed adjustment 18 Push button reverse drive 19 Push button emergency stop 20 Push button stepping run slow drive for equipment cleaning Please refer to the control panel diagram that resembles your machine on pages 4 and 5 INFORMATION The overlay has changed but the functions have remain the same GBC Films Group January 2001 Page 5 3 Orbit 2000 Operation and Maintenance Manual Operations dOls ANIHOVW LUVIS SNIHOVN oor 0 i 0 Sy Zo 08 oz 2 N 1 N oe oe ANN NMOG 09 or os D 00 u an dagas amp ad aqqg4d 1708 ayuNssaud vV N o ovozi Y O 0zt aYuNLVYdadWAL 6666 x ath webb ddO Y3LV3H 8 S133HS NISSIN NO o 440 NO o 440 5

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