Orbit Manufacturing 2000 manual

GBC Pro - T ech 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645 ORBIT ™ 2000 OPERA TION & MAINTENANCE MANUAL © January 2001 GBC Films Group Do not duplicate without written permission. Part number : 930 - 051[...]

Read me file Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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 w[...]

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Read me file Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Fax Corr espondence Fax number : ( 608 ) 246 - 8645 Date : T o : Sean Flood at GBC Pro-T ech 4151 Anderson Road DeForest, WI 53532 From : Company : Address : Phone number : ( ) Fax number : ( ) Re : Orbit™ 2000 Operations and Maintenance Manual ( 930051 ) [...]

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Page I T able of Contents Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 T able of Contents Section 1: Safety 1.1 Safety - Complete equipment......................................................................1 - 1 1.2 Safety - Rules for loading paper ................................................................[...]

Page II T able of Contents Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.14 Safety - Rules for the central drive maintenance ....................................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 kni[...]

Page III T able of Contents Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Section 4: Installation 4.0 Installation precautions ..............................................................................4 - 1 4.1 Pre-installation check list ..........................................................................[...]

Page IV T able of Contents Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.1.2 The control panel ...........................................................................5 - 3 Original overlay illustration ..........................................................5 - 4 New overlay illustration ....................[...]

Page V T able of Contents Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.3.3 Laminating rollers .........................................................................5 - 29 5.3.4 Spreader roller ( option ) .............................................................5 - 32 5.4 Separator Section .................[...]

Page VI T able of Contents Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Section 7: T r oubleshooting 7.1 Lamination troubleshooting ......................................................................7 - 2 7.2 W ave pattern tr oubleshooting ...................................................................7 - 4 [...]

Page 1 - 1 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.0 Safety regulations 1.1 Safety - Complete equipment 1/ 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. ATTENTION 2/ The operato[...]

Page 1 - 2 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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. ATTENTION 6/ T est all t h ree interlocke d sa fety gu ard s ea ch d ay ( t h e [...]

Page 1 - 3 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 10/ N ever p erfo rm a dju stm en t s w h il e the m a chin e i s ru n n ing. T h e m ach in e m u st first be stop ped , ad justed a n d th en restarted. ( E xcep t W h en A d justi n g L ap F or S heet S ize ! ) ATTEN TI O N 11 / Excercise caution whe[...]

Page 1 - 4 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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: 1/ Do not attempt to load paper while the machine is running. Your fi[...]

Page 1 - 5 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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 rul[...]

Page 1 - 6 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 4/ D o n ot p lace an y o b j ects o n th e up p er su rface o f t h e feed ing hea d o r feed er table. ATTEN TI O N 5/ Do not remove covers, fixed cover of the feeding head and/ or the protective rubber cover. ATTENTION 6/ O p erate th e turn ing k n [...]

Page 1 - 7 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.4 Safety - Rules for setting up the rollers and the hinged stops 1/ Do not touch the rollers or hinged stops while the machine is running. ATTENTION 2/ WARNING WARNING: The chrome roller may be hot. Contact will result in severe burns! 3/ The insertio[...]

Page 1 - 8 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 4/ WARNING Caution: Excercise extreme caution when adjusting the rollers to avoid pinching by the loading roller. 5/ H a nd le the ro l lers on ly w h en th e Plexi-glass cover o f the ch rom e roller i s closed . ATTEN TI O N 6/ Keep fingers, hands and[...]

Page 1 - 9 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.5 Safety - Rules for setup of the adjustable guide plates The guiding plates form paper before it enters into the chr ome roller . Their position must be adjusted for different paper weights. For a safe adjustment of plates follow these safety rules: [...]

Page 1 - 10 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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 ar ound the chrome and pr essur e r ollers completely . Near t[...]

Page 1 - 11 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5/ WARNING CAUTION: Do not use any tools for cleaning or removing remnants of films from the rollers while the machine is in operation. 6/ ELECTRICAL SHOCK Do not remove or modify any guards, covers or enclosures. Contact with any moving parts or/ and [...]

Page 1 - 12 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 10/ W ARNI NG W ARNI NG: De pr e s s t he l a mi na t o r S t o p b ut t on be f o r e a t t e mpt i n g t o pe rf or m any w e b up pro ce dure on t he l ami nat or . 11 / A lw ay s ensu re t h e ad h esive is faci n g a w ay from th e chro m e roller[...]

Page 1 - 13 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 14/ W ARNI NG W ARNI NG: Av oi d ma ki ng c on t a c t wi t h a ny o f t h e hot s ur f ac e a r e a s . Av o i d a l l p in c h p o in ts a n d cr u sh h a za rd a r ea s a s illu str a ted b e lo w . Side view a b a - DANGER: High temperature roller [...]

Page 1 - 14 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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: 1/ W ARNI NG CAUTI ON: Do n o t[...]

Page 1 - 15 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5/ WARNING CAUTION: Do not place any objects on the plastic snap roller guard. 6/ 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! The sna[...]

Page 1 - 16 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Regulating screw view from the stacking table CAUTION: Finger Crush hazard area Rear view of the Snap Roller Guard Cover[...]

Page 1 - 17 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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: 1/ WARNING CAU[...]

Page 1 - 18 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 3/ WARNING 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. 4/ WARNING WARNING: Disconnect power to the equi[...]

Page 1 - 19 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.9 Safety - Rules for the position adjustment of the decurling bar During lamination internal stress develops between paper and the chr ome roller . The decurling bar straightens the sheets before they exit the lamination section. During adjustment of[...]

Page 1 - 20 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.10 Safety - Rules for electrical installation 1/ WARNING CAUTION: Repairs, adjustments and/ or maintenance may be performed by a qualified technician ( excludes any operator maintenance and operator adjustments ). The word "qualified" is de[...]

Page 1 - 21 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 3/ WARNING WARNING: At no time should you attempt to overide/ by pass and safety shield, safety switches or safety device located on this equipment. 4/ ELECTRICAL SHOCK WARNING: Do not modify any part of the circuitry at any time or for any reason! 5/ [...]

Page 1 - 22 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.1 1 Safety - Rules for machine cleaning 1/ WARNING WARNING: Do not clean any part of the machine while the laminator is in operation. 2/ WARNING CAUTION: Never clean the surface of the rollers while the machine is running. Use the Slow FWD and Slow R[...]

Page 1 - 23 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 3/ WARNING WARNING: Hot surface. Exercise extreme caution when cleaning the chrome roller. Surface temperatures may be upwards of 248 O F to 275 O F ( 120 - 135 O C ). 4/ Always use cotton or Nomex gloves when cleaning the chrome roller. TM ATTENTION 5[...]

Page 1 - 24 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.12 Safety - Rules for machine maintenance and adjustments 1/ WARNING WARNING: Do not remove any covers or guards while the machine is in operation. 2/ WARNING WARNING: Do not start the machine with the guards or covers removed. 3/ WARNING WARNING: Sh[...]

Page 1 - 25 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5/ WARNING WARNING: Check the temperature on the temperature control display if power 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 maintenan[...]

Page 1 - 26 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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. T o ensur e your safety , the following safety rules should be followed: 1/ WARN[...]

Page 1 - 27 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.14 Safety - Rules for the central drive maintenance The main motor drives the feeding head, the feeding roller , and the chrome r oller . It is located on the opposite side from the operator , and protected by a fixed cover . For safe work, the follo[...]

Page 1 - 28 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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: 1/ W[...]

Page 1 - 29 Safety Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 1.16 Safety - Rules for maintenance/ replacement of the twin knife The twin knife is very sharp and extreme caution should be exer cised when working in its vicinity . For safe work, the following safety rules should be followed: 1/ WARNING WARNING: Kn[...]

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Page 2 - 1 W arranty Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 2.0 W arranty 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 r epair or replace any such defective part or pr oduct. These remedies ar[...]

Page 2 - 2 © GBC Films Group January 2001 W arranty 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 rub[...]

Page 2 - 3 W arranty Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 2.3.1 W arranty is not applicable to the following conditions: 1 / Damage to the chrome laminating r oller , rubberized feeding r ollers, pressur e rollers, pull r ollers and snapping rollers if caused by knives, razor blades or any other type of sha[...]

Page 2 - 4 © GBC Films Group January 2001 W arranty Orbit™ 2000 Operation and Maintenance Manual This page intentionally left blank.[...]

Page 3 - 1 Specifications Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 3.0 Specific dimensions and weight of the equipment 1956 mm 1325 mm 1010 mm 1010 mm 1210 mm 1025 mm 718 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 121[...]

Page 3 - 2 Specifications © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 3.2 SHIPPING CRA TE 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) W eight of the Machine with the c[...]

Page 3 - 3 Specifications Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 US VERSION EU VERSION 5 . ELECTRICAL CIRCUIT Power input 5 kV A +/- 10 % 5 kV A +/- 10 % Basic voltage requirements 3 phase 230 V 60 Hz 3 phase 400 V 50 wi th gro und Hz with ground Nominal current 3 0 A 3 0 A 6. PNEUMA TIC CIRCUIT Pressure in t[...]

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Page 4 - 1 Installation Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 4.0 Installation Precautions 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™ 2[...]

Page 4 - 2 Installation © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 4.1 Pre-installation checklist The installation 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. Prior to the machine installation it is[...]

Page 4 - 3 Installation Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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. ). Note The machine is also provided with a terminal to connect an additional conductor for the inter[...]

Page 4 - 4 Installation © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 4.2 Suggested floor layout Becker Compressor T4.25DSK Secondary Operation Secondary Operation Main Operation Min. 0.8 m ( Min. 2.6 ft. ) Min. 0.4 m ( Min. 1.3 ft. )[...]

Page 4 - 5 Installation Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 4.3 Shipping damage inspection Before signing the Bill of Lading, youshould inspect the crate and / or palletfor signs of damage or missing items; ifapplicable, make note of this on theBill of Lading. INFORMATION ALL SHIPMENTS ARE EX-WORKS. At our[...]

Page 4 - 6 Installation © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 4.4 T ransporting 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[...]

Page 4 - 7 Installation Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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 eq[...]

Page 4 - 8 Installation © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 4.6 Becker T4.25 DSK Compressor installation 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[...]

Page 4 - 9 Installation Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 4.7 Initial inspection 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 mou[...]

Page 4 - 10 Installation © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual – The voltage measured between the terminal PE and the test points may not exceed U =3.3V f o r S= 1.0 square millimeters U = 2.6V f o r S= 1.5 sq. millimeters U = 1.9V f o r S = 2.5 sq. millimeters ( U ) is the largest drop in voltage and ( S [...]

Page 4 - 11 Installation Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 g/ Perform a function check of the control panel switches. h/ Ensure all guides move corr ectly . i/ Install the stacking table.[...]

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Page 5 - 1 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.0 Operation WARNING WARNING: Only person(s) trained in all aspects of safety and operations may use this equipment. WARNING CAUTION: Do not wear ties, loose fit clothing or dangling jewelry. These items can get caught by the hinged stops or the fe[...]

Page 5 - 2 Operations © GBC Films Group Januar y 2001 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 contr ol panel (with the original overlay and the new overlay). 5.1.1 The mai[...]

Page 5 - 3 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.1.2 The contr ol panel Legend 1. Push button - start 2. Push button - stop 3. Speed indicator 4. Potentiometer - speed adjustment by means of the main motor 5. Push button - feeder table UP 6. Push button - feeder table DOWN 7. Push button - press[...]

Page 5 - 4 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual MACHINE START MACHINE STOP SPEED R0 0 0 10 20 30 40 50 60 70 80 90 100 F E E D E R UP DOW N PRESSURE ROLL UP DOW N TEMPERATURE PI LE L A M I N A T I N G S E C T I O N 9999 MISSI NG SHEET S HEATER OFF 120. 0 120.0 8"-1 4" 8"-1 1"[...]

Page 5 - 5 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 New overlay SPEED R0 0 0 10 20 30 40 50 60 70 80 90 100 UP DOWN UP DOWN TEMPERATURE 9999 HEATERS STOP 120.0 120.0 SNAP I M PULSE START STOP 0 10 20 30 40 50 60 70 80 90 100 SNAP SPEED EMERGENCY ST OP 1 2 4 3 5 7 9 11 13 15 17 19 6 8 10 12 14 16 18 2[...]

Page 5 - 6 Operations © GBC Films Group Januar y 2001 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 ar e the feeding table, the feeding head, fixed face stops, first gate, side stackers, feeding roller , a[...]

Page 5 - 7 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.2.1 Sheet stacking Face stacking The correct face position of the paper stack on the feeding table is pr ovided by the face stackers ( a ), and the first gate ( b ). The sheets must be pushed tight against the surface of the face stackers. One sho[...]

Page 5 - 8 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Side stacking The collation of paper pile on the sides is done by side stackers ( 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 sid[...]

Page 5 - 9 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.2.2 Feeder table positioning When the paper pile has been loaded, press the “ FEEDER ST ACK/ PILE UP ” button. The table ( f) starts lifting, and its top position is determined by the Paper Pile Height Sensor ( g ), adjust so that the first ga[...]

Page 5 - 10 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 5.2.3 The feeding head WARNING WARNING: Press the stop button before performing the following set-up procedure! Feeding head setup Loosen the clamp ( a ) using the handle bar ( b ). Push the head to its back position, away from the machine. Press [...]

Page 5 - 11 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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[...]

Page 5 - 12 Operations © GBC Films Group Januar y 2001 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. gg e 4/ Depending on the paper type, adjust vacuum as needed to lift the sheets via the transport suction cups by turning the regulat[...]

Page 5 - 13 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 6/ Adjust air blowing tubes ( k ) by turning the nut ( l ) so that 10 - 20 sheets at the top of the stack are feather ed. k l 7/ Regulator ( m ) sets up the stack height. m[...]

Page 5 - 14 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Feeding small sheet sizes WARNING WARNING: Press the stop button before performing the following set-up procedure! T o feed small sizes of paper sheets, less than the distance between the outside suction cups ( n ), you must loosen the screw ( o )[...]

Page 5 - 15 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.2.4 First gate WARNING CAUTION: Only a qualified service technician may adjust the first gate. The first gate assembly is calibrated at the factory and may be field calibrated by a qualified service technician only . Refer to Section 8 Maintenanc[...]

Page 5 - 16 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 5.2.5 Feed roller assembly The assembly consists of gravity rollers ( a), accelerating r ollers ( b ), plate holders ( c ) and the sheet overlap sensor ( d ). a b a b c d c Gravity r ollers The gravity rollers ar e always touching the paper pressi[...]

Page 5 - 17 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Accelerating r ollers 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 pr essure on the feeding r oller at the moment the second gate drop[...]

Page 5 - 18 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Plate holders The plate holders keeps the paper sheet on the lower guiding plate to prevent it fr om 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[...]

Page 5 - 19 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Sheet misfeed sensor The sheet misfeed sensor protects the supporting laminating r oller from the laminating adhesive. Check its function daily . T o check the sensor , follow the procedur e below . 1/ T ake a single sheet of paper , insert it unde[...]

Page 5 - 20 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Overlap adjustment WARNING WARNING: Only person(s) trained in all aspects of the equipment may perform any operator adjustments. WARNING CAUTION: NEVER TURN THE DIAL ( t ) WHEN THE MACHINE IS STOPPED! For each paper size, the speed of the feeding [...]

Page 5 - 21 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.2.6 Second gate 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 r eleasing the sheet so that the overlap of the individual sheets are within the r[...]

Page 5 - 22 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 5.2.7 Adjustable guide plates Sliding plates ( a ) guide the sheets into the pressur e area helping to minimize wrinkles of the sheets. They form the sheet before it enters the laminating r ollers. The plates position is adjusted by turning screw [...]

Page 5 - 23 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.3 Lamination section The lamination section consists mainly of the spool arbor , heating controls, laminating r ollers and the spreader r oller . The laminator serves the purpose of unwind the spool of film via the spool arbor , activating the th[...]

Page 5 - 24 Operations © GBC Films Group Januar y 2001 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. e d 3/ Loosen the 8 mm screw to the contr ol side conical cone ( f ) and slide it off of the spool arbor ( c ). c f 4/ Loose[...]

Page 5 - 25 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5/ Position the roll of film on the spool arbor ( c ) with r espect to the adhesive side (Poly-in or Poly- out). Refer to Section 6 Applications. c f 6/ Replace the control side conical cone ( f ) on the operator’ s side and leave the 8 mm scre w[...]

Page 5 - 26 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 8/ Tighten the 8 mm scr ews on both conical cones and tighten the nut ( g ) on the drive side conical cone ( h ) to secure the r oll of film to the spool arbor ( c ). h c g 9/ Use the lateral film adjust nut ( a ) to fine tune the positioning of t[...]

Page 5 - 27 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.3.2 Heating WARNING WARNING: The chrome roller can become extremely hot. Contact will result in severe burns! WARNING WARNING: Keep fingers, hands and other body parts away from the rollers. Heating is controlled by two means. ( 1 ) by using the [...]

Page 5 - 28 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Heat width selection For sheet width size between 8 - 1 1 in. ( 200-280 mm ), set the heater switch ( a ) to 8-1 1”. 12-14 in. ( 305-356 mm ) Chrome roller HEATERS STOP HEATER OFF 12"-14" 8"-11" New overlay Original overlay a[...]

Page 5 - 29 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.3.3 Laminating r ollers WARNING WARNING: Keep fingers, hands and other body parts away from the rollers. The upper chrome r oller combined with the lower pressur e roller make up the laminating rollers. The laminating r ollers function is to pres[...]

Page 5 - 30 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Adjusting pr essure W ARNI NG W ARNI NG: Do no t r e mo ve a n y c o v e r s or g u ar d s whi l e t he ma c h i ne i s i n o p e r at i o n. Pressur e may be adjusted by two air regulators. One for each side of the pull r ollers. T o adjust, foll[...]

Page 5 - 31 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Automatic pressur e cancellation The closure of the pr essure r ollers is controlled by the PLC. The PLC will open the pr essure rollers two minutes after the laminator stops to pr event damage to the rubber roller surface. Automatic pressur e canc[...]

Page 5 - 32 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 5.3.4 Spr eader roller ( option ) IN F O R M A T IO N T h e follow in g info rm ation is for tho se m a chin es t h at a re euip pe d w ith the op ti o na l sp rea der ro ll er. The spreader r oller ( a ) is designed to adjust so the laminate is e[...]

Page 5 - 33 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.4 Separator section This section consists of the decurling bar , pull roller , twin knives, snapping assembly and the stacking table. The separator section runs in conjunction with the laminator and feeder sections. W ARNI NG CAUTI ON: Do n o t w[...]

Page 5 - 34 Operations © GBC Films Group Januar y 2001 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 lb. to 100 lb., the decurling bar effects the web path. Decurling bar Chrome roller Thin p a p er For thicker papers, 12 pt. t[...]

Page 5 - 35 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Adjusting the decurling bar W ARNI NG W ARNI NG: Ke e p f i ng e r s , h an ds a n d ot he r b od y p a r t s awa y f r om t he r ol l e r s . Follow the steps below to adjust the decurling bar: 1/ Loosen the locking lever ( b ). 2/ T urn the decur[...]

Page 5 - 36 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual T o change the from R2 to R3 and vice versa, follow the steps below: 1/ Remove the four 8 mm bolts ( a ). 2/ T urn the decurling bar ( b ) with the desired radius up. 3/ Replace the four 8 mm bolts ( a ). Effects of the decurling bar The sheets sh[...]

Page 5 - 37 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.4.2 Pull r ollers WARNING WARNING: Keep fingers, hands and other body parts away from the rollers. W ARNI NG CAUTI ON: Do n o t we ar t i e s , l oo s e f i t c l o t hi ng o r da ng l i n g j e wel r y. The s e i t e ms c an ge t caug ht the r o[...]

Page 5 - 38 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual P APER PULL ADJUSTMENT T o adjust the paper pull force use the following steps: 1/ Loosen the locking nut ( b ). 2/ T urn the regulating bolt ( c ). 3/ The setting is indicated by the white marker of the control device ( d ) with r espect to the u[...]

Page 5 - 39 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Paper pull adjustment with regards to sheet weight. Li ght pul l Heav y pul l[...]

Page 5 - 40 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 5.4.3 T win knives D o n ot o pera te t h e lam in ator u nless th e plastic gua rd is in place a bo ve th e tw in k nife. ATTEN TI O N W ARNI NG CAUTI ON: Do n o t pl ac e y ou r f i n ge r s or a ny ot he r pa r t o f y ou r bo dy ne a r t he pl[...]

Page 5 - 41 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Positioning of the knife assembly with respect to sheet edge 5 - 6 m m Kni f e 1 Kni f e 2 we b Positioning of the knife assembly with r espect to sheet weight Heavier paper may requir e shims under the twin knifes to achieve a clean cut of the fil[...]

Page 5 - 42 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual 5.4.4 Snapping assembly WARNING WARNING: Keep fingers, hands and other body parts away from the rollers. W ARNI NG CAUTI ON: Do n o t we ar t i e s , l oo s e f i t c l o t hi ng o r da ng l i n g j e wel r y. The s e i t e ms c an ge t caug ht th[...]

Page 5 - 43 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 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. 3 - 5 o 5 - 10 o T [...]

Page 5 - 44 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Adjusting the upper snap roller Angling of the upper snap roller is achieved by turning the r egulating bolts ( b ). T o adjust the angle of the upper snap roller , use the following steps: b c d 1/ Loosen the locking nut ( c ). 2/ T urn the r egu[...]

Page 5 - 45 Operations Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 5.4.5 Stacking table The stacking table stacks the laminated sheets once the snap rollers have separated them. The stacking table guides ( a ) should be adjusted to accommodate the sheet size. T able slope adjustment The table slope may be adjusted[...]

Page 5 - 46 Operations © GBC Films Group Januar y 2001 Orbit™ 2000 Operation and Maintenance Manual Blower angle adjustment The blower angle may be adjusted to assist the sheet for stacking. T urn the blower angle handle ( a ) to the desired position. a Blower pr essure adjustment The blower pressur e can be adjusted with respect to the paper we[...]

Page 6 - 1 Applications Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 6.0 Applications ATTEN TI O N Do not ope ra te t hi s equi pment unl e ss you hav e r ea d and under s ta nd thi s ope ra t or manual a nd have bee n ful l y t rai ne d i n i t s o per at i on by a q ua l ified G B C service tech nician . This sec[...]

Page 6 - 2 Applications © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 6.2 General threading procedure W ARNI NG CAUTI ON: Do n o t we ar t i e s , l oo s e f i t c l o t hi ng o r da ng l i n g j e wel r y. The s e i t e ms c an ge t caug ht the r ol l er s whi l e wor ki n g a ro und or l oadi ng f i l m . W ARNI N[...]

Page 6 - 3 Applications Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 3/ Load the sheet stack on the feed table. ( Described in Section 5 ) 4/ Adhere one sheet of the same width as the sheets in the feeder to start the film web. 5/ Switch the compressor on and push the star t button at it’ s slowest speed. 6/ Stop[...]

Page 6 - 4 Applications © GBC Films Group January 2001 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 slop[...]

Page 6 - 5 Applications Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 6.3 Film threading diagram F ilm a r b o r F ilm r o ll Shee t s C h rom e ro l le r Decur l i ng bar P u l l ro lle r s S n a p r o lle r s St ack t abl e Poly-in / Poly-out webbing diagram P o ly - o u t P o ly - in Chr om e ro lle r Chr om e ro[...]

Page 6 - 6 Applications © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual This page intentionally left blank.[...]

Page 7 - 1 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 7.0 T roubleshooting W ARNI NG CAUTI ON: Do n o t we ar t i e s , l oo s e f i t c l o t hi ng o r da ng l i n g j e wel r y. The s e i t e ms c an ge t caug ht the r ol l er s whi l e wor ki n g a ro und or l oadi ng f i l m . ELECTRI CA L SHO[...]

Page 7 - 2 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 7.1 Lamination troubleshooting Blistering Cause: 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 [...]

Page 7 - 3 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Delamination Cause: Refers to either one of two conditions; 1) the adhesive separating from the laminate substrate, or 2) the laminate separating from the product being laminated. Solution: Delamination is eliminated by using the correct type o[...]

Page 7 - 4 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 7.2 W ave pattern troubleshooting W aves or ripples in laminated images can be caused by; paper tension, laminating temperatur e, incorrect nip, clutch tension, binding of film core on brakes or core ends, and cooling. Below is a description [...]

Page 7 - 5 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 Paper pull tension ( W ave 2 & 4 ) Cause: These patterns are caused by too little ( W ave 2 ) or too much ( W ave 4 ) tension of the laminated material between the laminating rollers and the pull rollers. Solution: T o r emove these waves, [...]

Page 7 - 6 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual W rinkles on either edge after the pr essure r oller ( W ave 9 ) Cause: Air pressure on the pressure roller from side to side may require off setting. Solution: T o prevent this type of waving, off set the pr essure roller by adjusting the ai[...]

Page 7 - 7 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 W ave patterns 1 - 6 W ave 1 W ave 2 Wa v e 4 Wa v e 6 Wa v e 3 Wa v e 5[...]

Page 7 - 8 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual W ave 7 W ave 8 Wa v e 1 0 Wa v e 1 2 Wa v e 9 Wa v e 1 1 ( sh eet ) W ave patterns 7 - 12[...]

Page 7 - 9 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 7.3 Feeder troubleshooting WARNING WARNING: Operator maintenance and operator adjustments may be performed only by person(s) trained in all aspects of the equipment. 1. The table move is sluggish even without paper load. WARNING CAUTION: Depres[...]

Page 7 - 10 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 7.4 Misfed sheets troubleshooting WARNING WARNING: Only person(s) trained in all aspects of the equipment may perform any troubleshooting procedures. PROBLEM F I X • Paper is not acclimatized – Feed at lower speed • Incorrect vacuum or[...]

Page 7 - 11 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 7.5 W eb 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 increas[...]

Page 7 - 12 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 7.6 Machine troubleshooting ATTEN TI O N A t no ti m e should a guard, panel , cabinet , d oor or cover be r em oved b y an ope ra t or f or t ro ubl es hoot i ng pur pos e ( not e ve n t ra i ned ope ra t or s ) . O nl y q ua l ified G B C [...]

Page 7 - 13 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 (2) Symptom: The light in the start button is off. Possible causes: – 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[...]

Page 7 - 14 T r oubleshooting © GBC Films Group January 2001 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 [...]

Page 7 - 15 T roubleshooting Obit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 (9) Symptom: continued Possible causes: – Adjust for snapping ( separation ) moves under actual snapping roller . – Adjust snapping position backward towards tension roller . (10) Symptom: The upper snapping roller doesn’t move up or dow[...]

Page 7 - 16 T r oubleshooting © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual This page intentionally left blank.[...]

Page 8 - 1 Maintenance Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 8.0 Maintenance 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 f[...]

Page 8 - 2 Maintenance © GBC Films Group January 2001 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 per[...]

Page 8 - 3 Maintenance Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 MONTHL Y – Tighten and grease all roller chains ANNUALL Y – Cleaning of the electrical assembly ELECTRI CA L SHOCK W ARNI NG: P owe r mu s t be di s c on ne c t e d t o ma c hi ne at f us ed di s c o nne c t ! – Dust can be removed by vacuumi[...]

Page 8 - 4 Maintenance © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual – The voltage measured between the terminal PE and the test points may not exceed U =3.3V f o r S= 1.o square millimeters U = 2.6V f o r S= 1.5 sq. millimeters U = 1.9V f o r S = 2.5 sq. millimeters Where U is the largest drop in voltage and S is[...]

Page 8 - 5 Maintenance Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 8.2 Operators Maintenance 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 1/ WARNING WARNING: [...]

Page 8 - 6 Maintenance © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual c/ Clean the exposed area of the rollers. d/ Repeat as necessary . 4/ WARNING WARNING: Hot surface. Exercise extreme caution when cleaning the chrome roller. Surface temperatures may be upwards of 248 O F to 275 O F ( 120 - 135 O C ). 5/ Always use[...]

Page 8 - 7 Maintenance Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 8.2.2 Safety - Rules for maintenance/ replacement of the twin knife The twin knife is very sharp and extreme caution should be exer cised when working in its vicinity . For safe work, the following safety rules should be followed: 1/ WARNING WARNIN[...]

Page 8 - 8 Maintenance © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 4/ 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. a/ Raise the snapping section safety shield. b/ Remove the lock down thumb scre w . c[...]

Page 8 - 9 Maintenance Orbit™ 2000 Operation and Maintenance Manual © GBC Films Group January 2001 8.2.3 Feed table chain tensioning a / T ensioning is done by means of turning the bolts where the chain connects to the feeding table. Tentioning bolt WARNING WARNING: Overturning of the bolt can result in disconnection of the chain to the feeding [...]

Page 8 - 10 Maintenance © GBC Films Group January 2001 Orbit™ 2000 Operation and Maintenance Manual 8.2.4 Paper release adjustment WARNING CAUTION: Only a qualified service technician may perform this set-up. WARNING WARNING: Press the stop button before performing the following set-up procedure! Proper feeding is obtained by setting the lift an[...]