Orbit Manufacturing ORBIT 2000 User Manual
ORBIT ™ 2000 OPERATION &
MAINTENANCE MANUAL
© January 2001 GBC Films Group
Do not duplicate without written permission.
GBC Pro - T ech
4151 Anderson Road
DeForest, WI 53532
Revision : Ph: ( 608 ) 246 - 8844
Part number : 930 - 051
Fx: ( 608 ) 246 - 8645
Read me fileOrbit™ 2000 Operation and Maintenance Manual
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The information in this publication is provided for reference and is believed to be accurate 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,
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DeForest, WI 53532
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Read me fileOrbit™ 2000 Operation and Maintenance Manual
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© GBC Films Group January 2001
Section 1: Safety
1.1 Safety - Complete equipment......................................................................1 - 1
1.2 Safety - Rules for loading paper .................................................................1 - 4
1.3 Safety - Rules for handling the feeding head ..............................................1 - 5
1.4 Safety - Rules for setting up the rollers and the hinged stops .....................1 - 7
T able of ContentsOrbit™ 2000 Operation and Maintenance Manual
Table of Contents
1.5 Safety - Rules for set-up of the adjustable guide plates ..............................1 - 9
1.6 Safety - Rules for the chrome and pressure rollers ..................................1 - 10
1.7 Safety - Rules for the snap roller area ......................................................1 - 14
1.8 Safety - Rules for the use of the twin knife ...............................................1 - 17
1.9 Safety - Rules for the position adjustment of the decurling bar ................1 - 19
1.10 Safety - Rules for electrical installation .................................................1 - 20
1.11 Safety - Rules for machine cleaning .......................................................1 - 22
1.12 Safety - Rules for machine maintenance and adjustments .....................1 - 24
1.13 Safety - Rules for the feeder table ..........................................................1 - 26
© GBC Films Group January 2001
Page I
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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 knife ..............1 - 29
Section 2: Warranty
2.1 Terms and conditions .................................................................................2 - 1
2.2 Limited period of warranty ........................................................................2 - 2
2.3 Limited warranty conditions ......................................................................2 - 2
Section 3: Specifications
3.0 Specific dimensions and weight of the equipment illustration ...................3 - 1
Page II
3.1 Dimensions and weight of the equipment ....................................................3 -1
3.2 Shipping crate dimensions ..........................................................................3 - 2
3.3 Basic technical data ...................................................................................3 - 2
© GBC Films Group January 2001
Section 4: Installation
4.0 Installation precautions ..............................................................................4 - 1
4.1 Pre-installation check list ...........................................................................4 - 2
4.2 Suggested floor layout ................................................................................4 - 4
4.3 Shipping damage inspection .......................................................................4 - 5
4.4 Transporting of the machine ......................................................................4 - 6
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4.5 Electrical installation .................................................................................4 - 7
4.6 Becker T4.25 DSK compressor installation ..............................................4 - 8
4.7 Initial inspection .........................................................................................4 - 9
Section 5: Operations
5.0 Operations ..................................................................................................5 - 1
5.1 General information ...................................................................................5 - 2
5.1.1 Main and secondary operator position ..........................................5 - 2
© GBC Films Group January 2001
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5.1.2 The control panel ...........................................................................5 - 3
Original overlay illustration ..........................................................5 - 4
New overlay illustration ................................................................5 - 5
5.2 Feeder section ............................................................................................5 - 6
5.2.1 Sheet stacking ................................................................................5 - 7
5.2.2 Feeder table positioning ................................................................5 - 9
5.2.3 The feeding head ..........................................................................5 - 10
5.2.4 First Gate ......................................................................................5 - 15
5.2.5 Feed roller assembly ....................................................................5 - 16
5.2.6 Second gate ...................................................................................5 - 21
5.2.7 Adjustable guide plates ................................................................5 - 22
5.3 Lamination section ....................................................................................5 - 23
Page IV
5.3.1 Film roll positioning .....................................................................5 - 23
5.3.2 Heating ...........................................................................................5 - 27
© GBC Films Group January 2001
T able of ContentsOrbit™ 2000 Operation and Maintenance Manual
5.3.3 Laminating rollers .........................................................................5 - 29
5.3.4 Spreader roller ( option ) .............................................................5 - 32
5.4 Separator Section ....................................................................................5 - 33
5.4.1 The decurling bar .........................................................................5 - 33
5.4.2 Pull rollers ....................................................................................5 - 37
5.4.3 Twin knife .....................................................................................5 - 40
5.4.4 Snapping assembly .......................................................................5 - 42
5.4.5 Stacking table ...............................................................................5 - 45
Section 6: Applications
6.1 Recommended film types ............................................................................6 - 1
6.2 General threading procedure .....................................................................6 - 2
6.3 Film threading diagram ..............................................................................6 - 5
© GBC Films Group January 2001
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Section 7: Troubleshooting
7.1 Lamination troubleshooting ......................................................................7 - 2
7.2 Wave pattern troubleshooting ...................................................................7 - 4
7.3 Feeder troubleshooting ..............................................................................7 - 9
7.4 Misfed sheets troubleshooting ..................................................................7 - 10
7.5 Web troubleshooting ..................................................................................7 - 11
7.6 Machine troubleshooting ...........................................................................7 - 12
Section 8: Maintenance
8.1 Maintenance schedule ...............................................................................8 - 2
8.2 Operators Maintenance .............................................................................8 - 5
8.2.1 Safety - Rules for machine cleaning ...............................................8 - 5
Page VI
8.2.2 Safety - Rules for maintenance/ replacement of the twin knife ......8 - 7
8.2.3 Feed table chain tensioning ...........................................................8 - 9
© GBC Films Group January 2001
1.0 Safety regulations
1.1 Safety - Complete equipment
ATTENTION
SafetyOrbit™ 2000 Operation and Maintenance Manual
1/
2/
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
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
and film must comply with conditions of Section 2 of the Technical Specifications.
The equipment is provided with means to control lamination functions. The
controls as set up by the factory may not be modified or altered.
3/
Do not operate , adjust, service or repair the Orbit 2000 if you are under the
influence of alcohol, drugs, or medication.
4/
Do not operate the Orbit 2000 if you are ill or tired.
© GBC Films Group January 2001
ATTENTION
ATTENTION
Page 1 - 1
Safety Orbit™ 2000 Operation and Maintenance Manual
ATTENTION
5/
6/
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
Test all three interlocked safety g ua rd s each d ay ( the ch ro m e roller gu ard ,
snap roller guard and the guard under the laminating and snap ARGA s ) and
the two em ergen cy stop sw itches ( one on the co ntrol p an el and on e on th e
drive side of th e feeder ) and the p ile up safety switch ( on the feeder ta b le
guide ra ils )to ensure tha t they fu nction p rop erly.
7/
8/
ATTENTION
Exercise extreme caution when working with sheets to avoid paper cuts.
ATTENTION
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.
ATTENTION
9/
Page 1 - 2
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 the rollers.
© GBC Films Group January 2001
ATTENTION
SafetyOrbit™ 2000 Operation and Maintenance Manual
10/
11/
Never p erfo rm ad ju stm en ts w hile the m a ch ine is run n ing. T h e m ach in e m u st first be
stopped , ad justed a nd th en restarted. ( Ex cep t When A d justing Lap For S h eet Size ! )
ATTENTION
Excercise caution when working around the feeder table, control panel and
stacking tray to avoid bumping you head.
ATTENTION
12/
13/
14/
The equipment must be fixed/ positioned on a firm and even floor. The
working station of the operator must be at the same level.
ATTENTION
The operator shall provide adequate lighting suitable for the given task.
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 - 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:
ATTENTION
1/
2/
3/
Do not attempt to load paper while the machine is running. Your fingers
couldbe hurt during the automatic insertion of paper.
WARNING
Ensure the feeder stack/ pile is in the bottom position before loading paper. To move
into that position, press the Pile/ Stack down push button.
CAUTION: Avoid bumping your head on the feeder when loading paper.
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.
Page 1 - 4
Feeder Stack/ Pile
Feeder Table
Chains
© GBC Films Group January 2001
SafetyOrbit™ 2000 Operation and Maintenance Manual
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:
WARNING
1/
2/
3/
Do not touch the feeder head while the machine is running. The moving
suction cups may hurt your hands or fingers.
ATTENTION
Do not adjust the feeding head while the machine is running with the
exception of the control buttons described in Section 5.0
ATTENTION
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
Clamp
© GBC Films Group January 2001
Locating bar
Page 1 - 5
Safety Orbit™ 2000 Operation and Maintenance Manual
ATTENTION
4/
Do n ot p lace an y o bjects on the u p p er su rface of th e feed ing h ead or f eeder tab le.
ATTENTION
5/
6/
Do not remove covers, fixed cover of the feeding head
and/ or the protective rubber cover.
ATTENTION
Op erate th e turn ing k n ob s carefu lly an d w ith on ly on e h an d w h ile the
machine is running. Only trained operators may use the machine. Do not wear
ties, loose fit clothing or dangling jew elry while operating the machine.
Page 1 - 6
Turning
knobs
© GBC Films Group January 2001
SafetyOrbit™ 2000 Operation and Maintenance Manual
1.4 Safety - Rules for setting up the rollers and the hinged
stops
ATTENTION
1/
2/
3/
Do not touch the rollers or hinged stops while the machine is running.
WARNING
WARNING: The chrome roller may be hot. Contact will result in severe burns!
ATTENTION
The insertion or removal of any weights is permissable only when the machine is idle.
Counter weights
© GBC Films Group January 2001
Page 1 - 7
Safety Orbit™ 2000 Operation and Maintenance Manual
WARNING
4/
5/
Caution: Excercise extreme caution when adjusting the rollers
to avoid pinching by the loading roller.
ATTENTION
Ha nd le the ro llers only w h en the P lexi-glass cover of th e ch rom e ro ller is closed.
ATTENTION
6/
7/
Keep fingers, hands and clothing clear away from the rollers
while the machine is in operation.
WARNING
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
SafetyOrbit™ 2000 Operation and Maintenance Manual
1.5 Safety - Rules for setup of the adjustable guide 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:
ATTENTION
1/
2/
3/
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.
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.
ATTENTION
Th e ch rom e ro ller gua rd must be in the fu lly closed p osition.
Se t-u p s c re w
© GBC Films Group January 2001
Chro m e ro ller guard
Chro m e ro ller
Pa p e r & f ilm s to c k
Pressure roller
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 pr essur e 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:
WARNING
1/
2/
WARNING: The chrome roller may be hot. Contact will result in severe burns!
WARNING
WARNING: Keep fingers, hands and other body parts away from the rollers.
WARNING
3/
4/
Page 1 - 10
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.
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.
© GBC Films Group January 2001
WARNING
SafetyOrbit™ 2000 Operation and Maintenance Manual
5/
6/
CAUTION: Do not use any tools for cleaning or removing remnants of films
from the rollers while the machine is in operation.
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!
WARNING
7/
8/
CAUTION: Do not cover the chrome roller guard ventilation holes.
ATTENTION
When cleaning, follow the rules for Safety - Rules for cleaning in Section 3.10
WARNING
9/
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
Page 1 - 11
Safety Orbit™ 2000 Operation and Maintenance Manual
WARNING
10/
11/
WARNING: Depress the laminator Stop button before attempting to
perform any web up procedure on the laminator.
ATTENTION
Alw ay s ensu re the ad h esive is facing away from the ch rom e ro ller wh en load ing film.
WARNING
12/
13/
CAUTION: Open the plastic chrome roller guard fully to prevent to
accidental closing onto your hands and fingers.
WARNING
WARNING: Hot surface. Ensure the chrome roller is below 122
O
F ( 50 OC )
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
WARNING
SafetyOrbit™ 2000 Operation and Maintenance Manual
14/
WARNING: Avoid making contact with any of the hot surface areas. Avoid all
pin ch points an 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 - DANGER: High temperature
roller surface area.
b - DANGER: Pinch/ Crush
point area.
a
b
© GBC Films Group January 2001
Rear view
WARNING: Hot surface area
WARNING: Crush hazard area
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:
WARNING
1/
2/
CAUTION: Do not adjust the regulating screws of the sn a pp ing roller w h ile the
lamina tor is in opera tion. D u ring op era tion the reg ulating screw h an d le is mov ing a n d
your fin gers may be cru shed b etw een the reg u lating screws and the P lexi-Glass co ver.
WARNING
CAUTION: Do not place your fingers or any other part of your body near the contact
point between the upper and lower snap rollers.
ATTEN TION
3/
4/
Page 1 - 14
Du ring o peration, the plastic cover mu st rem ain in the fu lly closed position.
WARNING
CAUTION: Open the plastic snap roller guard fully to prevent accidental
closing onto your hands or fingers.
© GBC Films Group January 2001
WARNING
SafetyOrbit™ 2000 Operation and Maintenance Manual
5/
CAUTION: Do not place any objects on the plastic snap roller guard.
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
ELECTRICAL
SHOCK
CAUTION: Keep fingers clear during
machine operation
Adjusting regulating screws
W ARNING: Pinch hazard area
DANGER: Crush point by
Regulating Screws
Top
Bottom
© GBC Films Group January 2001
Page 1 - 15
Safety Orbit™ 2000 Operation and Maintenance Manual
Regulating screw view from the stacking table
CAUTION: Finger Crush hazard area
Rear view of the Snap Roller Guard Cover
Page 1 - 16
© 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:
WARNING
SafetyOrbit™ 2000 Operation and Maintenance Manual
1/
2/
CAUTION: Do not place your fingers or any other part of your body near
the plastic guard while the machine is running.
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.
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
WARNING
3/
4/
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.
WARNING
WARNING: Disconnect power to the equipment before performing any task in the
vicinity of the twin knife requiring the removal of the cover
ATTEN TION
5/
6/
7/
Do not operate the laminator unless the plastic guard is in place above the twin knife.
WARNING
CAUTION: Do not place any objects on the plastic knife guard.
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
SafetyOrbit™ 2000 Operation and Maintenance Manual
1.9 Safety - Rules for the position adjustment of the decurling bar
During lamination 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:
WARNING
1/
2/
CAUTION: Exercise caution while loosening the decurling bar handle.
The securing screw and the edge of the groove on the regulating
wheel may collide during sudden loosening.
WARNING
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.
WARNING
3/
4/
CAUTION: Do not place your fingers near the groove on the regulating
wheel while changing the position of the decurling bar.
CAUTION: Due to heat eminating from the chrome roller and pressure
roller area, avoid contact with the decurling bar.
© GBC Films Group January 2001
WARNING
Page 1 - 19
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