Orbit Manufacturing ORBIT 2000 User Manual.pdf

ORBIT ™ 2000 OPERATION &

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 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, transmitted, or transferred, in 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 to return to the first PAGE, use to advance to the last PAGE, use to go back one PAGE and use to advance one PAGE. When moving from view to view, use to return to a previous VIEW and use to advance to the next

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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

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© 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 )

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© 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......................................................................	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
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

Table of Contents	Orbit™ 2000 Operation and Maintenance Manual
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
3.1	Dimensions and weight of the equipment ....................................................	3 -1
3.2	Shipping crate dimensions ..........................................................................	3	-	2
3.3	Basic technical data ...................................................................................	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 ..............................................................................	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
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

Page III

Table of Contents	Orbit™ 2000 Operation and Maintenance Manual
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
5.3.1 Film roll positioning .....................................................................	5	- 23
5.3.2 Heating ...........................................................................................	5	- 27

Page IV

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Orbit™ 2000 Operation and Maintenance Manual	Table of Contents
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

Page V

Table of Contents	Orbit™ 2000 Operation and Maintenance Manual

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
	8.2.2 Safety - Rules for maintenance/ replacement of the twin knife ......	8 - 7
	8.2.3 Feed table chain tensioning ...........................................................	8 - 9

Page VI

© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Safety

1.0Safety regulations

1.1Safety - Complete equipment

1/

2/

3/

4/

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.

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.

ATTENTION

Do not operate , adjust, service or repair the Orbit 2000 if you are under the influence of alcohol, drugs, or medication.

ATTENTION

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

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.

6/

7/

8/

9/

A T T E N T IO N

T est all three interlocked safety guards each day ( the chrom e roller guard, snap roller guard and the guard under the lam inating and snap A R G A s ) and the tw o em ergency stop sw itches ( one on the control panel and one on the drive side of the feeder ) and the pile up safety sw itch ( on the feeder table guide rails )to ensure that they function properly.

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

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.

Page 1 - 2

© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual

Safety

A T T E N T IO N

10/ N ever perform adjustm ents w hile the m achine is running. T he m achine m ust first be stopped, adjusted and then restarted. ( E xcept W hen A djusting L ap For Sheet Size ! )

11/		ATTENTION
	Excercise caution when working around the feeder table, control panel and
	stacking tray to avoid bumping you head.

12/		ATTENTION
	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

13/

The operator shall provide adequate lighting suitable for the given task.

ELECTRICAL

14/

S H O C K

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:

1/

2/

3/

ATTENTION

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: Avoi d bumping your head on th e feeder whe n 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.

Feeder Stack/ Pile

Feeder Table

Chains

Page 1 - 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:

1/

WARNING

Do not touch the feeder head while the machine is running. The moving

suction cups may hurt your hands or fingers.

2/		ATTENTION
	Do not adjust the feeding head while the machine is running with the
	exception of the control buttons described in Section 5.0

3/		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

Locating bar

Clamp

© GBC Films Group January 2001

Page 1 - 5

Safety

Orbit™ 2000 Operation and Maintenance Manual

A T T E N T IO N

4/

D o not place any objects on the upper surface of the feeding head or feeder table.

	ATTENTION
5/	Do not remove covers, fixed cover of the feeding head
	and/ or the protective rubber cover.

A T T E N T IO N

6/

O perate the turning knobs carefully and w ith only one hand w hile the

m achine is running. O nly trained operators m ay use the m achine. D o not w ear ties, loose fit clothing or dangling jew elry w hile operating the m achine.

T u rn in g k n o b s

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© 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

ATTENTION

1/

Do not touch the rollers or hinged stops while the machine is running.

WARNING

2/

WARNING: The chrome roller may be hot. Contact will result in severe burns!

ATTENTION

3/

The insertion or removal of any weights is permissable only when the machine is idle.

Counter weights

© GBC Films Group January 2001

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Safety

Orbit™ 2000 Operation and Maintenance Manual

4/

WARNING

Caution: Excercise extreme caution when adjusting the rollers

to avoid pinching by the loading roller.

A T T E N T IO N

5/

H andle the rollers only w hen the Plexi-glass cover of the chrom e roller is closed.

	ATTENTION
6/	Keep fingers, hands and clothing clear away from the rollers
	while the machine is in operation.

	W A R N IN G
7/	W A R N IN G : D o not be startled by the pressure roller dropping

approxim ately tw o m inutes after the lam inator has been stopped.

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Safety

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:

1/		ATTENTION
	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.

2/

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.

A T T E N T IO N

3/

T he chrom e roller guard m ust be in the fully closed position .

C hrom e roller gu ard

C hrom e roller

P ap er & film sto ck

S et-u p sc re w

P ress ure 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:

WARNING

1/

WARNING: The chrome roller may be hot. Contact will result in severe burns!

WARNING

2/

WARNING: Keep fingers, hands and other body parts away from the rollers.

3/

WARNING

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.

4/

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.

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual

Safety

5/

WARNING

CAUTION: Do not use any tools for cleaning or removing remnants of films

from the rollers while the machine is in operation.

ELECTRICAL

6/

S H O C K

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/

CAUTION: Do not cover the chrome roller guard ventilation holes.

ATTENTION

8/

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

10/

11/

12/

13/

W A R N IN G

W A R N IN G: D epress the lam inator Stop button before attem pting to perform any w eb up procedure on the lam inator.

A T T E N T IO N

A lw ays ensure the adhesive is facing aw ay from the chrome roller w hen loading film .

W A R N IN G

C A U T IO N : O pen 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 O C ) 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

14/

W A R N IN G

W A R N IN G : A void m aking contact w ith any of the hot surface areas. A void all

pinch points and crush hazard areas as illustrated below .

Side view

a - DANGER: High temperature roller surface area.

a

b - DANGER: Pinch/ Crush point area.

b

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:

1/

2/

W A R N IN G

C A U T IO N : D o not adjust the regulating screw s of the snapping roller w hile the lam inator is in operation. D uring operation the regulating screw handle is m oving and your fingers m ay be crushed betw een the regulating screw s and the Plexi-G lass cover.

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.

A T T E N T IO N

3/

D u rin g operation, th e plastic cover m u st rem ain in th e fully closed p osition .

WARNING

4/	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

WARNING

5/

CAUTION: Do not place any objects on the plastic snap roller guard.

ELECTRICAL

6/

S H O C K

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

D AN G E R : C ru s h p o in t b y

C AU TIO N : K ee p fin g ers clear d u rin g

R eg u latin g S crew s

m a ch in e o p era tio n

To p

Ad ju stin g reg u latin g screw s

W AR N IN G : P in ch h azard area

B o tto m

© 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

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:

1/

2/

WARNING

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

3/

4/

5/

6/

7/

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.

WARNING

WARNING: Disconnect power to the equipment before performing any task in the vicinity of the twin knife requiring the removal of the cover

A T T E N T IO N

D o n ot op erate the lam in ator un less th e p lastic guard is in p lace ab ove th e tw in k n ife.

WARNING

CAUTION: Do not place any objects on the plastic knife guard.

ELECTRICAL

S H O C K

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

1.9Safety - 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:

1/

2/

3/

4/

WARNING

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

CAUTION: Do not place your fingers near the groove on the regulating wheel while changing the position of the decurling bar.

W A R N IN G

C A U T IO N : D ue to heat em inating from the chrom e roller and pressure

roller area, avoid contact w ith 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

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

•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.

•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.

•Any GBC Technician, GBC Specialist, and / or GBC Pro-Tech Technician that has been through the GBC Pro-Tech service training course.

WARNING

2/ WARNING : Operato r maintenanc e an d operato r adjustment s ma y b e 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

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.

ELECTRICAL

S H O C K

4/

WARNING: Do not modify any part of the circuitry at any time or for any reason!

WARNING

5/ WARNING: All guards and covers must be returned to their original position after any repairs, adjustments and/ or maintenance has been completed.

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.

ELECTRICAL

7/

S H O C K

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

Safety	Orbit™ 2000 Operation and Maintenance Manual

1.11 Safety - Rules for machine cleaning

1/

2/

WARNING

WARNING: Do not clean any part of the machine while the laminator is in operation.

WARNING

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.

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

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 ).

ATTENTION

4/

Always use cotton or Nomex T M gloves when cleaning the chrome roller.

5/

WARNING

CAUTION: Do not use aggressive solvents that could cause damage to

the rubber rollers. Use only Mineral Spirits.

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.

ELECTRICAL

7/

S H O C K

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 - 23

Safety	Orbit™ 2000 Operation and Maintenance Manual

1.12 Safety - Rules for machine maintenance and adjustments

WARNING

1/

WARNING: Do not remove any covers or guards while the machine is in operation.

WARNING

2/

WARNING: Do not start the machine with the guards or covers removed.

WARNING

3/ WARNING: Shut off and lock the electric supply circuit breaker before performing any operator maintenance or operator adjustments.

4/

WARNING

WARNING: Hot surface! Ensure the chrome roller temperature is below

122 O F ( 50 O C ) before servicing or adjusting.

Page 1 - 24

© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Safety

5/

6/

7/

8/

9/

WARNING

W A R N I N G : 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 maintenance, operator adjustments or set-up.

WARNING

CAUTION: Do not wear ties, loose fit clothing or dangling jewelry. These items can get caught by moving parts while performing tasks.

WARNING

CAUTION: Always wear safety glasses when changing the springs. Uncontrolled springs can damage your eyes.

WARNING

WARNING : Operato r maintenanc e an d operato r adjustment s ma y b e performed only by person(s) trained in all aspects of the equipment.

ELECTRICAL

S H O C K

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:

1/

WARNING

WARNING: Operation of the feeder table may be performed only by

person(s) trained in all aspects of the equipment.

A T T E N T IO N

2/

U se th e P ile/ S tack U p or P ile/ S tack D ow n p u sh bu tton s to m ove th e feed er tab le.

ELECTRICAL

3/

S H O C K

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:

1/

WARNING

WARNING: Shut off the compressed air intake before setting up the

second hinged end-stops and pressure rollers.

2/

WARNING

WARNING: Only person(s) trained in all aspects of the equipment may

operate the central drive.

ELECTRICAL

3/

S H O C K

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

1.15Safety - 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:

WARNING

1/

WARNING: Turn power off at the main breaker before tentioning the chains or belts.

2/

A T T E N T IO N

O p erator m ain ten an ce for th e ch ain s an d belts are lim ited to lub rication an d

ten tion in g. A ll oth er w ork m ust b e perform ed b y a q u alified tech n ician .

ELECTRICAL

3/

S H O C K

Do not modify any guards, covers or enclosures. Contact with any

moving parts or/ and electrical voltage can result in injury or death!

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Safety

1.16Safety - 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:

1/

2/

3/

4/

WARNING

WARNING: Knife has sharp edges! Do not touch the sharp edges of the knives.

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.

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.

ELECTRICAL

S H O C K

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

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Safety	Orbit™ 2000 Operation and Maintenance Manual

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© 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, unauthorized 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

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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

•All belts

•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 void 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.

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Warranty

2.3.1 Warranty is not applicable to the following conditions:

1/ 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.

2/ 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.

3/ Damage to the Plexi-Glass panels or air regulator glass caused:

–mechanically

–by using cleaners that would harm the Plexi-Glass covers

4/ Damage to the exterior finish caused:

–mechanically

–by using cleaning solvents that would harm the finish. Refer to Section 8 Maintenance under cleaning the exterior for suitable cleaners.

5/ Damage to the feeding head by incompetent handling or adjusting.

6/ 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

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Warranty	Orbit™ 2000 Operation and Maintenance Manual

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Specifications

3.0 Specific dimensions and weight of the equipment

1956 mm				1010 mm

1325 mm

1010 mm

						1210 mm
	718 mm
			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 ft2	1.98 m2
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 VERSION
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/m2
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"	190 mm
	Length of rolled film 1700 ft 520 m

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)

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Specifications

		US VERSION
5.	ELECTRICAL CIRCUIT
	Power input	5 kVA +/- 10 %
	Basic voltage requirements	3 phase 230 V 60 Hz
		with ground
	Nominal current	30 A

6.	PNEUMATIC CIRCUIT
	Pressure in the machine circuit	90 psi @ 4 CFM
	The feeder pneumatic circuit
	- vacuum	- 0.6 Bar
	- pressure	+0.6 Bar

7.	MIN/ MAX	1ft./ min / 65 ft./ min
	Slow Forward	Variable speed
	Slow Reverse	Variable speed

EU VERSION

5 kVA +/- 10 %

3 phase 400 V 50 Hz with ground 30 A

0,6 MPa @ 113 l/min.

- 0.6 Bar

+0.6 Bar

.3 m/ min. / 20 m./ min Variable speed Variable speed

© GBC Films Group January 2001

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Specifications	Orbit™ 2000 Operation and Maintenance Manual

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Installation

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™ 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

•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.

•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 ProTech.

•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 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 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.

Becker Compressor

The Becker compressor supplies air to the feeding assembly, and is connected by means of a plug to the machine.

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.)

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Installation

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 interconnection, 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.

ELECTRICAL

S H O C K

Only a qualified electrician should connect power to the laminator. You can be severely shocked, electrocuted or cause a fire if power is improperly applied.

ELECTRICAL

S H O C K

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

Installation	Orbit™ 2000 Operation and Maintenance Manual

4.2 Suggested floor layout

Becker Compressor	T4.25DSK	Secondary	Operation
			Main	Operation
	Min. 0.8 m	Min. 2.6 ft. )
		(

Secondary

Operation

Min. 0.4 m ( Min. 1.3 ft. )

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© GBC Films Group January 2001

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; ifapplicable, make note of this on theBill of Lading.

INFORMATION

AL L SHIPMENT S AR E EX - WORKS . A t ourdock , titl e passe s t o th e buyer . Please review your insurance coverage prior to shipment, as you are responsible for all subsequent freight charges and risks.

WARNING

The Orbit™ 2000 is a large and heavy piece of equipment. It is necessary to emplo y LICENSE D RIGGER S ONL Y t o mov e th e machine . Th e machin e i s 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.

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 remove 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.

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© 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	25 A gTF 500V	25 A gTF 500V

Electrical 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

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Installation	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 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.

a

b

The pressure 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

ELECTRICAL

S H O C K

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

ELECTRICAL

S H O C K

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

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Installation	Orbit™ 2000 Operation and Maintenance Manual

c/

d/

e/

f/

– 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 smallest effective diameter of the protective conductor in the tested branch of the protective circuit.

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.

Perform a 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

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.

Check all roatations of motors: Feeder Pile-up, Feeder pile-down, main drive and

compressor/ feeder

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Installation

g/

h/

i/

Perform a function check of the control panel switches.

Ensure all guides move correctly.

Install the stacking table.

© GBC Films Group January 2001

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Installation	Orbit™ 2000 Operation and Maintenance Manual

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Operations

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 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.

A T T E N T IO N

D o not operate this equipm ent unless you have read and understand this operator m anual and have been fully trained in its operation by a qualified G B C 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	Secondary
Operation	Operation
	Main
	Operation

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© 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 by means of the main motor

5.Push button - feeder table UP

6.Push button - feeder table DOWN

7.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

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2001 January Group Films GBC ©

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E M E R G E N C Y				S E P A R A T O R				L A M I N A T I N G S E C T I O N			F E E D E R
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Operations

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 head, 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

5

6

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© 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.

b

a

© 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 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 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.

e

d

WARNING

CAUTION: Ensure the path of the side stackers are clear before making any adjustments.

c

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 ( f) 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.

ATTENTION

The capacity sensor may be adjusted by a qualified service technician only.

g

6 mm

First gate

f

© GBC Films Group January 2001

Page 5 - 9

Operations	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 the button FEEDER STACK/ 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.

b

a

c

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© 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.

5 - 7 mm

d

e

4 - 6 mm

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.

f				f

© GBC Films Group January 2001

Page 5 - 11

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.

g				g	e

4/

5/

Depending on the paper type, adjust vacuum as needed to lift the sheets via the transport suction cups by turning the regulator on the Becker compressor. The amount of vacuum can be observed on the manometer ( h ).

h

The proper air pressure required to feather the paper is set up by means of regulators ( i ) and ( j ).

i				j

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© GBC Films Group January 2001

Orbit™ 2000 Operation and Maintenance Manual	Operations

6/

7/

Adjust air blowing tubes ( k ) by turning the nut ( l ) so that 10 - 20 sheets at the top of the stack are feathered.

l

k

Regulator ( m ) sets up the stack height.

m

© GBC Films Group January 2001

Page 5 - 13

Operations	Orbit™ 2000 Operation and Maintenance Manual

Feeding small sheet sizes

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.

o

n				n

90o

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Orbit™ 2000 Operation and Maintenance Manual	Operations

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 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.

a

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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 ).

d
		c
a		a

c

b

b

Gravity rollers

e

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.

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Orbit™ 2000 Operation and Maintenance Manual	Operations

Accelerating rollers

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 moment of pressure is controlled by the control system and has been factory set. The spring ( g) determines the pressure.

g

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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.

10

10

Adjusting: Pressure is adjusted by moving the holder ( i ) , which is held by screw ( j ). Follow the procedure below.

1/

2/

3/

4/

Loosen the screw ( h ).

Insert one sheet of paper ( of the same

specific weight ) to be laminated.

Adjust the holders so the finger ( k )

touches the paper without bending.

Tighten the screw ( h ).

j

h

i

P re s s u re are a

k

F ee d er

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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 the sensor, follow the procedure below.

1/ Take a single sheet of paper, insert it under the sensor ( l ).

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.

l

WARNING

CAUTION: Only a qualified service technician may repair the sheet overlap sensor.

© GBC Films Group January 2001

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Operations	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

C A U T I O N : N E V E R T U R N T H E D I A L ( t ) W H E N T H E M A C H I N E I S S T O P P E D !

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

1/ Set the machine to its lowest running speed.

2/ Start the machine. u

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/

5/

6/

7/

Check the overlap.

Should you require a shorter overlap, turn the dial pointer ( u ) slightly toward the “larger sheet

size” direction.

Should you require a longer overlap, turn the dial pointer ( u ) slightly toward the “shorter sheet

size” direction.

After turning the dial pointer ( u ), always wait for 2 to 4 sheets, before continuing with the

adjustments. The variator has a slight delay.

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Orbit™ 2000 Operation and Maintenance Manual	Operations

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 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

mm.

b						2.3 - 2.7
						m m

a

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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.

b		a

c

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.

b

a

c

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Orbit™ 2000 Operation and Maintenance Manual	Operations

5.3 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

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.

a		b

c

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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.

e

*YOUR MACHINE MAY OR MAY NOT HAVE A

SUPPORT ARM.

d

3/ Loosen the 8 mm screw to the control side conical cone ( f ) and slide it off of the spool arbor ( c ).

c

f

4/ Loosen the nut ( g ) on the drive side conical cone ( h ) and leave loose measurement purposes.

g

h

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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.

c

f

6/

7/

Replace the control side conical cone ( f ) on the operator’s side and leave the 8 mm screw

loose for movemt.

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.

X + 1 0 m m X + 3 /8 in .

		X
b	a	5 m m

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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 ).

g

h

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.

i a

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Orbit™ 2000 Operation and Maintenance Manual	Operations

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 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 )

Decrease set point

120.0
120.0	Set temperature
	( Red numbers )
	Increase set point

© GBC Films Group January 2001

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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”.

HEATERS

S T O P

N e w overlay

a

	HEATER
	O F F
8"-11"	12"-14"	Original	Chrome
				12-14 in.
			roller
		overlay
				( 305-356 mm )

For sheet width size between 12 - 14 in. ( 305-356 mm ), set the heater switch ( a ) to 12-14”.

H E A T E R S

S T O P

New overlay

a

	H E A T E R
	OFF		Chrome
8"-11"	12"-14"	Original
			roller	8	-11 in.
		overlay
				( 200	-280 mm )

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Orbit™ 2000 Operation and Maintenance Manual	Operations

5.3.3 Laminating rollers

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 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 ).

a

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

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Operations	Orbit™ 2000 Operation and Maintenance Manual

Adjusting pressure

W A R N IN G

W A R N IN G : D o not rem ove any covers or guards w hile the m achine 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.

	L o c k e d		U n lo c k

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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 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. )

P R E S S U R E R O L L

U P U P

N e w o ve rla y

D O W N D O W N

O rig in a l o ve rla y

( 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.

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Operations	Orbit™ 2000 Operation and Maintenance Manual

5.3.4 Spreader roller ( option )

IN F O R M A T IO N

T he follow ing inform ation is for those m achines that are euipped

w ith 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/

2/

a

Loosen the lock nut ( b ).

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.

c

3/ Tighten the lock nut ( b ).

b

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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 the stacking table. The separator section runs in conjunction with the laminator and feeder sections.

W A R N IN G

C A U T IO N : D o not w ear ties, loose fit clothing or dangling jew elry. T hese item s can get caught the rollers w hile w orking around or loading film .

5.4.1 The decurling bar

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 film on the paper by the chrome roller.

WARNING

WARNING: The chrome roller may be hot. Contact will result in severe burns!

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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 lb. to 100 lb., the decurling bar effects the web path.

Thin paper

Chrome roller

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

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Orbit™ 2000 Operation and Maintenance Manual	Operations

Adjusting the decurling bar

W A R N IN G

W A R N IN G : K eep fingers, hands and other body parts aw ay from the rollers.

Follow the steps below to adjust the decurling bar:

1/ Loosen the locking lever ( b ).

2/ Turn the decurling bar adjustment lever ( a ) with respect to the paper thickness.

3/ Secure the decurling bar in position by tightening the locking lever ( b ).

a

b

For thin paper, radius R3 ( c ) may required if a line is caused by the decurling bar on the laminated sheets.

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Operations	Orbit™ 2000 Operation and Maintenance Manual

To change the from R2 to R3 and vice versa, follow the steps below:

1/

2/

3/

R2

Remove the four 8 mm bolts ( a ).

	R3
Turn the decurling bar ( b ) with the
desired radius up.
	b
Replace the four 8 mm bolts ( a ).	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

Stacking table

Stacking table

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Orbit™ 2000 Operation and Maintenance Manual	Operations

5.4.2 Pull rollers

WARNING

WARNING: Keep fingers, hands and other body parts away from the rollers.

W A R N IN G

C A U T IO N : D o not w ear ties, loose fit clothing or dangling jew elry. T hese item s can get caught the rollers w hile w orking 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.

a

© GBC Films Group January 2001

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Operations	Orbit™ 2000 Operation and Maintenance Manual

PAPER PULL ADJUSTMENT

To adjust the paper pull force use the following steps:

1/

2/

3/

Loosen the locking nut ( b ).

Turn the regulating bolt ( c ).

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 ).

c

e		b

d

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Orbit™ 2000 Operation and Maintenance Manual	Operations

Paper pull adjustment with regards to sheet weight.

L ig h t p u ll

H eavy p u ll

© GBC Films Group January 2001			Page 5 - 39