GBC ORBIT 2000, Operating & Maintenance Manual

Page 1: ...h 4151 Anderson Road DeForest WI 53532 Revision Ph 608 246 8844 Fx 608 246 8645 ORBIT 2000 OPERATION MAINTENANCE MANUAL January 2001 GBC Films Group Do not duplicate without written permission Part number 930 051 ...

Page 2: ... 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 ...

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Page 4: ... January 2001 Fax Correspondence Fax number 608 246 8645 Date To Sean Flood at GBC Pro Tech 4151 Anderson Road DeForest WI 53532 From Company Address Phone number Fax number Re Orbit 2000 Operations and Maintenance Manual 930051 Section Page Correction s Additional comments ...

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Page 6: ... 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...

Page 7: ...ve 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 techni...

Page 8: ... 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 ...

Page 9: ...llustration 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 10: ...ers 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 ...

Page 11: ...oubleshooting 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 12: ... 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 3 Do not operate adjust service or repair t...

Page 13: ...ency stop switches one on the control panel and one on the drive side of the feeder and the pile up safety switch on the feeder table guide rails to ensure that they function properly ATTENTIO N 7 Exercise extreme caution when working with sheets to avoid paper cuts ATTENTION 8 Never clean any rollers while the equipment is running If needed turn the rollers for cleaning or testing by using the sl...

Page 14: ... working around the feeder table control panel and stacking tray to avoid bumping you head ATTENTION 12 The equipment must be fixed positioned on a firm and even floor The working station of the operator must be at the same level ATTENTION 13 The operator shall provide adequate lighting suitable for the given task ATTENTION 14 ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosure...

Page 15: ...hile the machine is running Your fingers couldbe hurt during the automatic insertion of paper ATTENTION 2 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 3 WARNING Do not touch the stack pile table or chains with your fingers or other...

Page 16: ...d 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 Do not adjust the feeding head while the machine is running with the exception of the control buttons described in Section 5 0 ATTENTION 3 To move the head loosen the clamp on the locating bar then slide the head by gra...

Page 17: ...eder table ATTENTIO N 5 Do not remove covers fixed cover of the feeding head and or the protective rubber cover ATTENTION 6 Operate the turning knobs carefully and with only one hand while the machine is running Only trained operators may use the machine Do not wear ties loose fit clothing or dangling jewelry while operating the machine ATTENTIO N Turning knobs ...

Page 18: ...ng up the rollers and the hinged stops 1 Do not touch the rollers or hinged stops while the machine is running ATTENTION 2 WARNING WARNING The chrome roller may be hot Contact will result in severe burns 3 The insertion or removal of any weights is permissable only when the machine is idle ATTENTION Counter weights ...

Page 19: ...id pinching by the loading roller 5 Handle the rollers only when the Plexi glass cover of the chrome roller is closed ATTENTIO N 6 Keep fingers hands and clothing clear away from the rollers while the machine is in operation ATTENTION 7 W ARNING WARNING Do not be startled by the pressure roller dropping approximately two minutes after the laminator has been stopped ...

Page 20: ...stment of plates follow these safety rules 1 The plate s position may be adjusted while the equipment is running by using the set up screw This may only be performed by a trained operator ATTENTION 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 3 ATTENTIO N The chrome roller guard must be in the fully clo...

Page 21: ...y dangerous zone Because of that and the high temperature the following safety rules must be complied with 1 WARNING WARNING The chrome roller may be hot Contact will result in severe burns 2 WARNING 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 ...

Page 22: ... 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 7 WARNING CAUTION Do not cover the chrome roller guard ventilation holes 8 When cleaning follow the rules for Safety Rules for cleaning in Section 3 10 ATTENTION 9 WARNING WARNING Keep hands and fingers away from the pressure chrome roller when using Pressu...

Page 23: ...away from the chrome roller when loading film ATTENTION 12 W ARNING CAUTION Open the plastic chrome roller guard fully to prevent to accidental closing onto your hands and fingers 13 WARNING WARNING Hot surface Ensure the chrome roller is below 122 OF 50 OC before servicing or adjusting Check the temperature on the temperature control display or by using an external temperature sensor or wait 60 m...

Page 24: ...4 W ARNING WARNING Avoid making contact with any of the hot surface areas Avoid all pinch points and crush hazard areas as illustrated below Side view a b a DANGER High temperature roller surface area b DANGER Pinch Crush point area Rear view WARNING Hot surface area WARNING Crush hazard area ...

Page 25: ... screws of the snapping roller while the laminator is in operation During operation the regulating screw handle is moving and your fingers may be crushed between the regulating screws and the Plexi Glass cover 2 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 3 ATTE N TIO N During operation the plastic cover m...

Page 26: ...ler guard 6 ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death The snap roller side view CAUTION Keep fingers clear during m achine operation W ARNING Pinch hazard area DANGER Crush point by Regulating Screw s Top Bottom Adjusting regulating screw s ...

Page 27: ... 1 16 Safety Orbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 Regulating screw view from the stacking table CAUTION Finger Crush hazard area Rear view of the Snap Roller Guard Cover ...

Page 28: ...it is necessary to observe the following safety rules 1 WARNING CAUTION Do not place your fingers or any other part of your body near the plastic guard while the machine is running 2 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...

Page 29: ...nife 4 WARNING WARNING Disconnect power to the equipment before performing any task in the vicinity of the twin knife requiring the removal of the cover 5 ATTE N TIO N Do not operate the laminator unless the plastic guard is in place above the twin knife 6 WARNING CAUTION Do not place any objects on the plastic knife guard 7 ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures ...

Page 30: ... 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 2 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 3 WARNING CAUTION Do not place your fingers near t...

Page 31: ...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 T...

Page 32: ...y at any time or for any reason 5 WARNING WARNING All guards and covers must be returned to their original position after any repairs adjustments and or maintenance has been completed 6 WARNING 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 7 ELECTRICAL SHOCK Do not remove or modify any guards cover...

Page 33: ...ean 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 ex...

Page 34: ...leaning the chrome roller TM ATTENTION 5 WARNING CAUTION Do not use aggressive solvents that could cause damage to the rubber rollers Use only Mineral Spirits 6 WARNING 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 7 ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosure...

Page 35: ...covers or guards while the machine is in operation 2 WARNING WARNING Do not start the machine with the guards or covers removed 3 WARNING WARNING 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 OF 50 OC before servicing or adjusting ...

Page 36: ...et up 6 WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught by moving parts while performing tasks 7 WARNING CAUTION Always wear safety glasses when changing the springs Uncontrolled springs can damage your eyes 8 WARNING WARNING Operator maintenance and operator adjustments may be performed only by person s trained in all aspects of the equipment 9 E...

Page 37: ...d 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 2 ATTE N TIO N Use the Pile Stack Up or Pile Stack Down push buttons to move the feeder table 3 ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact with any moving parts or a...

Page 38: ...r 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 3 ELECTRICAL SHOCK Do not remove or modify any guards covers or enclosures Contact wi...

Page 39: ...tor For safe work the following safety rules should be followed 1 WARNING WARNING Turn power off at the main breaker before tentioning the chains or belts 2 ATTE N TIO N Operator maintenance for the chains and belts are limited to lubrication and tentioning All other work must be performed by a qualified technician 3 ELECTRICAL SHOCK Do not modify any guards covers or enclosures Contact with any m...

Page 40: ...e sharp edges of the knives 2 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 3 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 de...

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Page 42: ...tage fire accident floodorotherhazards 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 WARRANT...

Page 43: ...epair 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 personne...

Page 44: ...llers 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 ...

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Page 46: ...he equipment 1956 mm 1325 mm 1010 mm 1010 mm 1210 mm 1025 mm 718 mm 3 1 DIMENSIONS AND WEIGHT OF THE EQUIPMENT US VERSION EU VERSION Machine dimensions 77 x 39 76 x 47 64 1956 x 1010 x 1210 mm lengthxwidthxheight lengthxwidthxheight 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 ...

Page 47: ...TION 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 ft520 m 3 MACHINE PARAMETER Speed 65ft min 20m min Feeder ...

Page 48: ...uirements 3 phase 230 V 60 Hz 3 phase 400 V 50 withground Hz withground Nominalcurrent 30 A 30 A 6 PNEUMATIC CIRCUIT Pressure in the machine circuit 90 psi 4 CFM 0 6 MPa 113 l min The feeder pneumatic circuit vacuum 0 6 Bar 0 6 Bar pressure 0 6 Bar 0 6 Bar 7 MIN MAX 1ft min 65 ft min 3 m min 20 m min SlowForward Variable speed Variable speed Slow Reverse Variable speed Variable speed ...

Page 49: ...Page 3 4 Specifications GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual This page intentionally left blank ...

Page 50: ...fied as defined below GBC employedtechnician 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 engineerthathasexperiencewithelectricalandmechanicaldesignoflaminationequipment Theengineers shouldbefullyawareofallaspectsofsafetywithregardstolaminationequipment Anycommissioningorserviceengi...

Page 51: ...FM 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 mach...

Page 52: ... 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 SHOCK Only a qualified electrician should connect power to the laminator You can be severely shocked electrocuted or cause a fir...

Page 53: ...GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual 4 2 Suggested floor layout Becker Compressor T4 25DSK Secondary Operation Secondary Operation Main Operation Min 0 8 m Min 2 6 ft Min 0 4 m Min 1 3 ft ...

Page 54: ...re responsible for all subsequent freight charges and risks INFORMATION WARNING The Orbit 2000 is a large and heavy piece of equipment It is necessary to employ LICENSED RIGGERS ONLY to move the machine The machine is not designed to be tipped up or sideways in any way Such action disturbs the exact alignment of moving parts on the machine and requires extensive realignment You can be crushedor se...

Page 55: ...lished 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...

Page 56: ...nal standards for printing machines and their electrical wiring EU VERSION US VERSION Nominal voltage 3 NPE 400 V 230 V 50 Hz 3Phase with ground 230 10 VAC 60 Hz Operating voltage 24 VDC 24 VDC Powerinput 5 kVA 5 kVA Nominalcurrent 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 an...

Page 57: ...ing 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 b a The pressure and the vacuum valves are adjuste...

Page 58: ...bly inspection Componentmounting Terminal security Wire tightness Circuit breaker wires ELECTRICAL SHOCK Electrical troubleshooting should be left to qualified GBC service technicians Electrical shock hazard b Protective circuit inspection The safety of protective circuits may be checked by feeding a current of at least 10 A 50 Hz from the PELV source for at least 10 seconds The test is done betwe...

Page 59: ...hase with ground Check each leg A B nad C to ground for proper voltage drop Check main line voltage to locking plug connection on the Orbit 2000 Connect plug from Orbit 2000 to electrical supply d 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 e Power up...

Page 60: ...11 Installation Orbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 g Perform a function check of the control panel switches h Ensure all guides move correctly i Install the stacking table ...

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Page 62: ...ng 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 ATTENTIO N Do not operate this equipment unless you have read and understand this operator manual and have be...

Page 63: ...is 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 Operation Secondary Operation Main Operation ...

Page 64: ...re 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 butt...

Page 65: ... L L U P D O W N T E M P E R AT U R E P IL E L A M I N A T I N G S E C T I O N 9999 M IS S IN G S H E E T S H E AT E R O F F 120 0 120 0 8 14 8 11 S E P A R A T O R P U L L R O LL E R S N AP IM P U L S E K N IFE S E P M O T O R O N O F F O N O F F U P D O W N 0 10 20 30 40 50 60 70 80 90 100 S E P S P E E D R E V E R S E M AC H IN E IN C H E M E R G E N C Y 1 2 4 3 5 7 9 11 13 15 17 19 6 8 10 12 1...

Page 66: ...E 9999 H E AT E R S S T O P 120 0 120 0 S N AP IM P U LS E S T A R T S T O P 0 10 20 30 40 50 60 70 80 90 100 S N AP S P E E D E M E R G E N C Y S T O P 1 2 4 3 5 7 9 11 13 15 17 19 6 8 10 12 14 16 18 20 S T AR T S T O P F E E D E R L A M I N A T O R L A M I N A T O R M ISF E E D S E P A R A T O R C LO S E O PE N P U L L R O L L E R S T A R T S T O P S N AP M O T O R S L O W F W D S L O W R E V ...

Page 67: ...er 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 o...

Page 68: ...ng 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 a b ...

Page 69: ...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 a...

Page 70: ...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 The capacity sensor may be adjusted by a qualified service technician only ATTENTION 6 mm g First gate f ...

Page 71: ... 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 tight...

Page 72: ...e 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 d 5 7 mm 4 6 mm e 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 ...

Page 73: ... paper sheets between the cups are tight g g e 4 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 5 The proper air pressure required to feather the paper is set up by means of regulators i and j i j ...

Page 74: ...bit 2000 Operation and Maintenance Manual GBC Films Group January 2001 6 Adjust air blowing tubes k by turning the nut l so that 10 20 sheets at the top of the stack are feathered k l 7 Regulator m sets up the stack height m ...

Page 75: ...d 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...

Page 76: ...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 ...

Page 77: ...olders c and the sheet overlap sensor d a b a b c d c Gravity rollers The gravity rollers are always touching the paper pressing it against the feed rollers The position is factory set and remains unchanged for all sizes of paper For higher paper weights the pressure has to be increased For this purpose a set of weights e is supplied as accessories The weight is simply pulled out or inserted e ...

Page 78: ... 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 ...

Page 79: ...on 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 Loosen the screw h 2 Insert one sheet of paper of t...

Page 80: ...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 sen...

Page 81: ...inter u located below the control panel Steps 1 Set the machine to its lowest running speed 2 Start the machine 3 Set the dial pointer u to a value just short of the sheet length ie a 17 in sheet set the dial to 16 5 in 4 Check the overlap 5 Should you require a shorter overlap turn the dial pointer u slightly toward the larger sheet size direction 6 Should you require a longer overlap turn the di...

Page 82: ...vice 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 a b 2 3 2 7 mm ...

Page 83: ...eets 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 a b 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 pres...

Page 84: ...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 ...

Page 85: ... arm d by pressing down on the latch e and pull towards you from the control side e d 3 Loosen the 8 mm screw to the 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 h g YOUR MACHINE MAY OR MAY NOT HAVE A SUPPORT ARM ...

Page 86: ...plications c f 6 Replace the control side conical cone f on the operator s side and leave the 8 mm screw loose for movemt 7 Measure from operators side side frame to paper pile left margin a Always add 1 8 in 3 17 mm to this measurement Use the measurement just obtained with the 1 8 in 3 17 mm addition to measure the edge of the film b on the spool arbor to the operators side side frame X 10 m m X...

Page 87: ... 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 h c g 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 a i ...

Page 88: ...r 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 120 0 120 0 Actual temperature Green numbers Set temperature R...

Page 89: ...etween 8 11 in 200 280 mm set the heater switch a to 8 11 12 14 in 305 356 mm Chrome roller HEATERS STOP HEATER OFF 12 14 8 11 New overlay Original overlay a For sheet width size between 12 14 in 305 356 mm set the heater switch a to 12 14 8 11 in 200 280 mm Chrome roller HEATERS STOP HEATER OFF 12 14 8 11 New overlay Original overlay a ...

Page 90: ...s 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 wrin...

Page 91: ...hile the machine is in operation Pressure may be adjusted by two air regulators One for each side of the pull rollers To adjust follow the procedure below 1 Pull up on the outer part of the regulator knob to unlock 2 Turn clockwise to increase pressure and or counterclockwise to decrease pressure 3 Push the outer part of the regulator knob down to lock Locked Unlock ...

Page 92: ...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 New overlay O riginal overlay UP DO W N PRE SS URE RO LL UP DO W N The up indicator is illuminated when the pressure roller is up immediat...

Page 93: ...oller The spreader roller a is designed to adjust so the laminate is evenly applied across the chrome roller The adjustment is located on the operator side of the machine Follow the steps below to adjust the spreader roller 1 Loosen the lock nut b 2 Turn the adjustment knob c Clockwise to raise the control side of the spreader roller Counterclockwise to lower the control side of the spreader rolle...

Page 94: ...TION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film 5 4 1 The decurling bar 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 ...

Page 95: ...curling bar The position of the decurling bar is dependent of the paper thickness For thin paper 60 lb to 100 lb the decurling bar effects the web path Decurling bar Chrome roller Thin paper For thicker papers 12 pt to 18 pt the decurling bar should not effect the web path Decurling bar Chrome roller Thick paper ...

Page 96: ...dy parts away 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 ...

Page 97: ...teps below 1 Remove the four 8 mm bolts a 2 Turn the decurling bar b with the desired radius up 3 Replace the four 8 mm bolts a Effects of the decurling bar The sheets should lay flat when exiting the snapping rollers and are collected on the stacking table Stacking table Correctly decurled sheets Incorrectly decurled sheets Stacking table R3 R2 a b ...

Page 98: ...nds and other body parts away from the rollers W ARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught the rollers while working around or loading film The pull rollers a provide pull on the paper between the laminating section and the snapping rollers to achieve straight sheets on the decurling bar a ...

Page 99: ...JUSTMENT To adjust the paper pull force use the following steps 1 Loosen the locking nut b 2 Turn the regulating bolt c 3 The setting is indicated by the white marker of the control device d with respect to the upper roller position scale e 4 Tighten the locking nut b to secure the regulating bolt c c b d e ...

Page 100: ...Page 5 39 Operations Orbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 Paper pull adjustment with regards to sheet weight Light pull Heavy pull ...

Page 101: ...our fingers or any other part of your body near the plastic guard while the machine is running The twin knives slit the web of sheets for separation by the snapping assembly Due to the machines capability of operating at high speeds an oscillating knife assembly is used to maintain a consistant film cut Positioning of the knife assembly with respect to sheet width Sliding pin Position fixing bolt ...

Page 102: ...sheet weight Heavier paper may require shims under the twin knifes to achieve a clean cut of the film To add shims remove the four screws from the knife cover Remove the the four metric allen screws fro mthe twin knifes and insert one shim under each knife Reassemble the twin knife assembly and adjust the position of the knives Thin paper Heavier paper a b a b Face a of knife close to guide bar b ...

Page 103: ... dangling jewelry These items can get caught the rollers while working around or loading film The snapping assembly separates webbed overlapped sheets after the overlap has been knicked by the twin knives The snapping roller a separates the sheets from the web by moving downward toward the idler roller underneath The sheets pass between the snapping rollers and idler roller and at a set separation...

Page 104: ...1 Upper snap roller positioning with respect to sheet weight With respect to the type of laminating film and paper weight adjusting of the upper snap roller a angle may be necessary The idler roller b is not adjustable 3 5 o 5 10 o Thin paper O PP Film Heavy paper Polyester Nylon Film a b a b ...

Page 105: ...he upper snap roller is achieved by turning the regulating bolts b To adjust the angle of the upper snap roller use the following steps b c d 1 Loosen the locking nut c 2 Turn the regulating bolt d 3 Tighten the locking nut c Direction of the roller Direction of the regulating bolt Direction of the roller Direction of the regulating bolt ...

Page 106: ...sheets once the snap rollers have separated them The stacking table guides a should be adjusted to accommodate the sheet size Table slope adjustment The table slope may be adjusted by changing the length of the adjustable legs There are six possible positions Both sides must be in the same position when adjusting Sm allest slope Largest slope M IN M AX a ...

Page 107: ...sist the sheet for stacking Turn the blower angle handle a to the desired position a Blower pressure adjustment The blower pressure can be adjusted with respect to the paper weight To adjust the amount of air flow follow the procedure below 1 Loosen the locking nut b 2 Turn the regulating dial c clockwise or counterclockwise 3 Tighten the locking nut b b c ...

Page 108: ...ill illustrate the recommended types of films general threading procedure and film threadingdiagram 6 1 Recommended types of film for your Obit 2000 machine Polyester PET 1 7 mil 43u Hi Tac film Aggressive adhesive 8200 clear 30u 1 2 mil film EVA adhesive 1 7 mil 43u Nap Lam II film EVA adhesive Polypropylene OPP 8300 clear 33u 1 3 mil film EVA adhesive 1 2 mil 47u Nap Lam III film EVA adhesive GB...

Page 109: ...ther body parts away from the rollers W ARNING WARNING The chrome roller may be hot Contact will result in severe burns Once you have become trained in all aspects of the Orbit 2000 explained in Section 5 Operations and the safety rules explained in Section 1 Safety you may use this general threading procedure to web your machine 1 Set the heat required for the type of film being used Described in...

Page 110: ...t passes under the chrome roller and the leading edge of the paper appears to be at least 8 in 200 mm past the contact area between the laminating rollers 7 Press the pressure up button 8 At the slowest speed of the machine allow 2 3 sheets pass through the laminating rollers so you can thread the web through the snapping section 9 Feed the web through the decurling bar 10 Feed the web through the...

Page 111: ...the web is properly under the twin knives for knicking 14 Apply air to the pull roller so that the web is held tightly 15 Adjust the stack table guides and slope as necessary Described in Section 5 You may use an alternate method for webbing that is more comforatable to you It is strongly advised that all safety rules apply to your alternate method at all times INFO RM ATIO N ...

Page 112: ...e Manual GBC Films Group January 2001 6 3 Film threading diagram Film arbor Film roll Sheets Chrom e roller Decurling bar Pull rollers Snap rollers Stack table Poly in Poly out webbing diagram Poly out Poly in Chrom e roller Chrom e roller Film roll Film roll ...

Page 113: ...Page 6 6 Applications GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual This page intentionally left blank ...

Page 114: ...eath W ARNING WARNING Always exercise Lock out Tag out procedures when performing any type of troubleshooting to avoid injury to yourself others and to the equipment As an operator you may correct minor problems by performing some simple checks At no time should you attempt to remove or bypass and safety device on the machine Always pay careful attention to warnings placed throughout this section ...

Page 115: ...use Refers to one of three conditions 1 the anchor strength of adhesive to laminate substrate 2 the anchor strength of the laminating film to the product that has been laminated or 3 when two layers of film are laminated together the strength of the adhesive to adhesive bond Solution Bond strength can be ensured by using the correct amount of air pressure on the pressure roller as well correct chr...

Page 116: ...dhesive and the printed media Solution Heat related out gassing may be eliminated by reducing the operating temperature or increasing the speed If out gassing is due to incompatibility it will be necessary to change film or media Silvering Cause A term used to describe one of two occurrences 1 air bubbles trapped between the product and a thermal laminate generally caused by insufficient heat bein...

Page 117: ...ese waves check that the feed head is feeding the images smoothly and or check the nip pressure of the laminating rollers Laminating temperature Wave 2 Cause These are caused by the different rates of expansion and contraction of laminates and papers specifically coated ink jet and photographic papers during lamination The waves are induced when the laminate and paper are both heated and then cool...

Page 118: ...an flat finished product They are caused by stresses or unevenness in the laminate or the image Solution To prevent this type of waving reduce the tension on the film If this proves to be ineffective check for gauging uneven thickness across the width in the laminate Wrinkles on both edges after the pressure roller Wave 7 Cause Excessive film tension may be applied to the roll of film Solution To ...

Page 119: ...on should be achieved Adjusting the spreader roller may also assist with this type of wave form Wrinkles appear after the pull roller Wave 11 Cause Overlap may be set incorrectly for the weight of paper being used Pull roller tension may require adjustments Solution To prevent this type of waving check the overlap setting for the sheets Thinner 60 lb to 80 lb weighted sheets bend under the decurli...

Page 120: ...Page 7 7 Troubleshooting Obit 2000 Operation and Maintenance Manual GBC Films Group January 2001 Wave patterns 1 6 W ave 1 W ave 2 W ave 4 W ave 6 W ave 3 W ave 5 ...

Page 121: ...Page 7 8 Troubleshooting GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual W ave 7 W ave 8 W ave 10 W ave 12 W ave 9 W ave 11 sheet Wave patterns 7 12 ...

Page 122: ...UTION Depress the emergency stop button before checking for chain tension WARNING CAUTION Do not wear ties loose fit clothing or dangling jewelry These items can get caught by moving parts while performing tasks Check the tension of each chain and adjust properly Clean or lubricate leading spindles 2 The automatic operation is not consistent WARNING CAUTION Only a qualified service technician may ...

Page 123: ... procedures PROBLEM FIX Paper is not acclimatized Feed at lower speed Incorrect vacuum or pressure Adjust vacuum or pressure WARNING WARNING Press the stop button before performing any troubleshooting PROBLEM FIX Sheets are sticking Ream needs fanning Side stacker plates are tight Adjust for a slight gap Suctions cups are plugged Clean the suction cups Suction cups are not picking up Replace the d...

Page 124: ... sheets separate between the laminating section and the separator Cause The tension between the laminating rollers and the pull rollers is too great for the film Solution Decrease the paper pull adjustment on the pull rollers described in Section 5 The sheets are cut from the side by the twin knives Cause The gap between the knife s sharp edge and the leading pin is too small W ARNING WARNING Do n...

Page 125: ...ING WARNING Always exercise Lock out Tag out procedures when performing any type of troubleshooting to avoid injury to yourself others and to the equipment ELECTRICAL SHO CK Do not remove or modify any guards covers or enclosures Contact with any moving parts or and electrical voltage can result in injury or death 1 Symptom The machine cannot be started with the START button Possible causes Check ...

Page 126: ...n light in the start button if not start at that symptom A sheet of paper switched off the microswitch on the feeding head 4 Symptom The machine was running suddenly stopped and cannot be restarted again The red LED located in the electrical cabinet is not illuminated Possible causes The paper pile moved upwards causing the emergency microswitch on the feeding head to be depressed 5 Symptom When t...

Page 127: ...ping roller Because of the roller friction against paper the motor overheated and the fuse tripped Reset the fuse in the distributor Service technician repair only 8 Symptom The feeding table does not rise automatically Possible causes The reason may be while the paper pile was moved into its working position the table rise wasn t switched off by the sensor which is located on the roll bar in the ...

Page 128: ...repair only Check air cylinder solenoid 11 Symptom The snapping roller moves up and down only when the snapping roller drive motor is in the ON position Possible causes The snap roller push button was not pushed enough to engage the relay If the button is not illuminated the relay is not engaged Push the snap roller push button again 12 Symptom The machine doesn t run when the main breaker is swit...

Page 129: ...Page 7 16 Troubleshooting GBC Films Group January 2001 Orbit 2000 Operation and Maintenance Manual This page intentionally left blank ...

Page 130: ...aintenance is limited to that described in this manual Operator maintenance may only be performed by person s fully trained in all aspects of the equipment Service maintenance ServicemaintenancemayonlybeperformedbyaqualifiedGBC service technician Described in the Orbit 2000 Service Manual ELECTRICAL SHOCK Do not modify any guards covers or enclosures Contact with any moving parts or and electrical...

Page 131: ... of maintenance DAILY Check the quantity of condensed water in the air treatment unit If the amount in the vessel is higher than 20 mm release the fluid Check the presence of covers and bolts Check the correct function of sensors end switches of the feeding table capacity sensor sensor protecting the feeding head control sensors of removable covers emergency stop push button Cleaning of the roller...

Page 132: ...NING Never use compressed air to remove dust from the inside of the electrical cabinet Inspection of the electrical assembly Tightness of terminals Circuit breaker wires Loose wires Protective Circuit inspection Check whether protective connectors are tight Tighten loose connections The safety of protective circuits may be checked by feeding a current of at least 10 A 50 Hz from the PELV source fo...

Page 133: ...rotective conductor in the tested branch of the protective circuit The number of measurements of the protective circuit link is given by the requirements of particular regulations and standards valid in the user s country MAIN DRIVE AND FEED TABLE GEAR DRIVE Running in 300 hrs oil PP 90 H Normal operation 400 hrs oil PP 90 H In case of higher demands the ecologically acceptable oil TOP BLEND may b...

Page 134: ...machine cleaning 1 WARNING WARNING Do not clean any part of the machine while the laminator is in operation 2 WARNING CAUTION Never clean the surface of the rollers while the machine is running Use the Slow FWD and Slow Reverse to change the exposed area for cleaning Use the sequence described below a Press the Inch Slow FWD or Reverse Slow Reverse b Release the perspective push button and wait fo...

Page 135: ...use cotton or Nomex gloves when cleaning the chrome roller TM ATTENTION 6 WARNING CAUTION Do not use aggressive solvents that could cause damage to the rubber rollers Use only Mineral Spirits 7 WARNING 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 8 ELECTRICAL SHOCK Do not remove or modi...

Page 136: ... the sharp edges of the knives 2 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 3 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...

Page 137: ...rewdriver remove the four flat head shoulder bolts securing the twin knife safety cover d Replace the lock down thumb screw This will prevent the twin knife assembly from sliding e Use a 4 mm allen wrench to remove the two hex bolts securing the blade you are replacing f Replace the knife g Secure the knife reusing the same bolts and a 4 mm allen wrench h Remove the lock down thumb screw i Replace...

Page 138: ...ilms Group January 2001 8 2 3 Feed table chain tensioning a Tensioning is done by means of turning the bolts where the chain connects to the feeding table Tentioning bolt WARNING WARNING Overturning of the bolt can result in disconnection of the chain to the feeding table ...

Page 139: ...ained by setting the lift and release of the paper for correct timing For correct feeding the instant of paper release and the instant of suction must be adjusted precisely The adjustment is done by turning the slide valve p q The instant of release must be 1 5 to 2 mm before top dead center suction is adjusted simultaneously At the moment of suction the cups are in the rear position and start dro...