Page 1: Maintenance Manual
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...
Page 2 Orbit™ 2000 Operation and Maintenance Manual Read Me File ..The information in this publication is provided for reference and is believed to be accu- rate and complete. GBC Films Group is not liable for errors in this publication or for incidental or consequential damage in connection with the furnishing or use of the information in this publication, including, but not limited to, any implied warranty of fitness or merchantability for any particular use.
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Page 4 Orbit™ 2000 Operation and Maintenance Manual Fax Correspondence Fax number : ( 608 ) 246 - 8645 To : Sean Flood at GBC Pro-Tech 4151 Anderson Road DeForest, WI 53532 From : Company : Address : Phone number : ( Re : Orbit™...
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Page 6: Table Of Contents
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...
Page 7 Table of Contents 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...
Page 8 Orbit™ 2000 Operation and Maintenance Manual 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...
Page 9 Table of Contents 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...
Page 10 Orbit™ 2000 Operation and Maintenance Manual 5.3.3 Laminating rollers ...5 - 29 5.3.4 Spreader roller ( option ) ...5 - 32 5.4 Separator Section ...5 - 33 5.4.1 The decurling bar ...5 - 33 5.4.2 Pull rollers ...5 - 37 5.4.3 Twin knife ...5 - 40 5.4.4 Snapping assembly ...5 - 42 5.4.5 Stacking table ...5 - 45...
Page 11 Table of Contents 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...
Page 12: Section 1: Safety
Do not operate , adjust, service or repair the Orbit 2000 if you are under the Do not operate the Orbit 2000 if you are ill or tired.
Page 13 Safety 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. 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...
Page 14 Orbit™ 2000 Operation and Maintenance Manual 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 ! ) Excercise caution when working around the feeder table, control panel and The equipment must be fixed/ positioned on a firm and even floor.
Page 15: Safety - Rules For Loading Paper
Safety 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: Do not attempt to load paper while the machine is running. Your fingers couldbe hurt during the automatic insertion of paper.
Page 16: Safety - Rules For Handling The Feeding Head
Orbit™ 2000 Operation and Maintenance Manual 1.3 Safety - Rules for handling the feeding head The feeding head grabs the paper sheet and inserts it into the pull rollers. When changing paper size, the position of the feeding head must also be changed. For safe adjustments, the following safety rules apply: Do not touch the feeder head while the machine is running.
Page 17 Safety D o not place any objects on the upper surface of the feeding head or feeder table. Do not remove covers, fixed cover of the feeding head O perate the turning knobs carefully and w ith only one hand w hile the m achine is running.
Page 18: Safety - Rules For Setting Up The Rollers And The Hinged Stops
Orbit™ 2000 Operation and Maintenance Manual 1.4 Safety - Rules for setting up the rollers and the hinged stops Do not touch the rollers or hinged stops while the machine is running. WARNING: The chrome roller may be hot. Contact will result in severe burns! The insertion or removal of any weights is permissable only when the machine is idle.
Page 19 Safety Orbit™ 2000 Operation and Maintenance Manual WARNING Caution: Excercise extreme caution when adjusting the rollers to avoid pinching by the loading roller. AT T E N T IO N H andle the rollers only w hen the Plexi-glass cover of the chrom e roller is closed. ATTENTION Keep fingers, hands and clothing clear away from the rollers while the machine is in operation.
Page 20: Safety - Rules For Setup Of The Adjustable Guide Plates
Orbit™ 2000 Operation and Maintenance Manual 1.5 Safety - Rules for setup of the adjustable guide plates The guiding plates form paper before it enters into the chrome roller. Their position must be adjusted for different paper weights. For a safe adjustment of plates follow these safety rules: The plate's position may be adjusted while the equipment is running by using the set-up screw.
Page 21: Safety - Rules For The Chrome And Pressure Rollers
Safety 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.
Page 22 Orbit™ 2000 Operation and Maintenance Manual CAUTION: Do not use any tools for cleaning or removing remnants of films from the rollers while the machine is in operation. 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! CAUTION: Do not cover the chrome roller guard ventilation holes.
Page 23 Safety 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 lw ays ensure the adhesive is facing aw ay from the chrome roller w hen loading film . C A U T IO N : O pen the plastic chrome roller guard fully to prevent to accidental closing onto your hands and fingers.
Page 24: Side View
Orbit™ 2000 Operation and Maintenance Manual 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 . b - DANGER: Pinch/ Crush point area.
Page 25: Safety - Rules For The Snap Roller Area
Safety 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: 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.
Page 26 Orbit™ 2000 Operation and Maintenance Manual Safety WARNING CAUTION: Do not place any objects on the plastic snap roller 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! 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...
Page 27 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...
Page 28: Safety - Rules For The Use Of The Twin Knife
Orbit™ 2000 Operation and Maintenance Manual 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: CAUTION: Do not place your fingers or any other part of your body near the plastic guard while the machine is running.
Page 29 Safety 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 WARNING: Disconnect power to the equipment before performing any task in the vicinity of the twin knife requiring the removal of the cover 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.
Page 30: Safety - Rules For The Position Adjustment Of The Decurling Bar
Orbit™ 2000 Operation and Maintenance Manual 1.9 Safety - Rules for the position adjustment of the decurling 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: CAUTION: Exercise caution while loosening the decurling bar handle.
Page 31: Safety - Rules For Electrical Installation
Safety 1.10 Safety - Rules for electrical installation CAUTION: Repairs, adjustments and/ or maintenance may be performed by a qualified technician ( excludes any operator maintenance and operator adjustments ). The word "qualified" is decribed below. • 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.
Page 32 Orbit™ 2000 Operation and Maintenance Manual WARNING: At no time should you attempt to overide/ by pass and safety shield, safety switches or safety device located on this equipment. WARNING: Do not modify any part of the circuitry at any time or for any reason! WARNING: All guards and covers must be returned to their original position after any repairs, adjustments and/ or maintenance has been completed.
Page 33: Safety - Rules For Machine Cleaning
Safety 1.11 Safety - Rules for machine cleaning WARNING: Do not clean any part of the machine while the laminator is in operation. 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. a/ Press and hold the Inch/ Slow FWD or Reverse/ Slow Reverse push button.
Page 34 Orbit™ 2000 Operation and Maintenance Manual WARNING: Hot surface. Exercise extreme caution when cleaning the chrome roller. Surface temperatures may be upwards of 248 Always use cotton or Nomex CAUTION: Do not use aggressive solvents that could cause damage to WARNING: Crush hazard exists near any rollers.
Page 35: Safety - Rules For Machine Maintenance And Adjustments
Safety 1.12 Safety - Rules for machine maintenance and adjustments WARNING: Do not remove any covers or guards while the machine is in operation. WARNING: Do not start the machine with the guards or covers removed. WARNING: Shut off and lock the electric supply circuit breaker before performing any operator maintenance or operator adjustments.
Page 36 Orbit™ 2000 Operation and Maintenance Manual 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.
Page 37: Safety - Rules For The Feeder Table
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: WARNING WARNING: Operation of the feeder table may be performed only by person(s) trained in all aspects of the equipment.
Page 38: Safety - Rules For The Central Drive Maintenance
Orbit™ 2000 Operation and Maintenance Manual 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: WARNING: Shut off the compressed air intake before setting up the WARNING: Only person(s) trained in all aspects of the equipment may...
Page 39: Safety - Rules For Snapping Assembly/ Chain/ Belt Drive Maintnenance
Safety Orbit™ 2000 Operation and Maintenance Manual 1.15 Safety - Rules for Snapping assembly/ chain/ belt drive maintenance The chain and belt drives are protected by a fixed cover and is located on the opposite side from the operator. For safe work, the following safety rules should be followed: WARNING WARNING: Turn power off at the main breaker before tentioning the chains or belts.
Page 40: Safety - Rules For Maintenance/ Replacement Of The Twin Knife
Orbit™ 2000 Operation and Maintenance Manual 1.16 Safety - Rules for maintenance/ replacement of the twin knife The twin knife is very sharp and extreme caution should be exercised when working in its vicinity. For safe work, the following safety rules should be followed: WARNING: Knife has sharp edges! Do not touch the sharp edges of the knives.
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Page 42: Section 2: Warranty
Orbit™ 2000 Operation and Maintenance Manual 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.
Page 43: Limited Period Of Warranty
Warranty 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 •...
Page 44 Orbit™ 2000 Operation and Maintenance Manual 2.3.1 Warranty is not applicable to the following conditions: Damage to the chrome laminating roller, rubberized feeding rollers, pressure rollers, pull rollers and snapping rollers if caused by knives, razor blades or any other type of sharp tool. Damage to the chrome laminating roller, rubberized feeding rollers, pressure rollers, pull rollers and snapping rollers if caused by: –...
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Page 46: Section 3: Specifications
Orbit™ 2000 Operation and Maintenance Manual 3.0 Specific dimensions and weight of the equipment 1956 mm 1010 mm 3.1 DIMENSIONS AND WEIGHT OF THE EQUIPMENT Machine dimensions Base dimensions Floor area Weight of the Machine © GBC Films Group January 2001 1325 mm US VERSION 77"...
Page 47: Shipping Crate Dimensions
Specifications 3.2 SHIPPING CRATE DIMENSIONS AND WEIGHT Dimensions of the crate with machine Weight of the Machine with the crate 3.3 BASIC TECHNICAL DATA PAPER SPECIFICATION Max. paper size Min. paper size Smallest paper size FILM SPECIFICATIONS Types of useable films Film gauge Inside film roll diameter Outside film roll diameter...
Page 48 Orbit™ 2000 Operation and Maintenance Manual ELECTRICAL CIRCUIT Power input Basic voltage requirements Nominal current PNEUMATIC CIRCUIT Pressure in the machine circuit The feeder pneumatic circuit - vacuum - pressure MIN/ MAX Slow Forward Slow Reverse © GBC Films Group January 2001 US VERSION EU VERSION 5 kVA +/- 10 %...
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Page 50: Installation Precautions
Orbit™ 2000 Operation and Maintenance Manual 4.0 Installation Precautions 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.
Page 51: Pre-Installation Checklist
Installation 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: –...
Page 52 Orbit™ 2000 Operation and Maintenance Manual The Floor The machine must be placed on a firm and reasonably even floor capable of supporting a load of 2500 kg/ square meter ( 36165 lb/ sq.ft. ). Note The machine is also provided with a terminal to connect an additional conductor for the inter- connection, since the value of leakage currents from noise suppression elements is higher than 3.5 mA AC.
Page 53: Suggested Floor Layout
Installation Orbit™ 2000 Operation and Maintenance Manual 4.2 Suggested floor layout Page 4 - 4 © GBC Films Group January 2001...
Page 54: Shipping Damage Inspection
Orbit™ 2000 Operation and Maintenance Manual 4.3 Shipping damage inspection Before signing the Bill of Lading, youshould inspect the crate and / or palletfor signs of damage or missing items; ifapplicable, make note of this on theBill of Lading. ALL SHIPMENTS ARE EX-WORKS. At ourdock, title passes to the buyer. Please review your insurance coverage prior to shipment, as you are responsible for all The Orbit™...
Page 55: Transporting Of The Machine
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.
Page 56: Electrical Installation
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.
Page 57: Becker T4.25 Dsk Compressor Installation
Installation 4.6 Becker T4.25 DSK Compressor installation WARNING: Do not place the compressor near machines that have 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.
Page 58: Initial Inspection
Orbit™ 2000 Operation and Maintenance Manual 4.7 Initial inspection Remove power to the laminator before performing step ( a ) below. Contact with electrical components while power is supplied can result in injury or death! Electrical assembly inspection – Component mounting –...
Page 59 Installation – The voltage measured between the terminal PE and the test points may not exceed U =3.3V U = 2.6V U = 1.9V ( 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.
Page 60 Orbit™ 2000 Operation and Maintenance Manual Perform a function check of the control panel switches. Ensure all guides move correctly. Install the stacking table. © GBC Films Group January 2001 Installation Page 4 - 11...
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Page 62: Operations
Orbit™ 2000 Operation and Maintenance Manual 5.0 Operation WARNING: Only person(s) trained in all aspects of safety and operations 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™...
Page 63: General Information
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).
Page 64: The Control Panel
Orbit™ 2000 Operation and Maintenance Manual 5.1.2 The control panel Legend Push button - start Push button - stop Speed indicator Potentiometer - speed adjustment by means of the main motor Push button - feeder table UP Push button - feeder table DOWN Push button - pressure roller UP Push button - pressure roller DOWN Laminated sheets counter...
Page 65: Original Overlay Illustration
Operations Orbit™ 2000 Operation and Maintenance Manual Original overlay Page 5 - 4 © GBC Films Group January 2001...
Page 67: New Overlay Illustration
Operations 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.
Page 68: Sheet Stacking
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.
Page 69 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.
Page 70: Feeder Table Positioning
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.
Page 71: The Feeding Head
Operations 5.2.3 The feeding head 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.
Page 72 Orbit™ 2000 Operation and Maintenance Manual The separating elements setup 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.
Page 73 Operations Set up the center suction cups ( g ) by adjusting strips ( e ) so the paper sheets between the cups are tight. 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.
Page 74 Orbit™ 2000 Operation and Maintenance Manual Adjust air blowing tubes ( k ) by turning the nut ( l ) so that 10 - 20 sheets at the top of the stack are feathered. Regulator ( m ) sets up the stack height. ©...
Page 75 Operations Feeding small sheet sizes 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 ).
Page 76: First Gate
Orbit™ 2000 Operation and Maintenance Manual 5.2.4 First gate 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.
Page 77: Feed Roller Assembly
Operations 5.2.5 Feed roller assembly The assembly consists of gravity rollers ( a), accelerating rollers ( b ), plate holders ( c ) and the sheet overlap sensor ( d ). Gravity rollers The gravity rollers are always touching the paper pressing it against the feed rollers.
Page 78 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.
Page 79 Operations 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.
Page 80 Orbit™ 2000 Operation and Maintenance Manual 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. Take a single sheet of paper, insert it under the sensor ( l ). Block the sensor repeatedly by sliding the sheet of paper in and out from under the sensor.
Page 81 Operations Overlap adjustment WARNING: Only person(s) trained in all aspects of the equipment may 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.
Page 82: Second Gate
Orbit™ 2000 Operation and Maintenance Manual 5.2.6 Second gate 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.
Page 83: Adjustable Guide Plates
Operations 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 ).
Page 84: Lamination Section
Orbit™ 2000 Operation and Maintenance Manual 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.
Page 85 Operations Lower the spool arbor support arm ( d ) by pressing down on the latch ( e ) and pull towards you from the control side. Loosen the 8 mm screw to the control side conical cone ( f ) and slide it off of the spool arbor ( c ).
Page 86 Orbit™ 2000 Operation and Maintenance Manual 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. Replace the control side conical cone ( f ) on the operator’s side and leave the 8 mm screw loose for movemt.
Page 87 Operations 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 ). Use the lateral film adjust nut ( a ) to fine tune the positioning of the spool arbor with respect to the pile stack and use the unwind brake nut ( i ) to apply tension to film roll on shaft.
Page 88: Heating
Orbit™ 2000 Operation and Maintenance Manual 5.3.2 Heating WARNING: The chrome roller can become extremely hot. 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.
Page 89 Operations Heat width selection For sheet width size between 8 - 11 in. ( 200-280 mm ), set the heater switch ( a ) to 8-11”. HEATERS STOP overlay HEATER O F F 8"-11" 12"-14" Original overlay For sheet width size between 12 - 14 in. ( 305-356 mm ), set the heater switch ( a ) to 12-14”. HEATERS N e w S T O P...
Page 90: Laminating Rollers
Orbit™ 2000 Operation and Maintenance Manual 5.3.3 Laminating rollers 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.
Page 91 Operations Adjusting pressure 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.
Page 92 Orbit™ 2000 Operation and Maintenance Manual 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: –...
Page 93: Spreader Roller ( Option )
Operations 5.3.4 Spreader roller ( option ) T he follow ing inform ation is for those m achines that are euipped 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: Loosen the lock nut ( b ).
Page 94: Separator Section
Orbit™ 2000 Operation and Maintenance Manual 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. 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 .
Page 95: Thin Paper
Operations 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. Chrome roller Decurling bar For thicker papers, 12 pt. to 18 pt., the decurling bar should not effect the web path. Chrome roller Decurling bar Page 5 - 34...
Page 96 Orbit™ 2000 Operation and Maintenance Manual Adjusting the decurling bar 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: Loosen the locking lever ( b ). Turn the decurling bar adjustment lever ( a ) with respect to the paper thickness.
Page 97 Operations To change the from R2 to R3 and vice versa, follow the steps below: Remove the four 8 mm bolts ( a ). Turn the decurling bar ( b ) with the desired radius up. 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.
Page 98: Pull Rollers
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 AR 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 .
Page 99 Operations PAPER PULL ADJUSTMENT To adjust the paper pull force use the following steps: 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 ).
Page 100 Orbit™ 2000 Operation and Maintenance Manual Operations Paper pull adjustment with regards to sheet weight. L ig h t p u ll H ea vy p u ll © GBC Films Group January 2001 Page 5 - 39...
Page 101: Twin Knife
Operations Orbit™ 2000 Operation and Maintenance Manual 5.4.3 Twin knives AT T E N T IO N D o not operate the lam inator unless the plastic guard is in place above the tw in knife. W AR N IN G C A U T IO N : D o not place your fingers or any other part of your body near the plastic guard w hile the m achine is running.
Page 102 Orbit™ 2000 Operation and Maintenance Manual Operations Positioning of the knife assembly with respect to sheet edge K n ife 1 K n ife 2 5 - 6 m m w eb Positioning of the knife assembly with respect to sheet weight Heavier paper may require shims under the twin knifes to achieve a clean cut of the film.
Page 103: Snapping Assembly
Operations Orbit™ 2000 Operation and Maintenance Manual 5.4.4 Snapping assembly WARNING WARNING: Keep fingers, hands and other body parts away from the rollers. W AR 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 .
Page 104 Orbit™ 2000 Operation and Maintenance Manual 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. T h in p a p e r ( O P P F ilm ) 3 - 5...
Page 105 Operations Adjusting the upper snap roller Angling of the upper snap roller is achieved by turning the regulating bolts ( b ). To adjust the angle of the upper snap roller, use the following steps: Loosen the locking nut ( c ). Turn the regulating bolt ( d ) Tighten the locking nut ( c ).
Page 106: Stacking Table
Orbit™ 2000 Operation and Maintenance Manual 5.4.5 Stacking table The stacking table stacks the laminated sheets once the snap rollers have separated them. The stacking table guides ( a ) should be adjusted to accommodate the sheet size. Table slope adjustment The table slope may be adjusted by changing the length of the adjustable legs.
Page 107 Operations Blower angle adjustment The blower angle may be adjusted to assist the sheet for stacking. Turn the blower angle handle ( a ) to the desired position. Blower pressure adjustment The blower pressure can be adjusted with respect to the paper weight. To adjust the amount of air flow follow the procedure below.
Page 108: Section 6: Applications
Orbit™ 2000 Operation and Maintenance Manual 6.0 Applications 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 This section will illustrate the recommended types of films, general threading procedure and film threading diagram.
Page 109: General Threading Procedure
Applications 6.2 General threading procedure 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 . W A R N IN G : K eep fingers, hands and other body parts aw ay from the rollers.
Page 110 Orbit™ 2000 Operation and Maintenance Manual Load the sheet stack on the feed table. ( Described in Section 5 ) Adhere one sheet of the same width as the sheets in the feeder to start the film web. Switch the compressor on and push the start button at it’s slowest speed. Stop the machine at the instant the first sheet passes under the chrome roller and the leading edge of the paper appears to be at least 8 in.
Page 111 Applications Grab the web beyond the snapping rollers and pull straight and tight ensuring the web is properly under the twin knives for knicking. Apply air to the pull roller so that the web is held tightly. Adjust the stack table guides and slope as necessary. ( Described in Section 5 ) Y ou m ay use an alternate m ethod for w ebbing that is m ore com foratable to you.
Page 112: Film Threading Diagram
Orbit™ 2000 Operation and Maintenance Manual Applications 6.3 Film threading diagram F ilm ro ll F ilm a rb o r C h ro m e ro lle r S n a p ro lle rs D e c u rlin g b a r P u ll ro lle rs S h e e ts S ta c k ta b le...
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Page 114: Section 7: Troubleshooting
Obit™ 2000 Operation and Maintenance Manual 7.0 Troubleshooting 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 . D o not rem ove or m odify any guards, covers or enclosures.
Page 115: Lamination Troubleshooting
Troubleshooting 7.1 Lamination troubleshooting Blistering Cause: A condition where the paper coating is bubbled up from the image paper causing a “blister”. It is created by using excessive heat during the lamination process. Blistering is most commonly found with photographic and ink jet media. Solution: Blistering can be avoided by ensuring you are using the correct operating parameters for the media type and film type being used.
Page 116 Obit™ 2000 Operation and Maintenance Manual Delamination Cause: Refers to either one of two conditions; 1) the adhesive separating from the laminate substrate, or 2) the laminate separating from the product being laminated. Solution: Delamination is eliminated by using the correct type of film for the type of media being used and setting the machine to the optimal operating parameters.
Page 117: Wave Pattern Troubleshooting
Troubleshooting 7.2 Wave pattern troubleshooting Waves or ripples in laminated images can be caused by; paper tension, laminating temperature, incorrect nip, clutch tension, binding of film core on brakes or core ends, and cooling. Below is a description of some common waves. Please refer to the wave illustration associated with each description. Paper tension ( Wave 1 ) Cause: These waves, visible in the finished image, are caused by uneven paper tension across...
Page 118 Obit™ 2000 Operation and Maintenance Manual Paper pull tension ( Wave 2 & 4 ) Cause: These patterns are caused by too little ( Wave 2 ) or too much ( Wave 4 ) tension of the laminated material between the laminating rollers and the pull rollers. Solution: To remove these waves, adjust the paper pull adjustment and/or laminating roller pressure.
Page 119 Troubleshooting Wrinkles on either edge after the pressure roller ( Wave 9 ) Cause: Air pressure on the pressure roller from side to side may require off setting. Solution: To prevent this type of waving, off set the pressure roller by adjusting the air regulators on the pressure rollers.
Page 120 Obit™ 2000 Operation and Maintenance Manual Wave patterns 1 - 6 W a ve 1 W a ve 3 W a ve 5 © GBC Films Group January 2001 Troubleshooting W a ve 2 W a ve 4 W a ve 6 Page 7 - 7...
Page 121 Troubleshooting Wave patterns 7 - 12 W a ve 7 W a ve 9 W a ve 11 Page 7 - 8 Orbit™ 2000 Operation and Maintenance Manual W a ve 8 W a ve 10 W a ve 12 ©...
Page 122: Feeder Troubleshooting
Obit™ 2000 Operation and Maintenance Manual 7.3 Feeder troubleshooting WARNING: Operator maintenance and operator adjustments may be performed only by person(s) trained in all aspects of the equipment. The table move is sluggish even without paper load. CAUTION: Depress the emergency stop button before checking for chain tension! CAUTION: Do not wear ties, loose fit clothing or dangling jewelry.
Page 123: Misfed Sheets Troubleshooting
Troubleshooting 7.4 Misfed sheets troubleshooting WARNING: Only person(s) trained in all aspects of the equipment may PROBLEM • Paper is not acclimatized • Incorrect vacuum or pressure WARNING: Press the stop button before performing any troubleshooting! PROBLEM • Sheets are sticking •...
Page 124: Web Troubleshooting
Obit™ 2000 Operation and Maintenance Manual 7.5 Web troubleshooting A stripe appears across the laminated paper sheets Cause: The stripe is caused by the decurling bar. Solution: This may be corrected by turning the bar over to a larger radius ( described in Section 5 ) and/or increasing pressure on the pull rollers ( described in Section 5 ).
Page 125: Machine Troubleshooting
Troubleshooting 7.6 Machine troubleshooting A t no tim e should a guard, panel, cabinet, door or cover be rem oved by an operator for troubleshooting purpose ( not even trained operators ). O nly qualified G B C service technicians m ay perform any troubleshooting w here internal com ponents m ust be checked.
Page 126 Obit™ 2000 Operation and Maintenance Manual (2) Symptom: The light in the start button is off. Possible causes: – Check the Lucite cover over the chrome roller is closed. – Check the Lucite cover over the separator is closed. – Check the side door under the control panel is closed. –...
Page 127 Troubleshooting (6) Symptom: Large variations in the sheet overlap Possible causes: – The sheets may slip under the rolls during feeding of heavy paper without weights in the gravity rollers. Add weights to the gravity rollers. – The sheets are pressed excessively against the gates during feeding of very light paper if the weights in the gravity rollers are to large.
Page 128 Obit™ 2000 Operation and Maintenance Manual (9) Symptom: continued Possible causes: – Adjust for snapping ( separation ) moves under actual snapping roller. – Adjust snapping position backward towards tension roller. (10) Symptom: The upper snapping roller doesn’t move up or down. Possible causes: –...
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Page 130: Section 8: Maintenance
Orbit™ 2000 Operation and Maintenance Manual 8.0 Maintenance WARNING: To avoid injury to yourself or damage to the equipment, please read and understand the instructions in this manual before you attempt to install, operate or service the laminator! This section explains maintenance for operator and service: Operator Maintenance –...
Page 131: Maintenance Schedule
Maintenance 8.1 Maintenance schedule It is necessary to lubricate and inspect individual parts at regular intervals to prolong the life and ensure the correct functioning of the machine. Safety as described in Section 1 of this manual must be followed when performing any type of maintenance. DAILY –...
Page 132 Orbit™ 2000 Operation and Maintenance Manual MONTHLY – Tighten and grease all roller chains ANNUALLY – Cleaning of the electrical assembly W A R N IN G : Pow er m ust be disconnected to m achine at fused disconnect! –...
Page 133 Maintenance – The voltage measured between the terminal PE and the test points may not exceed U =3.3V U = 2.6V U = 1.9V Where U – 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.
Page 134: Operators Maintenance
Orbit™ 2000 Operation and Maintenance Manual 8.2 Operators Maintenance WARNING: Always exercise Lock out/ Tag out procedures when performing any type of maintenance to avoid injury to yourself, others and to the equipment. 8.2.1 Safety - Rules for machine cleaning WARNING: Do not clean any part of the machine while the laminator is in operation.
Page 135 Maintenance c/ Clean the exposed area of the rollers. d/ Repeat as necessary. WARNING: Hot surface. Exercise extreme caution when cleaning the chrome roller. Surface temperatures may be upwards of 248 Always use cotton or Nomex CAUTION: Do not use aggressive solvents that could cause damage to WARNING: Crush hazard exists near any rollers.
Page 136: Safety - Rules For Maintenance/ Replacement Of The Twin Knife
Orbit™ 2000 Operation and Maintenance Manual 8.2.2 Safety - Rules for maintenance/ replacement of the twin knife The twin knife is very sharp and extreme caution should be exercised when working in its vicinity. For safe work, the following safety rules should be followed: WARNING: Knife has sharp edges! Do not touch the sharp edges of the knives.
Page 137 Maintenance WARNING: Always exercise Lock out/ Tag out procedures when performing any type of maintenance to avoid injury to yourself, others and to the equipment. Raise the snapping section safety shield. Remove the lock down thumb screw. With a #3 flat tip screwdriver, remove the four flat head shoulder bolts securing the twin knife safety cover.
Page 138: Feed Table Chain Tensioning
Orbit™ 2000 Operation and Maintenance Manual Maintenance 8.2.3 Feed table chain tensioning 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 Maintenance 8.2.4 Paper release adjustment CAUTION: Only a qualified service technician may perform this set-up. WARNING: Press the stop button before performing the following set-up procedure! Proper feeding is obtained by setting the lift and release of the paper for correct timing. For correct feeding, the instant of paper release and the instant of suction must be adjusted precisely.

GBC ORBIT 2000 Operating & Maintenance Manual

Section 1: Safety

Section 2: Warranty

Section 3: Specifications

3 Specific Dimensions and Weight of the Equipment Illustration

4 Installation Precautions

5 Operations

Section 6: Applications

Section 7: Troubleshooting

Section 8: Maintenance

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