GBC ORBIT 2000 Installation and operation manual

GBCPro-Tech
4151AndersonRoad
DeForest, WI 53532
Revision : Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
ORBIT ™ 2000 OPERATION &
MAINTENANCE MANUAL
©January2001GBCFilms Group
Do not duplicate without written permission.
Partnumber : 930-051

Read me fileOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
Read Me File . . . . . . . . .
The information in this publication is provided for reference and is believed to be accu-
rate and complete. GBC Films Group is not liable for errors in this publication or for incidental
or consequential damage in connection with the furnishing or use of the information in this
publication, including, but not limited to, any implied warranty of fitness or merchantability for
any particular use.
GBC Films Group reserves the right to make changes to this publication and to the
products described in it without notice. All specifications and information concerning products
are subject to change without notice.
Reference in this publication to information or products protected by copyright or patent
does not convey any license under the rights of GBC Films Group or others. GBC Films
Group assumes no liability arising from infringements of patents or any other rights of third
parties.
This publication is copyrighted © 2000 by GBC Films Group. All rights reserved. The
information contained in this publication is proprietary and may not be reproduced, stored,
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© GBC Films Group January 2001
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© GBC Films Group January 2001
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Fax number : ( 608 ) 246 - 8645 Date :
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4151 Anderson Road
DeForest, WI 53532
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Page I
Table ofContentsOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
Table of Contents
Section 1: Safety
1.1 Safety - Complete equipment......................................................................1 - 1
1.2 Safety - Rules for loading paper .................................................................1 - 4
1.3 Safety - Rules for handling the feeding head ..............................................1 - 5
1.4 Safety - Rules for setting up the rollers and the hinged stops .....................1 - 7
1.5 Safety - Rules for set-up of the adjustable guide plates ..............................1 - 9
1.6 Safety - Rules for the chrome and pressure rollers ..................................1 - 10
1.7 Safety - Rules for the snap roller area ......................................................1 - 14
1.8 Safety - Rules for the use of the twin knife ...............................................1 - 17
1.9 Safety - Rules for the position adjustment of the decurling bar ................1 - 19
1.10 Safety - Rules for electrical installation .................................................1 - 20
1.11 Safety - Rules for machine cleaning .......................................................1 - 22
1.12 Safety - Rules for machine maintenance and adjustments .....................1 - 24
1.13 Safety - Rules for the feeder table ..........................................................1 - 26

Page II
Tableof Contents Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
1.14 Safety - Rules for the central drive maintenance ....................................1 - 27
1.15 Safety - Rules for snapping assembly/ chain/ belt drive maintnenance ..1 - 28
1.16 Safety - Rules for maintenance/ replacement of the twin knife ..............1 - 29
Section 2: Warranty
2.1 Terms and conditions .................................................................................2 - 1
2.2 Limited period of warranty ........................................................................2 - 2
2.3 Limited warranty conditions ......................................................................2 - 2
Section 3: Specifications
3.0 Specific dimensions and weight of the equipment illustration ...................3 - 1
3.1 Dimensions and weight of the equipment ....................................................3 -1
3.2 Shipping crate dimensions ..........................................................................3 - 2
3.3 Basic technical data ...................................................................................3 - 2

Page III
Table ofContentsOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
Section 4: Installation
4.0 Installation precautions ..............................................................................4 - 1
4.1 Pre-installation check list ...........................................................................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 IV
Tableof Contents Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
5.1.2 The control panel ...........................................................................5 - 3
Original overlay illustration ..........................................................5 - 4
New overlay illustration ................................................................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 V
Table ofContentsOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
5.3.3 Laminating rollers .........................................................................5 - 29
5.3.4 Spreader roller ( option ) .............................................................5 - 32
5.4 Separator Section ....................................................................................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 VI
Tableof Contents Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
Section 7: Troubleshooting
7.1 Lamination troubleshooting ......................................................................7 - 2
7.2 Wave pattern troubleshooting ...................................................................7 - 4
7.3 Feeder troubleshooting ..............................................................................7 - 9
7.4 Misfed sheets troubleshooting ..................................................................7 - 10
7.5 Web troubleshooting ..................................................................................7 - 11
7.6 Machine troubleshooting ...........................................................................7 - 12
Section 8: Maintenance
8.1 Maintenance schedule ...............................................................................8 - 2
8.2 Operators Maintenance .............................................................................8 - 5
8.2.1 Safety - Rules for machine cleaning ...............................................8 - 5
8.2.2 Safety - Rules for maintenance/ replacement of the twin knife ......8 - 7
8.2.3 Feed table chain tensioning ...........................................................8 - 9

Page 1 - 1
SafetyOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
1.0 Safety regulations
1.1 Safety - Complete equipment
1/
Do not operate this equipment unless you have read and understand this
operator manual and have been fully trained in its operation by a
qualified GBC service technician.
ATTENTION
2/
The operator may use the Orbit 2000 only for the lamination of paper sheets.
The equipment may not be used for any other type of work. The type of paper
and film must comply with conditions of Section 2 of the Technical Specifications.
The equipment is provided with means to control lamination functions. The
controls as set up by the factory may not be modified or altered.
ATTENTION
3/
Do not operate , adjust, service or repair the Orbit 2000 if you are under the
influence of alcohol, drugs, or medication.
ATTENTION
4/
Do not operate the Orbit 2000 if you are ill or tired.
ATTENTION

Page 1 - 2
Safety Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
5/
All safety covers must be in place during operation. The equipment must not be started
and used, if all covers are not in place, and safety switches are not operational.
ATTENTION
6/
Test all three interlocked safety guards each day ( the chrome roller guard,
snap roller guard and the guard under the laminating and snap ARGAs ) and
the two emergency 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.
ATTENTION
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 slow forward or slow reverse push buttons.
ATTENTION
9/
When using the slow forward and slow reverse push buttons, push and
release the buttons and wait for the machine to stop before cleaning
the exposed area of the rollers.
ATTENTION

Page 1 - 3
SafetyOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
10/ Never perform adjustments while the machine is running. The machine must first be
stopped, adjusted and then restarted. ( Except When Adjusting Lap For Sheet Size ! )
ATTENTION
11/
Excercise caution when 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 enclosures. Contact with any
moving parts or/ and electrical voltage can result in injury or death!

Page 1 - 4
Safety Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
1.2 Safety - Rules for loading paper
Thenormal functionoftheequipment istoinsert paper andlaminateit. Forasafeloading ofpaper
it is necessary to follow these safety rules:
1/
Do not attempt to load paper while 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 body
parts when the table is moving or the laminator is running.
Feeder Stack/ Pile
Feeder Table
Chains

Page 1 - 5
SafetyOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
1.3 Safety - Rules for handling the feeding head
The feeding head grabs the paper sheet and inserts it into the pull rollers. When changing paper
size,the position ofthefeeding head mustalsobechanged. Forsafeadjustments,the following safetyrules
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 grabbing the upper handle bar and gently pull or push.
ATTENTION
Clamp
Locating bar
Handle bar

Page 1 - 6
Safety Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
4/ Do not place any objects on the upper surface of the feeding head or feeder table.
ATTENTION
5/
Do not remove covers, fixed cover of the feeding head
and/ or the protective rubber cover.
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.
ATTENTION
Turning
knobs

Page 1 - 7
SafetyOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
1.4 Safety - Rules for setting up the rollers and the hinged
stops
1/
Do not touch the rollers or hinged stops while the machine is running.
ATTENTION
2/
WARNING
WARNING: The chrome roller may be hot. Contact will result in severe burns!
3/
The insertion or removal of any weights is permissable only when the machine is idle.
ATTENTION
Counter wei
g
hts

Page 1 - 8
Safety Orbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
4/
WARNING
Caution: Excercise extreme caution when adjusting the rollers
to avoid pinching by the loading roller.
5/ Handle the rollers only when the Plexi-glass cover of the chrome roller is closed.
ATTENTION
6/ Keep fingers, hands and clothing clear away from the rollers
while the machine is in operation.
ATTENTION
7/
WARNING
WARNING: Do not be startled by the pressure roller dropping
approximately two minutes after the laminator has been stopped.

Page 1 - 9
SafetyOrbit™ 2000 Operation and Maintenance Manual
© GBC Films Group January 2001
1.5 Safety - Rules for setup of the adjustable guide plates
Theguidingplatesformpaperbeforeitentersintothechromeroller.Theirpositionmustbeadjusted
fordifferentpaperweights.Forasafeadjustmentofplatesfollowthesesafetyrules:
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/
ATTENTION
The chrome roller guard must be in the fully closed position.
Chrome roller guard
Set-up screw
Chrome roller
Paper & film stock
Pressure roller