Orbinox CC User manual

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www.orbinox.com
INSTALLATION, OPERATION AND
MAINTENANCE MANUAL
CC MODEL
CHANNEL GATE

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-2/14
Reserves the right to change specifications without notice
www.orbinox.com
INDEX Page
0. Introduction ........................................................................................................................ 2
1. Handling and Storage………………………………………………………………………..…...…. 2
2. Installation .......................................................................................................................... 3
2.1. Installation: Embedded in Concrete............................................................................... 3
2.2. Installation: Face Mounted in Existing Channel............................................................... 5
2.3. Installation: Wall Mounted………………………..………………………………....………… 7
3. Operation........................................................................................................................... 9
4. Maintenance...................................................................................................................... 10
4.1. Cleaning and lubrication............................................................................................. 10
4.2. Side Seals and Bottom Seal replacement……………….…………...…….……...…..…...... 11
5. Trouble shooting................................................................................................................. 12
6. Annex: civil work acceptable tolerance................................................................................. 13
7. Environmental considerations............................................................................................... 14
0. INTRODUCTION
Ç
•This manual describes the recommended procedures for installation, operation, maintenance and safety
precautions for ORBINOX CC model channel gates
•Please read thoroughly all the instructions in the manual prior to installation, and contact an ORBINOX
representative in case of any questions
•The manual makes reference to the “General Arrangement Drawing” (GAD). The GAD is the drawing that is sent
to and approved by the customer prior to the production of the gate
•ORBINOX assumes no responsibility or liability if the CC channel gate is not installed, operated and maintained
in strict accordance to the procedures described in this manual
1. HANDLING AND STORAGE
Ç
Standard safety procedures should be followed to prevent personal injury or equipment damage. Additionally, the
following instructions shall be followed during handling and storage to prevent any damage to the product:
•Stems have precision surfaces and should never be used as a means to lift the slide gate
•Equipment shall be stored in a dry, clean and even area on a raised even wood surface to prevent distortion of
the frame.
•Do not stack slide gates
•Stems and extensions that are shipped separately shall be supported over their entire length to prevent any
bending or distortion while in storage

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-3/14
Reserves the right to change specifications without notice
www.orbinox.com
2. INSTALLATION
Ç
2.1. Installation: embedded in concrete
▶ Required Materials:
As a standard, ORBINOX CC Channel Gates are mounted Embedded in Concrete (EC). Field adjustment hex
bolts are required to center the gate in the appropriate recess prior to embedding in concrete. For detailed
information about the type, size and quantity of the required bolts, or any other specific installation notes or
materials, please refer to the notes on the “General Arrangement Drawing”.
▶ Installation procedure:
Step 1: Concrete construction inspection
•The concrete construction shall be flat, level and
plumb, and shall be in accordance to DIN 18202
or ACI 117-06 standards (see section 6). If
necessary, use non-shrink grout in order to meet the
specified standard. The minimum concrete strength
shall be 25Mpa (3,625 PSI)
Step 2: Align the channel gate in the wall recess
•Position and center the channel gate in the recess
of the wall, using the field adjustment bolts screwed
in the “Side Centering Fittings” and “Bottom
Leveling Brackets” (see Figure 1). Make sure that
the channel gate is centered in the channel. NOTE:
the smaller CC Channel Gates do not come with
“Bottom Leveling Brackets”. If this is the case, follow
Step 1B prior to starting with “Step 2” in order to
be able to align the gate vertically
•Align the gate vertically adjusting the bolts on the
“Bottom Leveling Brackets” (see Figure 2). Make
sure that the frame invert is flush with the invert of
the channel
•Align the gate horizontally adjusting the bolts on
the “Lateral Centering Fittings” (see Figure 3).
Make sure that the Frame Guide is flush with the
channel side wall. Additionally, make sure that the
gate is perpendicular to the side walls of the
channel
Step 3: Embed the channel gate in the wall recess
•Pour the second phase of concrete. Take special
care not to damage the seals
•Do not pour in more than one meter concrete
columns to avoid damage to the frame
Figure 1

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-4/14
Reserves the right to change specifications without notice
www.orbinox.com
Figure 2
Figure 3
Step 1B: Align the gate vertically (without the
Bottom Balancing Brackets)
Smaller CC Channel Gates do not come with “Bottom
Balancing Brackets”. Therefore, the following procedure
shall be followed to align the gate vertically (After “Step
1”):
•Get two parts as support in order to levelling the
channel gate vertically (“Supports”). Rise the
slide enough to introduce the two supports
between the frame and slide and close the slide
to fix the supports (See Figure 4)
•Proceed with “Step 2”. When the gate is
positioned in the recess, the supports will
maintain the frame invert flush with the invert of
the channel (See Figure 4)
CAUTION!: Do not use pieces of wood or metal with
sharp edges or with a bad surface condition in order to
avoid any damage to the bottom seal.
Figure 4

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-5/14
Reserves the right to change specifications without notice
www.orbinox.com
2.2. Installation: face mounted in existing channel
Required Materials:
•For the Face Mounted in Existing Channel (FM) mounting option, the CC channel gate is installed by means of
mechanical anchor bolts. All the gaps shall be grout filled afterwards and shaped in order to get a smooth
transition. For detailed information about the type, size and quantity of the required anchor bolts or any other
specific installation notes or materials, please refer to the notes on the “General Arrangement Drawing”.
Installation Procedure:
Step 1: Concrete construction inspection
•The concrete construction shall be flat, level and plumb, and shall be in accordance to DIN 18202 or ACI 117-
06 standards. If necessary, use non-shrink grout in order to meet the specified standard. The minimum concrete
strength shall be 25Mpa (3,625 PSI)
Step 2: Anchor the gate to the channel
•Position the channel gate in the existing channel.
Make sure that the gate is perfectly aligned and
centered in the channel (see Figure 6).
•Install the bottom anchor bolts, and then the
lateral anchor bolts (see Figure 7). All Face
Mounted Channel Gates incorporate bottom
and lateral mounting brackets. For smaller sizes
(typically same or under 1500mm/60”), the
channel gate includes lateral flexible brackets
(as seen in Figure 8) that require no field
adjustment. For bigger sizes (typically over
1500mm/60”), the channel gate includes “Field
Adjustment Brackets”. In order to adjust the
bracket, the following steps shall be followed
(see Figure 5):
oUntighten nut
oAdjust the bracket until it is completely
leaning against the wall.
oTight the nut
oInstall the anchor bolt
Figure 5
Figure 6
Figure 7

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-6/14
Reserves the right to change specifications without notice
www.orbinox.com
Step 3: Grout fill
•Grout fill the remaining voids (See Figure 8), both at the bottom and laterals of the gate. Remember that the
objective of the grout fill is twofold:
oFill the voids between the frame, frame invert and the channel
oMake a smooth transition for water flow. Therefore, the grout shall be built-up to the level of the frame as
shown in Figure 9
CAUTION! Make sure not to get grout or any other foreign material on the gate’s seals, guides or stem as this
may cause leakage or damage.
Figure 8
Figure 9

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-7/14
Reserves the right to change specifications without notice
www.orbinox.com
2.3. Installation: Wall Mounted
▶Required Materials:
•For the Wall Mount (WM) mounting option, the CC channel gate is installed by means of mechanical anchor bolts
and construction sealant (Sikabond/Sikaflex 11FC or equivalent). Note that as standard, anchor bolts and
construction sealant are not supplied with the gate. For detailed information about the type, size and quantity of
the required anchor bolts, or any other specific installation notes or materials, please refer to the notes on the
‘General Arrangement Drawing’.
▶ Installation Procedure:
Step 1: Concrete construction inspection
•The concrete construction shall be flat, level and plumb, and shall be in accordance to DIN 18202 or ACI 117-
06 standards. If necessary, use non-shrink grout in order to meet the specified standard. The minimum concrete
strength shall be 25Mpa (3,625 PSI)
•The wall surface shall be dry, for the
construction sealant to adhere
properly. If necessary, the wall can
be dried with the help of a
blowtorch or a hot-air fan
Step 2: Pre-installation of the
channel gate
•Position the channel gate against the
wall and line up with the opening
(See Figure 10). The gate shall be in
the closed position
•Drill and install an anchor bolt on
each side of the gate. After installing
the first anchor bolt, and prior to
drilling the hole on the other side,
make sure the frame is perfectly
leveled (see Figure 11)
Figure 10
Step 3: Construction sealant application (Sikabond/Sikaflex 11FC or equivalent)
In order to avoid leakage between the frame and the wall, construction sealant shall be applied on the back side of
the frame:
•Remove the channel gate from the wall (first remove the nuts of the anchor bolts)
•Apply construction sealant all around the perimeter of the frame, where it will be in contact with the wall.
Sikabond/Sikaflex 11FC (200 ml/m) or equivalent construction sealant shall be used (See Figure 12). Be sure not
to get sealant on the gate’s seals, guides, and/or stem, as this may cause leakage or damage

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-8/14
Reserves the right to change specifications without notice
www.orbinox.com
Step 4: Final installation of channel gate
•Place back the slide gate on the wall
•Drill and install the rest of the anchor bolts (see Figure 13)
CAUTION!: If the channel gate is not completely in contact with the wall, do not over-tighten the anchor bolts.
Over tightening may bend or distort the frame. If the wall flatness and levelness is according to the specified
standards, the construction sealant will fill in the remaining void (see Figure14)
Figure 11
Figure 12
Figure 13
Figure 14
Do not
overtight
anchor
bolts
Wall
Construction
sealant
Void
Back side of CC frame (side in
contact with the wall)

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-9/14
Reserves the right to change specifications without notice
www.orbinox.com
Initial Operation:
Before cycling the channel gate, make sure there are no foreign deposits or materials on the seals, guides or
sealing area. Gate seals could be damaged if the area is not cleaned and coated with a light grease. Please refer
to section “Materials needed for maintenance and seal replacement” for detailed information about the required
grease type. (see section 4.1)
•Manual
Apply a light grease on the stem before initial operation after the installation. If the operation is difficult due to
high torque, stop operation of the gate and check stem alignment.
•Electric actuator
oRefer to the Electric Motor Instruction Manual section before cycling the slide gate
oElectric actuators must be limited with limit and torque switches. Electric actuators without these limiters shall
not be used with ORBINOX channel gates. The electric actuators for CC channel gates are factory set,
except in cases where the motor is not yoke-mounted. To adjust the limit switches, follow the next
instructions:
▪Position the slide in the nearly closed position (leave 10mm/0,40” open). From this position, manually
(using the handwheel) operate the slide until it is completely closed (check tightness with a
0,05mm/0,002” gauge). In this position, set the limit switch for the CLOSED position
▪Position the slide in the nearly open position (leave 10mm/0,40” closed). From this position, manually
(using the handwheel) operate the slide until it is completely open. In this position, set the limit switch
for the OPEN position
oBe aware when the gate is almost fully OPEN or CLOSED. If the gate does not stop once the fully open or
fully closed position is reached, stop immediately and correct adjusting again the limit and torque
switches
Operation:
•CAUTION! Do not force the operator to close the gate, as it may cause damage to the stem and it does not
improve the sealing system. The maximum applicable force on the handwheel is 25 kg /55 bs
•The CC Channel Gate is closed by a clockwise rotation, and opened by a counter-clockwise rotation of the
operator
•The CC Channel Gate is designed to be self-locking, so that the slide maintains its position in any position
3. OPERATION
Ç

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-10/14
Reserves the right to change specifications without notice
www.orbinox.com
4. MAINTENANCE
Ç
4.1. Cleaning And Lubrication
ORBINOX model CC Channel Gates need practically no maintenance. In order to assure maximum performance
of the channel gate, the following maintenance inspections shall be carried out periodically every 6 months:
•Stem and stem nut shall be cleaned and greased. For non-rising stem configurations, the stem may be in
contact with water and dirt. Under these conditions, the threads of the stem and/or stem nut may wear, and
they shall be checked every 3 months
•Clean the gate with clear water and remove any deposits, especially on the seals and in the guides.
•Check the seals and make sure they are not damaged. Seals shall be replaced if damaged. See section
‘Maintenance: Seal Replacement’ for detailed procedures about seal replacement. (See section 4.2)
•Seals shall be wet while operating. If the slide gate has not been used for a long period of time under dry
conditions, the seals shall be wetted with clear water before operating the channel gate. Operating the gate
with dry seals may damage the seals. Additionally, more torque may be required to operate the channel
gate
Spare parts:
ORBINOX does not recommend stocking any spare parts by the owner of the equipment as the channel gates are
designed for a very long life cycle. If a repair part is required, please contact an ORBINOX representative and
provide the following information:
•ORBINOX S/O number
•“ORBINOX General Arrangement Drawing” number
•Project name (if applicable)
•Vendor’s company name
Materials needed for maintenance and seal replacement:
Material
Type
Recommended or equivalent
Grease
Silica-Gel Silicone Grease
Verkosil G-2 (no tóxico)
Glue
Instant adhesive
Loctite 406 and Cleaner 770

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-11/14
Reserves the right to change specifications without notice
www.orbinox.com
4.2. Seals Replacement
Slide Removal (Figure15)
•Step 1: Start from the closed position
•Step 2: Remove bolts and nuts (items 3 and 4) that
are used to join the stem (item 5) and slide (item 2).
For the non-rising stem configuration, the stem nut
shall be detached from the gate
•Step 3: Remove bolts and nuts (item 9 and 10) with
caution, as major components of the gate (yoke,
operator and stem) are no longer secured. Remove
the stem (item 5), yoke (item 8) and the operator
(item 11) as one item
•Step 4: Remove bolts and nuts (items 6 and 7) in
order to be able to remove the slide.
•Step 5: Remove the slide (item 2)
Side seals replacement (Figure 16)
•Step 6: Remove bolts, washers and nuts (items 3, 4
and 7) from the gate and remove retainers (items 2),
lateral (U)HMWPE guides (items 4) and front
(U)HMWPE guides (items 5)
•Step 7: Remove side seals (item 8) and replace it by
the new seal. Apply glue where the bottom seal and
side seals join. After installing the new seal, apply
grease on it to ease operation
Bottom seal replacement (Figure 16)
•Step 8: Remove bolts and nuts (items 10 and 12) and
remove bottom retainer (item 9)
•Step 9: Remove bottom seal (item 13) and replace it
by the new seal. Apply glue where the bottom seal
and side seals join
Reassembly
•Follow Steps 9 to 1
Figure 15
Figure 16

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-12/14
Reserves the right to change specifications without notice
www.orbinox.com
5. TROUBLE SHOOTING
Ç
SYMPTOM
CAUSE
SOLUTION
Leakage between channel gate
and concrete wall (for Face
Mounted in Existing Channel
Configuration)
Gaps between frame and
face of wall due to missapplication
of grout fill
Rellenar con mortero expansivo las
oquedades
Loose anchor bolts
Tighten anchor bolts
Incorrect anchor bolts
Check the ‘General Arrangement
Drawing’ and make sure the right anchor
bolts have been installed
Leakage between channel gate
and concrete wall (for Wall
Mounted Configuration)
Concrete wall does not meet the
required std
Un-install the slide gate and fix the wall
Not enough construction sealant
Un-install the slide gate, clean the
wall and apply a new layer of
construction sealant
Loose anchor bolts
Tighten anchor bolts
Incorrect anchor bolts
Check the ‘General Arrangement
Drawing’ and make sure the right anchor
bolts have been installed
Leakage through the side seals
Damaged seal
Replace seal
Leakage through the bottom
seal
Foreign material trapped between
frame invert and slide
Remove the foreign material. Check if
there is any damage to the seal
Damaged seal
Replace seal
Excessive force required to
operate the slide gate
Dirty stem and/or stem nut
Clean and lubricate stem and/or stem nut

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-13/14
Reserves the right to change specifications without notice
www.orbinox.com
6. ANNEX: CIVIL WORK TOLERANCES
Ç
•X: opening width
•Y: opening height
•YY: invert to coping distance
•DLx: linear deviation (with respect to X dimension)
•DLy: linear deviation (with respect to Y dimension)
•DLyy: linear deviation (with respect to YY dimension)
•DAy: angular deviation (with respect to Y dimension)
•DAx: angular deviation (with respect to X dimension)
•DAyy: angular deviation (with respect to YY dimension)
•DFy: flatness deviation (with respect to Y dimension)
•DFx: flatness deviation (with respect to X dimension)
•DFyy: flatness deviation (with respect to YY dimension)
Deviations shall be within the tolerances defined in DIN 18202:
Deviation
Maximun deviation
Linear deviation (DLx, DLy, DLyy)
DIN 18202, table 1, group 2 (for DLx and DLy)
DIN 18202, table 1, group 5 (for DLyy)
Angular deviation (DAx, DAy, DAyy)
DIN 18202, tabla 2
Flatness deviation (DFx, DFy, DFyy)
DIN 18202, tabla 3, grupo 7
The following tables show the tolerances defined in DIN18202:
DIN 18202
TABLE 1
Group
Applicable to
Max. admissible deviation (mm) for target size (m)
≤1
> 1 ≤3
> 3 ≤6
> 6 ≤15
>15 ≤30
>30
Linear deviation
Group 2
DLx, DLy
+-10
+-12
+-16
-
-
-
Group 5
DLyy
+-10
+-16
+-16
+-20
+-30
+-30
DIN 18202
TABLE 2
Group
Applicable to
Max. admissible deviation (mm) for target size (m)
≤0,5
>0,5 ≤1
≥ 1 < 3
≥ 3 < 6
≥ 6 < 15
≥15 ≤ 30
≥ 30
Angular deviation
DAx, DAy, DAyy
3
6
8
12
16
20
30
DIN 18202
TABLE 3
Group
Applicable to
Max. admissible deviation (mm) for target size (m)
< 0,1
≥ 0,1 < 1
≥ 1 < 4
≥ 4 < 10
≥ 4 < 10
Flatness deviation
Group 7
DFx, DFy, DFyy
2
3
8
15
20

MODEL
CC CHANNEL GATES
EDITION 09-2020
CC-14/14
Reserves the right to change specifications without notice
www.orbinox.com
7. ENVIRONMENTAL CONSIDERATIONS
• The packaging is made from environmentally friendly materials. Dispose of the packaging through the
available recycling channels
• The valve is designed and manufactured with materials that can be recycled by specialised recycling
firms. Once the life of the product is expired, you have to consider a proper disposal of the product in
order to prevent any negative impact on the environment and allows for the recycling of valuable
commodities
• Please follow the local environmental rules in your country for proper disposal