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Orbit Manufacturing 2000 Section 7: Troubleshooting, Section 8: Maintenance

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Table of 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

Contents

Main Read Me File . . . . . . . . . Page Fax Correspondence Page Table of Contents Section 1: Safety Section 2: Warranty Section 3: Specifications Section 4: Installation Section 5: Operations Page Section 6: Applications Section 7: Troubleshooting Section 8: Maintenance 1.0 Safety regulations 1.1 Safety - Complete equipment Page Page Page 1 - 4 Safety Orbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 1.2 Safety - Rules for loading paper Page 1 - 5 GBC Films Group January 2001 1.3 Safety - Rules for handling the feeding head Page 1.4 Safety - Rules for setting up the rollers and the hinged stops Page 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 1.6 Safety - Rules for the chrome and pressure rollers Page Page 14/ Side view Rear view 1.7 Safety - Rules for the snap roller area 5/ 6/ Page 1 - 15 GBC Films Group January 2001 The snap roller side view Page 1.8 Safety - Rules for the use of the twin knife Page Page 1 - 19 GBC Films Group January 2001 1.9 Safety - Rules for the position adjustment of the decurling bar Page 1 - 20 Safety Orbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 1.10 Safety - Rules for electrical installation Qualified Page 1.11 Safety - Rules for machine cleaning 5/ 6/ 7/ Page 1 - 23 GBC Films Group January 2001 1.12 Safety - Rules for machine maintenance and adjustments Page 1.13 Safety - Rules for the feeder table Page 1 - 27 GBC Films Group January 2001 1.14 Safety - Rules for the central drive maintenance 1.15 Safety - Rules for Snapping assembly/ chain/ belt drive maintenance Page 1 - 29 GBC Films Group January 2001 1.16 Safety - Rules for maintenance/ replacement of the twin knife Page Page 2 - 1 Warranty GBC Films Group January 2001 2.0 Warranty 2.1 Terms and conditions 2.1.1 2.1.2 2.1.3 2.2 Limited period of warranty 2.3 Limited warranty conditions 2.3.1 Warranty is not applicable to the following conditions: Page Page 3 - 1 SpecificationsOrbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 3.0 Specific dimensions and weight of the equipment 3.1 DIMENSIONS AND WEIGHT OF THE EQUIPMENT US VERSION EU VERSION Page 3 - 2 Specifications 3.2 SHIPPING CRATE DIMENSIONS AND WEIGHT US VERSION EU VERSION 3.3 BASIC TECHNICAL DATA Page Page Page 4 - 1 GBC Films Group January 2001 4.0 Installation Precautions Qualified Page 4 - 2 GBC Films Group January 2001 4.1 Pre-installation checklist Prior to the machine installation it is necessary to provide: Becker Compressor Machine position Page 4 - 3 The Floor Note 4.2 Suggested floor layout Page 4 - 5 GBC Films Group January 2001 4.3 Shipping damage inspection Page 4 - 6 GBC Films Group January 2001 4.4 Transporting of the machine Page 4 - 7 GBC Films Group January 2001 4.5 Electrical installation 4.6 Becker T4.25 DSK Compressor installation b a Page 4 - 9 GBC Films Group January 2001 4.7 Initial inspection a/ b/ Page 4 - 10 GBC Films Group January 2001 c/ d/ e/ f/ Page Page Page 5 - 1 GBC Films Group January 2001 5.0 Operation 5.1 General information 5.1.1 The main and secondary operator positions Page 5 - 3 GBC Films Group January 2001 5.1.2 The control panel Legend Please refer to the control panel diagram that resembles your machine on pages 4 and 5. Original overlay Page 5 - 4 R00 S E P A R A T O R L A M I N A T I N G S E C T I O N New overlay S E P A R A T O R R00 % F E E D E R L A M I N A T O RL A M I N A T O R 5.2 Feeder Section New overlay Oroginal overlay Page Side stacking 5.2.2 Feeder table positioning 5.2.3 The feeding head Feeding head setup The separating elements setup 1/ ff 2/ Page Page Feeding small sheet sizes Page 5.2.5 Feed roller assembly Gravity rollers Accelerating rollers g Page 5 - 18 GBC Films Group January 2001 Plate holders 1/ 2/ 3/ 4/ Sheet misfeed sensor Overlap adjustment 5.2.6 Second gate Position of the second gate 2.3 - 2.7 mm 5.2.7 Adjustable guide plates a a b c b c 5.3 Lamination section 5.3.1 Film roll positioning 1/ * Page 5 - 25 GBC Films Group January 2001 5/ c f 6/ 7/ a b Page Page 5 - 27 GBC Films Group January 2001 5.3.2 Heating Temperature adjustment 120.0 120.0 Page 5 - 28 GBC Films Group January 2001 Heat width selection a For sheet width size between 8 - 11 in. ( 200-280 mm ), set the heater switch ( a ) to 8-11. a For sheet width size between 12 - 14 in. ( 305-356 mm ), set the heater switch ( a ) to 12-14. 5.3.3 Laminating rollers Adjusting pressure Page 5 - 31 GBC Films Group January 2001 Automatic pressure cancellation Automatic pressure cancellation occurs when: 5.3.4 Spreader roller ( option ) 1/ 2/ 3/ 5.4 Separator section 5.4.1 The decurling bar Position of the decurling bar Thick paper Adjusting the decurling bar 1/ 2/ 3/ Effects of the decurling bar 5.4.2 Pull rollers a PAPER PULL ADJUSTMENT Page 5.4.3 Twin knives Positioning of the knife assembly with respect to sheet width Positioning of the knife assembly with respect to sheet edge Positioning of the knife assembly with respect to sheet weight 5.4.4 Snapping assembly a Upper snap roller positioning with respect to sheet weight Adjusting the upper snap roller 5.4.5 Stacking table Table slope adjustment Blower angle adjustment Blower pressure adjustment Page 6 - 1 ApplicationsOrbit 2000 Operation and Maintenance Manual GBC Films Group January 2001 6.0 Applications 6.1 Recommended types of film for your Obit 2000 machine 6.2 General threading procedure 1/ 2/ Page Page 6.3 Film threading diagram Poly-in / Poly-out webbing diagram Page 7.0 Troubleshooting 7.1 Lamination troubleshooting Blistering Bond strength Coiling / curling Delamination Out gassing Silvering 7.2 Wave pattern troubleshooting Paper tension ( Wave 1 ) Laminating temperature ( Wave 2 ) Nip ( Wave 3 ) Paper pull tension ( Wave 2 & 4 ) Brake tension ( Wave 5 ) Cooling / brake tension ( Wave 6 ) Wrinkles on both edges after the pressure roller ( Wave 7 ) Wrinkles from center to edge after pressure roller ( Wave 8 ) Wrinkles on either edge after the pressure roller ( Wave 9 ) No pattern wrinkles after the pressure roller ( Wave 10 ) All wave patterns are illustrated on page 7-7 and 7-8. Wrinkles appear after the pull roller ( Wave 11 ) Wrinkles appear after the snapping roller ( Wave 12 ) Page Wave patterns 7 - 12 Page 7 - 9 TroubleshootingObit 2000 Operation and Maintenance Manual GBC Films Group January 2001 7.3 Feeder troubleshooting 1. 2. 7.4 Misfed sheets troubleshooting Page 7.6 Machine troubleshooting (1) Symptom: The machine cannot be started with the START button Page Page Page Page Page 8 - 1 GBC Films Group January 2001 8.0 Maintenance Operator Maintenance Service maintenance 8.1 Maintenance schedule DAILY EVERY TWO WEEKS Page 8 - 3 GBC Films Group January 2001 MONTHLY ANNUALLY MAIN DRIVE AND FEED TABLE GEAR DRIVE VARIATOR 8.2 Operators Maintenance 8.2.1 Safety - Rules for machine cleaning Page Page 8 - 7 GBC Films Group January 2001 8.2.2 Safety - Rules for maintenance/ replacement of the twin knife Page 8.2.3 Feed table chain tensioning a 8.2.4 Paper release adjustment q