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© GBC Films Group April 2000

Voyager Operation and Maintenance Manual

Page 1 - 16

Specifications

Electrical Requirements:

Product Warranty:

Net Weight:

Shipping Weights:

220 VAC, 3-Phase 100 AMPS

See warranty information per Sales Representative

Approximately 2,700 lbs. ( 1,226 kg )

Approximately 3,300 lbs. ( 1,498 kg )

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Summary of Contents for VOYAGER

Page 1: ...GBC Voyager Laminator Instruction Manual ...

Page 2: ...ch 4151 Anderson Road DeForest WI 53532 Revision Ph 608 246 8844 Fx 608 246 8645 GBC VOYAGER OPERATION MAINTENANCE MANUAL March 2000 GBC Films Group Do not duplicate without written permission Part number 930 047 ...

Page 3: ...tand the instructions in this manual before you attempt to install operate or service the laminator 1 TheGBCVoyagerSystemmustonlybeinstalledbya GBCemployedtechnician 2 Anymovingoruninstallingoftheequipmentmayalso only be done by a GBC employed technician 3 Once the machine is installed all cables remaining on the floor from the electrical cabinet to the machine must be covered to avoid any acciden...

Page 4: ... GBC Films Group April 2000 Voyager Operation and Maintenance Manual Page 1 2 Installation This page intentionally left blank ...

Page 5: ... of each part of the laminator Section 3 0 SPECIFICATIONS Provided here are the detailed specifications for the GBC Voyager Section 4 0 OPERATION This section describes the controls and instruments givesinstructionforloadingandthreadingfilm andprovidescompleteproceduresforstarting operating andshuttingdownthelaminator Section 5 0 Application Detailed here are the processes for loading the sheets s...

Page 6: ... GBC Films Group April 2000 Voyager Operation and Maintenance Manual Page 1 4 Manual This page intentionally left blank ...

Page 7: ...tionsanddescriptionsitcontainswereaccuratefor the GBC VOYAGER LAMINATOR at the time of thismanual sproduction However succeedingmanuals andlaminatorsaresubjecttochangewithoutnotification Therefore General Binding Corporation assumes no liabilityfordamagesincurreddirectlyorindirectlyfrom errors omissions ordiscrepanciesbetweenthelaminator andthismanual ...

Page 8: ... GBC Films Group April 2000 Voyager Operation and Maintenance Manual Page 1 6 Disclaimer This page intentionally left blank ...

Page 9: ...ation incorrectlinevoltage fire accident flood or other hazard 1 3 1 Limited Warranty Thiswarrantyspecificallydoesnotcoverdamage to the laminating rollers caused by knives razor blades other sharp objects failure caused by adhesives or improper use of the machine Warranty repair or replacement does not extend the warranty beyond the initialoneyearperiodfromthedateofdelivery CAUTION Unauthorized cu...

Page 10: ...ified Any engineerthathasexperiencewithelectrical and mechanical design of lamination equipment The engineers should be fully aware of all aspects of safety withregardstolaminationequipment Anycommissioningorserviceengineermustbe of competent nature trained and qualified to GBC Pro Tech standards to fulfill that job This person will have completedandpassedthefullservicetrainingcoursefrom GBC Pro T...

Page 11: ...eriorproductquality Range of Films Laminator runs polyester polypropylene and GBCLay Flatthermalfilms Speed One sided lamination at up to 100 fpm limited by the speed of the sheet separator CurlControl Built inbreakerbarassemblydecurlstheproduct ControlConstruction Fabricated from 3 8 inch 10 mm steel The rigid heavy dutybodyimprovesreliabilityofoperation FilmSupplyShaft Mechanical drop lock chuck...

Page 12: ...rollerandthebottom unheatedcounter pressure roller Leveling Feet Eight adjustable leveling feet are provided to assure proper setup of the laminator Electric Eye Gap Detector Stopsthesystemautomaticallyifasheetismisfed Heating Unit Providesheatedwatertochromerollerwithquick and easy controls and a self diagnostic at start up Film Supply Shaft Dropluckmanualchuck thatpivotsoutforease offilmloading ...

Page 13: ...headjustingknobvariesthepressure and the gauge shows the air pressure FWD REV Controls This switch is used to reverse the roll direction foreaseofcleaningandmaintenance Speed Control Turning the knob adjusts the speed at which the rollersturn Upper Roll Temp Controller This unit displays the actual chrome roller temperature and also allows the operator to adjust the operating temperature of the he...

Page 14: ...rmitsoperationatalower rollertemperature Breaker Bar Assembly This assembly decurls the laminated web as the web passes through it The breaker bar can be rotated to produce the desired degree of break in the paper Pull Rollers Thispairofrollershelpstodrawthefilmthrough thelaminator maintainingthewebtensionacrossthedecurl unit Snapping Rollers This pair of rollers snaps the film enabling the images...

Page 15: ...llows the operator to control the laminatorsectioninacentrallocation Control panel Heater This panel allows the operator to control the heatingsectioninacentrallocation Control panel Feeder This panel allows the operator to control the feedingsectioninacentrallocation Air Pressure Regulator Thiscontrolsetstheincomingairpressure ...

Page 16: ... GBC Films Group April 2000 Voyager Operation and Maintenance Manual Page 1 14 Introduction This page intentionally left blank ...

Page 17: ...1 Sided Slitter Safety Features Min 12 inches 305 mm Max 30 inches 762 mm Min 12 inches 305 mm Max 40 inches 1 016 mm 3 inch diameter 76 mm 15 5 inches 394 mm 100 fpm 30 5 m min 80 lb C2S stock to 18 pt board maximum 1 2 mil to 1 7 mil OPP PET GBC LAY FLAT Top Water heated chrome roller with 3 RMS Bottom Hyplon rubber coated Whenavailablefilmistoowide slittercancutfilmto the proper size Safety cov...

Page 18: ...nd Maintenance Manual Page 1 16 Specifications Electrical Requirements ProductWarranty Net Weight ShippingWeights 220 VAC 3 Phase 100 AMPS SeewarrantyinformationperSalesRepresentative Approximately 2 700 lbs 1 226 kg Approximately 3 300 lbs 1 498 kg ...

Page 19: ...re attempting to operate the laminator WARNING Do not wear ties loose fit clothing or dangling jewelry while operating or servicing the laminator These items can get caught in the nip and choke you or you can be crushed or burned 4 1 Laminator controls 1 EMERGENCY STOP E STOP When pressed stopsthemachinefromoperation raisestheheatingroller 2 EMERGENCY STOP RESET When pressed resets the machine aft...

Page 20: ...e feeder to compensate forthelaminatorspeedchange 12 SHEETEXITBLOWERdial Adjuststheamount of air flow comes out the sheet blower valve Figure 4 1 1 Control panel Laminator 13 SHEET COUNTER Can be selected to display totalsheetsorsheetsperminute Totalsheetscanbereset back to zero 14 HOUR METER Keeps track of the total amount ofoperatingtimeonyourmachine 15 NIP PRESSURE GAUGE Indicates the amount of...

Page 21: ... AIR PRESSURE REGULATOR Adjusts the amountofincomingairtothemachine 3 BOW ROLLER ADJUST Increases film tension ordecreasesfilmtensionwhenturned 3 LAP CONTROL KNOB DIAL INDICATOR Adjusts the amount of overlap per sheet The indicator shows a reference point 4 KNIFE TIMING ADJUST Changes the timing of theknifewhenturned 5 DECURLINGANGLEADJUST whenturnedcan eitheraddacurlingangleordecreasethecurlingan...

Page 22: ...theupperpullrollwhenturned 8 SNAPPING ADJUST The right adjust dial controls the control side snapping speed and strength Theleftadjustdialcontrolsthedrivesidesnapping speed and strength 9 DRAWROLLERGUIDES Guides the sheets after the snap onto the catch table 10 DRAW CONTROL ROLLER Adjusts the angle ofthesheetexitingthelaminator 11 LATERAL FILM ADJUST Moves the unwind shaft from one side to the oth...

Page 23: ...thepneumaticbrake Seeimage above 15 FILM SLITTER PRESSURE ADJUST Adjusts theamountofpressureappliedtothebladepressedagainst the roll of film The closer to the roll of film the more pressure applied 4 2 Feeder controls 1TABLEUP Raisesthesheettablewhilepressed When released the sheet table stops See image below 2 TABLEDOWN Whenpressed startsthesheettable to lower Press again to stop the travel of th...

Page 24: ... used on both adjusters 6 DRIVE SIDE TABLE SHEET GUIDE ADJUST When turned moves the drive side table sheet guide closer or farther from the center 7 FEEDING HEAD UNIT This unit lifts the sheets and feeds them onto the conveyor The two adjustments on the feeding head unit are the sheet brushes and the sheetclips 8 LATERAL FEEDING HEAD UNIT ADJUST Moves the feeding head unit back or forth 9 FEEDING ...

Page 25: ... OFF Turns the system pressurepumponoroff Thisshouldbeturnedonfirstat start up See image above Refer to Figure 4 3 1 Switches 4 FEEDER PUMP INDICATOR LIGHT When illuminated indicates the feeder pump is on See image below Refer to Figure 4 3 2 Indicators 5 POWERINDICATORLIGHT Illuminatesifpower to the heater unit is supplied Refer to Figure 4 3 2 Indicators Figure 4 3 2 Indicators 6 FLOW PUMP INDIC...

Page 26: ...ueoftheheaterunit 10 SET POINT DOWN When pressed decreases the set point value of the heater unit See image above INFORMATION When using or must be pressed in conjunction 11 DELIVERY PRESSURE GAUGE Displays the amountofpressurebuildupfromthedeliverysystem 12 RETURN PRESSURE GAUGE Displays the amountofpressurebuildupfromthereturnsystem 13 RESERVOIRSITEGLASS Indicatesthevolume ofheattransfermediumin...

Page 27: ...de on top of the electrical box 2 SAFETY SHIELD HEAT ROLLER This shield coversthemainheattransferroller Whenthesafetyshield is raised the laminator will only operate when the E STOP RESET and the FORWARD or REVERSE buttonsarepressedsimultaneously 3 SAFETYSHIELD PULLROLLERS Thisshield covers the knife section as well as the pull rollers When thesafetyshieldisraised thelaminatorwillonlyoperate when ...

Page 28: ... Limits the travel of thesheettablefromloweringorraising 6 UPPER UNWIND ARM LATCH Designed to securetheupperpartoftheunwindshaftarmintheraised positionwhileloadingarolloffilm 7 POWER ON OFF LOCK OUT Push up on the black tab located on the handle which will allow a pad lock to secure the handle in the off position ...

Page 29: ...Before you begin laminating check all safety devices and controls for proper operation You will obtain the best lamination by using the minimumrollertemperature nippressure filmtensionand brake required to do the job Read the Over view to obtain a better understanding of the Voyager before proceeding 5 1 Loading the sheets Thefirstthingtodoisswitchonelectricalpower at the Main Power Switch Turn on...

Page 30: ...position d Load the sheets onto the sheet table e Fold the top sheet in half and replace back on top of the sheet stack f Adjusttheleftandrighttablesheetguidessothecrease ofthefoldedsheetalignswiththecentertablesheetguide g Raise the table INFORMATION The eletric eye will stop the table at the right height when pressing table up ...

Page 31: ...steps are followed precisely To load the sheets take the following steps a Slide the feeding head unit forward toward the sheet stack b Stop when the sheet stack tabs make slight contact with the back of the sheets c Press laminator start INFORMATION Do not turn the VACUUM PUMP on You only want the feeding head unit to move not feed sheets d Set laminator speed to 15 e Use the feeding height adjus...

Page 32: ...ght of the feeding head unit so the suction cups come down and kiss the top sheet Do not allow the suction cups to jam down into the sheet stack CAUTION g Press laminator stop h Adjustthetwosheetbrushesforslightpressureonthe sheet stack i Adjust the four sheet clips for slight pressure on the sheet stack ...

Page 33: ...extend beyond the edge of the sheetbecauseanyfilmexposedtoeitherlaminatingroller willleavemeltedadhesivestuckontheroller The rollers must be kept free of adhesive at all timesduringthelaminatingprocess GBC Film Group recommends that sheets be printed with more than 1 4 inch 6 mm of unprinted margin at the edges to avoid several possible problems Slightshiftsoffilmpositioncanhappenduringa laminatio...

Page 34: ... proper lifting practices when lifting heavy objects You can become seriously injured or crushed e Slidetherolloffilmontheunwindshaftwithregardsto thelaminateused f Place the unwind arm back into its saddle and lower theupperunwindarm f Tocorrectlypositiontheleftedgeofthefilm measure thedistancefromtheleft handinnerfaceofthelaminator to the edge of the sheet If the edge of the film is set in too f...

Page 35: ...to ink a oppose to paper the snapping quality may be less than acceptable 5 4 Adjusting the slitter Caution should always be exercised adjusting the film slitter Sharp blade can cut you WARNING Forapplicationwherethefilmistoowide slitter is provided to cut the film to the correct width as it is pulledoffthefilmroll To position the slitter take the following steps a Determinethedistancefromtheleft ...

Page 36: ... slidethebladeoutorin andtightenthesetscrew Thebladeholdingblockgenerallyshouldbeata right angle with the slitter frame however you can vary theangleatwhichtheblademeetstheroll Tochangethe blade angle loosen the set screw pivot the block to desired angle and tighten the set screws You can vary the pressure on the blade by swingingthecylindricalweighttowardtheslittersupport bar to decrease pressure...

Page 37: ...y use asastartingpointinselectingtherollertemperature a Forpolypropylenefilms thetemperaturewillbeinthe range of 200 to 240 o F 90 to 115 o C b Forpolyesterfilms thetemperaturewillbeintherange of 240 to 260 o F 115 to 127 o C c For GBC LAY FLAT Films the starting point temperature will be between 250 to 280o F 121 to 138 o C Thickerpaper darkercolorsandhigherspeedof operationresultina needforhighe...

Page 38: ...he laminator Threadingmaybedoneinotherways butthis methodkeepsthefilmfromwrappingaroundapullroller and it is especially appropriate if one person alone must start the operation To thread the laminator take the following steps a Switch on power at the Main Power Switch b Set the temperature for the heat roller Caution should always be exercised when using the laminator with the safety shields raise...

Page 39: ...llowthefilm to hang about half way over the heat roller e Adhere one sheet to the activated film on the heat roller f Guidethefreeendofthesheetintothemainniprollers i Engagetheunwindshaftclutch j Settheunwindbrakepressureto5p s i Refertoimage aboveJustenoughtoholdthefilminplace k Turn VACUUM PUMP to ON l Press LAMINATOR START ...

Page 40: ... Raisethepullrollersafetyshield o Close the main roller safety shield INFORMATION The E STOP RESET must be pressed and held in step p p Press and hold the E STOP RESET while pressing NIP then press JOG FORWARD until about 4 feet of web has passed through the main roller nip and then q Guide the web through the decurling bar r Guidethewebthroughthepullrollers ...

Page 41: ...g rollers t Pull the web taunt and lower the pull roller u Turntheknifeadjustwheelsothatapproximately 1 2 in of the blade is over the web v Closethepullrollersafetyshield w Press LAMINATOR START x Turn KNIFE SNAP to KNIFE SNAP position y Adjust the knife cutting position so that the cut is at the edge of the top sheet overlap ...

Page 42: ...filmroll and use of the slitter Therearevariouswaysofadjustingthefilmtension 1 First adjust the bow to smooth the film out across the bowrollerasmuchaspossible priortoapplyingthebrake tension 2 Applyfilmtensionbyturningtheairpressureadjusting knobonthecontrolpanel Wrinklesinthefilmwillgivea waterfall like appearance to the film near the point whereitmeetsthechromeroller 3 Byslowlyturningtheadjusti...

Page 43: ...ollertemperature and nip pressure from slow starting alternately increase one and then the other to keep from setting either temperature or pressure higher than necessary If the sheet wrinkles going into the nip decrease the nip pressure Whenyoumustadjustthenippressure remember thatthisadjustmentcanchangetheamountofunderlap Do earing at the breaker bar indicates that the amount of under lap needs ...

Page 44: ...r Laminator Exit 5 8 Shutting down At the end of the run take the following steps a Press LAMINATOR STOP b Raisethepullroller c Separate the main rollers d Cool heater to 180 o F e Turn MAIN POWER to OFF f Turn off the compressed air at the Air Pressure Regulator Takingairpressureoffthelaminatingrollerswhen they are not in use prevents the development of a flat spot on the counter pressure roller ...

Page 45: ... preferablywhiletherollerisstill warm A Chrome Roller that has recently been in use maystillbehotenoughtoburnyou CleantheCounter PressureRollerwithasoftrag andsolvent Ifthiscleaningleavesadhesiveon theroller useaplasticscouringpad likeScotch Brite to remove the adhesive To prevent damage to roller surfaces never use metaltoolsorabrasivecleanerstocleaneitherof theLaminatingRollers 6 2 Periodical Ma...

Page 46: ... GBC Films Group April 2000 Voyager Operation and Maintenance Manual Page 1 44 Maintenance This page intentionally left blank ...

Page 47: ...ing the removal of a cabinet cover or guard should be performed by a qualified technician only Thewordqualifiedisdefinedas Qualified Any engineerthathasexperiencewithelectrical and mechanical design of lamination equipment The engineers should be fully aware of all aspects of safety withregardstolaminationequipment Anycommissioningorserviceengineermustbe ofcompetentnature trainedandqualifiedtoGBCF...

Page 48: ...ening valve airmustslightlyliftleadingedgeofsheet c Vent hole on air pump is plugged reducing the vacuum cleanit d Check for disconnected or broken air lines e Missing or cracked suction cups a Vacuum on feed table needs to be adjusted up or down b Upper infeed wheels not properly adjusted to head stop Adjustthemsothattheinfeedwheelscontactlowerinfeedwheels whenthetheheadstopsareflushwithinfeedtra...

Page 49: ...s dirty d Heat is to high e Extremelypoorfilmquality a Heat is not properly set for film type Too High film melts stretches bubbles TooLow silvering milky noadhesion b BowRollerisnotadjustedcorrectly allowinganairpocket betweenfilmandroller c Film has absorbed moisture or is aged d Dyne level too low for product e Dirty or damaged heat or nip rollers WARNING A heat roller that has recently been in...

Page 50: ...ry out moisture content of the sheets d Pressure not set properly for type of sheet e Sheet weight is below paper specifications for machine f Heat is set too high g Uneven ink coverage from left to right of sheet h Worn or damaged nip roller i Worn or damaged heat roller In some cases guards may have to be removed Ensure the guards replaced when problem has been resolved CAUTION INFORMATION Chang...

Page 51: ...rn or broken at heat draw or snap roller g Worn draw roller or guide cylinder h Snap roller closing not adjusted properly a Air pressure is too low incoming air must not drop below 100 psi b Broken or damaged air line c Dirt water or oil in pneumatic system d Maladjustedcushioningvalveorflowcontrolunit e Worn or broken knife mechanism f Prox switch or Read switch not properly adjusted oraligned a ...

Page 52: ...ols notproperlyadjusted b Skew wheel applying too much or too little bow to the web c Exit roller is not applying enough draw pressure to the left side of the web d Insufficientnippressureappliedatlaminatingprocess e Insufficient nip pressure applied at nip or draw roller f Knicking knife not cutting film at lap or cutting into paper afterknickinglap Thisconditioncanhappenislapvariesgreatly g Full...

Page 53: ...technicians Mostpneumaticproblemsarecausedbywateroroilpresentin thesystem Thistypeorliquidcontaminationcausesimpaired airflow stickingorinternalaircomponents andprematurewear of not only pneumatics but excessive wear of the components that they operate a Low water level in tank b Thermo safety switch open or activated c Motor overload switch needs resetting d Blownfuses e Booster pump motor burn o...

Page 54: ...use d Circulating pump breaker inside has popped a Cooling valve is stuck open b Heat Element is stuck open c Controllermalfunction d TemperatureProbemalfunction a Heating element burn out will not hold temperature while running b Venting valve is stuck open steam coming out of tank vent afterreachingsetpoint c Malfunctioningcontrollerortemp probe d Relief valve from heat exchange is leaking water...

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