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© March 2001 Genral Binding Corporation

Voyager Operation and Maintenance Manual

Installation

Installation Precautions

W A R N I N G

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 Voyager System must only be installed by a
GBC employed technician.

2. Any moving or un-installing of the equipment may also,
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 accidents.

Summary of Contents for GBC VOYAGER

Page 1: ...Provided By http www MyBinding com http www MyBindingBlog com GBC Voyager Operation Maintenance Manual ...

Page 2: ... Road DeForest WI 53532 Revision Ph 608 246 8844 Fx 608 246 8645 GBC VOYAGER OPERATION MAINTENANCE MANUAL MARCH 2001 GENERAL BINDING CORPORATION ALL RIGHTS RESERVED Do not duplicate without written permission Part number 930 047 ...

Page 3: ...nderstand the instructions in this manual before you attempt to install operate or service the laminator 1 TheGBCVoyagerSystemmustonlybeinstalledbya GBCemployedtechnician 2 Anymovingorun installingoftheequipmentmayalso 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 a...

Page 4: ...Page 1 2 March 2001 Genral Binding Corporation Voyager Operation and Maintenance Manual 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: ...normodification 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 Unaut...

Page 10: ...tc Qualified 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 GB...

Page 11: ...rproductquality Range of Films Laminator runs polyester polypropylene and GBCLay Flatthermalfilms Speed One sided lamination at up to 130 fpm limited by the speed of the sheet separator CurlControl Built inbreakerbarassemblydecurlstheproduct ControlConstruction Fabricated from 1 2 inch 12 70 mm steel The rigid heavy duty body improves reliability of operation FilmSupplyShaft Mechanical drop lock c...

Page 12: ...tom unheatedcounter pressure roller Leveling Feet Eight adjustable leveling feet are provided to assure proper setup of the laminator Electric Eye Gap Detector Stops the system automatically if a sheet is misfed Heating Unit Provides heated liquid media to chrome roller with quick and easy controls and a self diagnostic at start up Film Supply Shaft Drop lock manual chuck that pivots out for ease ...

Page 13: ...eadjustingknobvariesthepressure 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 hea...

Page 14: ...mitsoperationatalower 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 This pair of rollers draws the film through the laminator maintainingthewebtensionacrossthedecurl unit Snapping Rollers This pair of rollers snaps the film enabling the image...

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: ...ided Slitter Safety Features Min 8 5 inches 215 90 mm Max 30 inches 762 mm Min 11 inches 279 40 mm Max 40 inches 1 016 mm 3 inch diameter 76 mm 15 5 inches 394 mm 130 fpm 39 6 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...

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: ...mpting 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 stops the machine from operation separates the laminating rollers 2 EMERGENCY STOP RESET When pressed resets the mach...

Page 20: ... feeder to compensate for the laminator speed change 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 total sheets or sheets per minute Total sheets can be reset back to zero 14 HOUR METER Keeps track of the total amount ofoperatingtimeonyourmachine 15 NIP PRESSURE GAUGE Indicates t...

Page 21: ...FF ON 2 AIR PRESSURE REGULATOR Adjusts the amountofincomingairtothemachine 3 BOW ROLLER ADJUST To remove film wrinkles over heat roller 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 eitheraddacurlingangleordecreasethecurlingangleof th...

Page 22: ...s theupperpullrollwhenturned 8 SNAPPING ADJUST The right adjust dial controls the control side snapping speed and strength Theleftadjustdialcontrolsthedrivesidesnapping speed and strength 9 EXITROLLER Helpspullthesheetsafterthesnap onto the catch table 10 SKEW WHEEL ROLLER Creates lift in drive side of sheet to help snapping 11 LATERAL FILM ADJUST Moves the unwind shaft from one side to the other ...

Page 23: ...icbrake 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 the sheet ta...

Page 24: ...VE 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 Movesthefeedingheadunitbackorforthforsheetlength changes 9 FEEDING HEAD UNIT HEIG...

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: ...theheaterunit 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 amount of pressure build up from the delivery system 12 RETURN PRESSURE GAUGE Displays the amountofpressurebuildupfromthereturnsystem 13 RESERVOIRSITEGLASS Indicatesthevolume ofheattransfermedi...

Page 27: ...e on top of the electrical box 2 SAFETY SHIELD HEAT ROLLER This shield covers the main heat transfer roller When the safety shield is raised the laminator will only operate when the E STOP RESET and the FORWARD or REVERSE buttons are pressed simultaneously 3 SAFETYSHIELD PULLROLLERS Thisshield covers the knife section as well as the pull rollers When thesafetyshieldisraised thelaminatorwillonlyope...

Page 28: ...mits the travel of the sheet table from lowering or raising 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: ...fully closed position and the E STOP RESET is not flashing Before you begin laminating check all safety devices and controls for proper operation 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 the compressed air supplyandcheckthesuppliedpressureattheAirPressure R...

Page 30: ... the top sheet in half and place on sheet table e Adjusttheleftandrighttablesheetguidessothecrease ofthefoldedsheetalignswiththecentertablesheetguide f Load the sheets onto the sheet table g While raising the table adjust the feed head to rear of the pile INFORMATION The eletric eye will stop the table at the right height when pressing table up ...

Page 31: ... steps are followed precisely To adjust the feed head 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...

Page 32: ...ightofthefeedingheadunitsothepileheight is about 1 8 inch below the feeder gate 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: ... will never 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 un printed margin at the edges to avoid several possible problems Slightshiftsoffilmpositioncanhappenduri...

Page 34: ...lifting practices when lifting heavy objects You can become seriously injured or crushed e Slidetherolloffilmontheunwindshaftwithregardsto thelaminateused polyinorpolyout 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 ...

Page 35: ... 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 pulled off the film roll To position the slitter take the following steps a Determine the distance from the left hand i...

Page 36: ...adeoutorin 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 or away fr...

Page 37: ...g point in selecting the roller temperature a For polypropylene films the temperature will be in the range of 200 to 220 o F 90 to 104 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 240 to 280 o F 115 to 138 o C Thicker paper darker colors and higher speed of operation result in a need ...

Page 38: ...ator Threading may be done in other ways but this method keeps the film from wrapping around a pull roller 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 shiel...

Page 39: ...ilm 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 Set the unwind brake pressure to 5 p s i Refer to image above just enough to hold the film in place 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: ... taunt and lower the pull roller u Turn the knife adjust wheel so that approximately 1 2 in of the blade is over the web v Close the pull roller safety shield w Press LAMINATOR START x Turn KNIFE SNAP to KNIFE position y Adjust the knife cutting position so that the cut is at the edge of the top sheet overlap z Turn KNIFE SNAP to KNIFE SNAP position ...

Page 42: ...ion size of the film roll and use of the slitter Therearevariouswaysofadjustingthefilmtension 1 First adjust the bow to smooth the film out across the bow roller as much as possible prior to applying the brake tension 2 Applyfilmtensionbyturningtheairpressureadjusting knobonthecontrolpanel Wrinklesinthefilmwillgivea waterfall like appearance to the film near the point whereitmeetsthechromeroller 3...

Page 43: ...sing both roller temperature 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 Dog earing at the breaker bar indicates that the amount of und...

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: ...till warm A Chrome Roller that has recently been in use maystillbehotenoughtoburnyou Clean the Counter Pressure Roller with a soft rag and mineral spirits If this cleaning leaves adhesive on the roller use a plastic scouring pad like Scotch Brite to remove the adhesive To prevent damage to roller surfaces never use metaltoolsorabrasivecleanerstocleaneitherof theLaminatingRollers 6 2 Periodical Mai...

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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: ...e on air pump is plugged reducing the vacuum cleanit d Check for disconnected or broken air lines e Missing or cracked suction cups f Rearpileheightisuneven a Vacuum on feed table needs to be adjusted up or down b Upper infeed wheels not properly adjusted to head stop Adjustthemsothattheinfeedwheelscontactlowerinfeedwheels when the head stops are flush within feed tray Wheels must spinwithlittleco...

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: ...eat draw or snap roller f Worn draw roller or guide cylinder g 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 Film too close to...

Page 52: ... 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 bleed of ink and or coating of sheets h Worn snap roller exit roller or skew wheel i Poor adhesion j Poorfilmquality a Fuse ...

Page 53: ...echnicians 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 ou...

Page 54: ...r a no power condition c Blown fuse 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 fro...

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