GBC VOYAGER User manual

GBC Voyager Laminator
Instruction Manual

GBC Pro - Tech
4151 Anderson Road
DeForest, WI 53532
Revision : Ph: ( 608 ) 246 - 8844
Fx: ( 608 ) 246 - 8645
GBC VOYAGER™ OPERATION
& MAINTENANCE MANUAL
©March2000GBCFilmsGroup
Do not duplicate without written permission.
Partnumber:930-047

© GBC Films Group April 2000
Voyager Operationand Maintenance Manual
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Installation
Installation Precautions
WARNING
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. TheGBCVoyagerSystemmustonlybeinstalledbya
GBCemployedtechnician.
2. Anymovingoruninstallingoftheequipmentmayalso,
onlybe donebya GBCemployedtechnician.
3.Oncethe machineisinstalled, allcables remainingon
thefloorfrom theelectricalcabinet tothemachine must
becovered,to avoid any accidents.

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Installation
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Manual
1.0 THE MANUAL
Tohelpyouoperateandmaintainyourlaminator
efficientlyandsafely,GBCprovidesthisoperatorsmanual.
WARNING
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!
Section 2.0 INTRODUCTION TO THE
LAMINATOR
Thissectiondescribesthe featuresand
benefits of the GBC VOYAGER ™, lists optional
equipment,andexplains the purpose ofeachpartof the
laminator.
Section 3.0 SPECIFICATIONS
Providedhere are thedetailedspecifications for
theGBC Voyager.
Section 4.0 OPERATION
This section describes the controls and
instruments,givesinstructionforloadingandthreadingfilm,
andprovidescompleteproceduresfor starting,operating
andshuttingdownthelaminator.
Section 5.0 Application
Detailed here are the processes for loading the
sheets,settingthefeedheadunit,loadingthefilm,adjusting
theslitter,heating,threading, an overviewofoperation
andshutdown.
Section 6.0 Maintenance
Provided here are details on how to keep your
machinerunningsmoothlyandefficiently.
Section 7.0 Troubleshooting
Thissectionwillassistyouinbasicandnon-basic
troubleshootingintheeventaproblemshouldoccur.

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Manual
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Disclaimer
1.2 DISCLAIMER
Thismanualhasbeenreviewedforaccuracy. The
instructionsanddescriptionsitcontainswereaccuratefor
the GBC VOYAGER™ LAMINATOR at the time of
thismanual’sproduction. However,succeedingmanuals
andlaminatorsaresubjecttochangewithoutnotification.
Therefore, General Binding Corporation assumes no
liabilityfor damagesincurred directlyorindirectlyfrom
errors,omissions,ordiscrepanciesbetweenthelaminator
andthismanual.

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Disclaimer
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Voyager Operationand Maintenance Manual
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Warranty
1.3 Warranty
GBCFilmsGroup warrantstheequipment sold
is free from defects in material and workmanship for a
period of one(1)yearpartsand90days labor from
thedateofinstallation.Thiswarrantyistheonlywarranty
made by GBC Films Group and cannot be modified or
amended.
GBC Films Group’s sole and exclusive
liability and the customer’s sole and exclusive
remedyunderthiswarranty shallbe,atGBCFilms
Group’s option, to repair or replace any such
defectivepartor product. These remediesareonly
availableifGBCFilmsGroup’sexamination of the
productdisclosestoGBCFilmsGroup’ssatisfaction
thatsuchdefectsactuallyexistand were not caused
bymisuse,neglect,attempttorepair,unauthorized
alterationormodification,incorrectlinevoltage,fire,
accident,flood,or otherhazard.
1.3.1 Limited Warranty
Thiswarrantyspecificallydoesnotcoverdamage
tothelaminating rollerscausedby knives, razorblades,
other sharp objects, failure caused by adhesives or
improper use of the machine. Warranty repair or
replacement does not extend the warranty beyond the
initialone yearperiod fromthe dateof delivery.
CAUTION
Unauthorized customer alterations will
void this warranty.
THE WARRANTY MADE HEREIN IS IN
LIEU OF ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, INCLUDING
ANY WARRANTY OR
MERCHANTABILITY OR FITNESS
FOR A PARTICULAR PURPOSE. GBC
PRO-TECH WILL NOT BE LIABLE
FOR PROPERTY DAMAGE OR
PERSONAL INJURY ( UNLESS
PRIMARILY CAUSED BY ITS
NEGLIGENCE ), LOSS OF PROFIT OR
OTHER INCIDENTAL OR
CONSEQUENTIAL DAMAGES
ARISING OUT OF THE USE OR
INABILITY TO USE THE EQUIPMENT.
1.3.2 Exclusions to the
Warranty
This warranty specifically does not
cover;
1. Damagetothelaminatingrollscausedby knives,razor
blades, other sharp objects or failure caused by
adhesives.

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Voyager OperationandMaintenance Manual
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Warranty
2. Damagetothemachinecausedbylifting,tiltingand/or
anyattempt topositionthemachineotherthanrolling
on the installed castors on evensurfaces.
3. Improperuseof the machine.
4. Damageduefromunqualifiedperson(s)servicingthe
machine.
Qualified
•Any engineerthathasexperiencewithelectrical
and mechanical design of lamination equipment. The
engineersshouldbefullyawareofallaspectsofsafety
withregardstolaminationequipment.
•Anycommissioningorserviceengineermustbe
ofcompetentnature, trained and qualifiedtoGBCPro-
Techstandards to fulfill that job. This person will have
completedandpassedthefullservicetrainingcoursefrom
GBCPro-Tech.
•AnyGBCTechnician,GBCSpecialist,and/ or
GBCPro-TechTechnicianthathasbeenthroughtheGBC
Pro-Techservicetraining course.

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Voyager Operationand Maintenance Manual
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Introduction
2.0 INTRODUCTION TO
THE LAMINATOR
Congratulations on your purchase of the GBC
FilmProductsVoyagerone-sidedlaminator. TheVoyager
operatesathighspeedswithpolyester,polypropyleneand
GBCLAY-FLAT® thermal lamination films. With its
high-qualityperformanceanddependability,theVoyager
offers the premier laminating capabilities required by
today’sprintingandgraphicsarts industries.
2.1 FEATURES
Heated Roller
High-glosschromerollerisgivena3RMSmicro
finishforsuperiorproductquality
Rangeof Films
Laminator runs polyester, polypropylene and
GBCLay-Flatthermalfilms.
Speed
One-sidedlaminationatup to 100 fpm, limited
bythespeedofthesheetseparator.
CurlControl
Built-inbreakerbarassemblydecurlstheproduct.
ControlConstruction
Fabricated from 3/8 inch ( 10 mm) steel. The
rigid,heavy-dutybodyimprovesreliabilityofoperation.
FilmSupplyShaft
Mechanicaldrop-lockchuck that pivots out for
easeoffilmloading.
Warm-upTime
Warm-upis fast,takingat most20minutes.
TemperatureControl
Controller provides easy service and accurate
controlofheatwithabilitytoquicklydecreasetemperature
setting.
WARNING
SAFETY STOP MODE
Automatically stops and gaps the nip
rollers, if anyone pushes one of the
two emergency stop buttons.

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Introduction
2.2 COMPONENTS OF
THE LAMINATOR
Laminating Rollers
Thelaminatingrollers consistofthe top, heated
chromerollerandthebottom,unheatedcounter-pressure
roller.
Leveling Feet
Eight adjustable leveling feet are provided to
assureproper setup ofthe laminator.
Electric Eye Gap Detector
Stopsthesystemautomaticallyifasheetismisfed.
Heating Unit
Providesheatedwatertochromerollerwithquick
andeasycontrols, andaself-diagnosticat start-up.
Film Supply Shaft
Dropluckmanualchuck,thatpivotsoutforease
offilmloading.

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Voyager Operationand Maintenance Manual
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Introduction
Emergency Stop Button
Pressingthisbuttoncausesthelaminatingandpull
rollerstoseparate and all therollersto stop.
Nip Pressure Controls
The“On-Off”switch applies air pressuretothe
laminatingrollers. Theadjustingknobvariesthepressure,
andthegauge showstheairpressure.
FWD/REV Controls
This switch is used to reverse the roll direction
foreaseofcleaningandmaintenance.
Speed Control
Turningtheknob adjusts thespeedat which the
rollersturn.
Upper Roll Temp Controller
This unit displays the actual chrome roller
temperature and also allows the operator to adjust the
operatingtemperature of theheatroller,up or down.
Main Power Switch
Switchesonoroff,allthepower tothelaminator
andheatingunit.

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Voyager OperationandMaintenance Manual
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Introduction
Film Slitter
This device cuts the film on-line, to the width
neededfor afinishedproduct. The unusedfilmremains
onthecoreforease of disposal.
Bow Roller
Thisrollerhelpstoremovewrinklesfromthefilm
andincreasesthedwelltimeoffilmontheheatedchrome
roller. Increaseddwelltimepermitsoperationatalower
rollertemperature.
Breaker Bar Assembly
Thisassemblydecurls thelaminatedwebas the
webpasses throughit. Thebreaker barcanbe rotatedto
producethedesireddegreeofbreakinthe paper.
Pull Rollers
Thispairofrollershelpstodrawthefilmthrough
thelaminator,maintainingthewebtensionacrossthedecurl
unit.
Snapping Rollers
This pair of rollers snaps the film enabling the
imagestobeseparatedafter the web has been knicked.
Knicker Assembly
Places a knick into the web at the set interval.
Thisallows forthesnapping rollerstoseparate theweb.

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Voyager Operationand Maintenance Manual
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Introduction
Control panel - Laminator
This panel allows 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.

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Introduction
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Specifications
3.0 SPECIFICATIONS
WorkingWidths:
WorkingLengths:
CoreSize:
MaximumFilmRoll Diameter:
MaximumSpeed:
ProductRange:
Films:
Rollers:
1-SidedSlitter:
Safety Features:
Min: 12inches( 305 mm )
Max: 30inches(762mm )
Min: 12inches( 305 mm )
Max: 40inches(1,016mm)
3inchdiameter (76mm)
15.5inches (394mm)
100fpm( 30.5 m/min.)
80 lb. C2S stock to 18 pt. board maximum
1.2milto1.7milOPP, PET, GBC LAY-FLAT®
Top: Water-heatedchromeroller with3RMS
Bottom: Hyplonrubber-coated
Whenavailablefilmistoowide,slittercan cutfilmto
thepropersize.
Safetycovers andEmergencystops

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Specifications
ElectricalRequirements:
ProductWarranty:
NetWeight:
ShippingWeights:
220 VAC, 3-Phase 100 AMPS
SeewarrantyinformationperSalesRepresentative
Approximately2,700lbs. (1,226kg)
Approximately3,300lbs.( 1,498 kg )

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Operations
4.0 OPERATION
Operating procedures given in this manual are
presentedassuggestionsfortheoperator’sconsideration.
An operator experienced in the art of lamination may
preferdifferentproceduresundercertainconditions.
YournewGBCVoyager™Laminatorisadurable
machinedesignedforheavy work loads. By following
theproceduressuggestedinthismanualandtakingproper
care of your unit, you can be assured of years of
professionalqualitylaminating.
This section will explain the controls of the
laminator,thefeederandtheheatingunit.Anycontrolnot
describedwithinthissectionisdonesointentionally.These
controlsare notfor operatormanipulation.
WARNING
To avoid injury to yourself or damage
to the equipment, please read and
understand the Operations section
of this manual before 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.EMERGENCYSTOP (E-STOP):Whenpressed,
stopsthemachinefromoperation,raisestheheatingroller.
2. EMERGENCY STOP RESET: When pressed,
resetsthemachineafter an E-STOP has been pressed.
3.SHEETSIZEselector:Enables theoperatortoselect
thesheetsize ( Short /long).
4. KNIFE/ KNIFE & SNAP selector: Enables the
operatortoengagetheknifeonly,knifeandsnaporneither.
5.JOGFORWARD:Engagesthemachineinaforward
directionforthedurationofthepress.Whenasafetyshield
is raised, JOG FORWARD and E-STOP RESET must
bepressedsimultaneously.
6.JOGREVERSE: Engages the machine inareverse
directionforthedurationofthepress.Whenasafetyshield
israised, JOGREVERSE andE-STOPRESETmustbe
pressedsimultaneously.
7. LAMINATOR STOP: When pressed, stops all
motiontothemachine.
8.LAMINATORSTART:Whenpressed,engagesall
motiononthemachine.

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Operations
9.NIPUP/DOWN:Whenpressedand illuminates,the
niprolleris inthedown position. Whenpressedand the
lightextinguishes,theniprollerisintheupposition.
10.VACUUMPUMPselector:Engagesor disengages
thevacuumpump.
11.LAMINATORSPEEDdial:Adjuststhemachine
speed.Automaticallyadjuststhefeedertocompensate
forthe laminatorspeed change.
12.SHEETEXITBLOWERdial:Adjuststheamount
ofair flowcomesout thesheetblower valve.
Figure 4.1.1 Control panel - Laminator
13. SHEET COUNTER: Can be selected to display
totalsheetsorsheetsperminute.Totalsheetscanbereset
back to zero.
14.HOURMETER:Keeps track of the total amount
ofoperatingtimeonyourmachine.
15.NIPPRESSUREGAUGE: Indicates the amount
ofpressure presentedatthe mainrollernip.
16. NIP PRESSURE ADJUST dial: Adjusts the
amountof pressurepresentedat themain rollernip.
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16