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MyBinding GBC VOYAGER Operation & Maintenance Manual

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Operation
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Summary of Contents for MyBinding GBC VOYAGER

  • Page 1 GBC Voyager Operation & Maintenance Manual Provided By http://www.MyBinding.com http://www.MyBindingBlog.com...
  • Page 2 GBC VOYAGER™ OPERATION & MAINTENANCE MANUAL © MARCH 2001 GENERAL BINDING CORPORATION. ALL RIGHTS RESERVED. Do not duplicate without written permission. GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844...

  • Page 3: Installation Precautions

    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.
  • Page 4 Installation Voyager Operation and Maintenance Manual This page intentionally left blank. Page 1 - 2 © March 2001 Genral Binding Corporation...
  • Page 5 LAMINATOR Provided here are details on how to keep your machine running smoothly and efficiently. This section describes the features and benefits of the GBC VOYAGER ™ , lists optional equipment, and explains the purpose of each part of the laminator.
  • Page 6 Manual Voyager Operation and Maintenance Manual This page intentionally left blank. Page 1 - 4 © GBC Films Group April 2000...
  • Page 7 1.2 DISCLAIMER This manual has been reviewed for accuracy. The instructions and descriptions it contains were accurate for the GBC VOYAGER™ LAMINATOR at the time of this manual’s production. However, succeeding manuals and laminators are subject to change without notification.
  • Page 8 Disclaimer Voyager Operation and Maintenance Manual This page intentionally left blank. Page 1 - 6 © GBC Films Group April 2000...

  • Page 9: Limited Warranty

    Voyager Operation and Maintenance Manual Warranty 1.3 Warranty CAUTION Unauthorized customer alterations will void this warranty. GBC Films Group warrants the equipment sold is free from defects in material and workmanship for a period of one ( 1 ) year parts ( excludes wear items ) and 90 days labor from the date of installation.
  • Page 10 Warranty Voyager Operation and Maintenance Manual 2. Damage to the machine caused by lifting, tilting and/ or any attempt to position the machine on uneven surfaces. 3. Improper use of the machine. 4. Damage due from unqualified person(s) servicing the machine.
  • Page 11 Voyager Operation and Maintenance Manual Introduction Curl Control 2.0 INTRODUCTION TO THE LAMINATOR Built-in breaker bar assembly decurls the product. Control Construction Fabricated from 1/2 inch ( 12.70 mm) steel. Congratulations on your purchase of the GBC The rigid, heavy-duty body improves reliability of Film Products Voyager one-sided laminator.
  • Page 12 Introduction Voyager Operation and Maintenance Manual Electric Eye Gap Detector 2.2 COMPONENTS OF THE LAMINATOR Stops the system automatically if a sheet is misfed. Laminating Rollers Heating Unit The laminating rollers consist of the top, heated Provides heated liquid media to chrome roller chrome roller and the bottom, unheated counter-pressure with quick and easy controls, and a self-diagnostic at roller.
  • Page 13 Voyager Operation and Maintenance Manual Introduction Emergency Stop Button Speed Control Pressing this button causes the laminating Turning the knob adjusts the speed at which the rollers to separate and all the rollers to stop. rollers turn. Upper Roll Temp Controller Nip Pressure Controls This unit displays the actual chrome roller The “On-Off”...
  • Page 14 Introduction Voyager Operation and Maintenance Manual Film Slitter Pull Rollers This device cuts the film on-line, to the width This pair of rollers draws the film through the needed for a finished product. The unused film remains laminator, maintaining the web tension across the decurl on the core for ease of disposal.
  • Page 15 Voyager Operation and Maintenance Manual Introduction Control panel - Laminator Air Pressure Regulator This panel allows the operator to control the This control sets the incoming air pressure. laminator section in a central location. Control panel - Heater This panel allows the operator to control the heating section in a central location.
  • Page 16 Introduction Voyager Operation and Maintenance Manual This page intentionally left blank. Page 1 - 14 © GBC Films Group April 2000...

  • Page 17: Specifications

    Voyager Operation and Maintenance Manual Specifications 3.0 SPECIFICATIONS Working Widths: Min: 8.5 inches ( 215.90 mm ) Max: 30 inches ( 762 mm ) Working Lengths: Min: 11 inches ( 279.40 mm ) Max: 40 inches ( 1,016 mm ) Core Size: 3 inch diameter ( 76 mm ) Maximum Film Roll Diameter:...
  • Page 18 Specifications Voyager Operation and Maintenance Manual Electrical Requirements: 220 VAC, 3-Phase 100 AMPS Product Warranty: See warranty information per Sales Representative Net Weight: Approximately 2,700 lbs. ( 1,226 kg ) Shipping Weights: Approximately 3,300 lbs. ( 1,498 kg ) Page 1 - 16 ©...

  • Page 19: Operation

    2. EMERGENCY STOP RESET: When pressed, Your new GBC Voyager™ Laminator is a durable resets the machine after an E-STOP has been pressed. machine designed for heavy work loads. By following the procedures suggested in this manual and taking proper care of your unit, you can be assured of years of professional quality laminating.
  • Page 20 Operations Voyager Operation and Maintenance Manual 9. NIP UP/ DOWN: When pressed and illuminates, the 13. SHEET COUNTER: Can be selected to display nip roller is in the up position. When pressed and the light total sheets or sheets per minute. Total sheets can be extinguishes, the nip roller is in the down position.
  • Page 21 Voyager Operation and Maintenance Manual Operations Other controls on the laminator 3. LAP CONTROL KNOB/ DIAL INDICATOR: Adjusts the amount of overlap per sheet. The indicator shows a reference point. 1. MAIN POWER ON/ OFF: Engages power to the machine or removes power to the machine. 4.
  • Page 22 Operations Voyager Operation and Maintenance Manual 6. KNIFE ADJUST: Moves the table and knife from 9. EXIT ROLLER : Helps pull the sheets after the snap one side to the other side when turned. onto the catch table. 7. PULL ROLLER NIP ADJUST: Raises or lowers the upper pull roll when turned.
  • Page 23 Voyager Operation and Maintenance Manual Operations 12. UNWIND BRAKE ON/ OFF: Engages air or 4.2 Feeder controls disengages air to the pneumatic brake to the unwind shaft. See image below. 1 TABLE UP: Raises the sheet table while pressed. When released, the sheet table stops.
  • Page 24 Operations Voyager Operation and Maintenance Manual 5. CONTROL SIDE TABLE SHEET GUIDE 7. FEEDING HEAD UNIT: This unit lifts the sheets ADJUST : When turned, moves the control side table and feeds them onto the conveyor. The two adjustments sheet guide closer or farther from the center. on the feeding head unit are the sheet brushes and the sheet clips.
  • Page 25 Voyager Operation and Maintenance Manual Operations 5. POWER INDICATOR LIGHT: Illuminates if power 4.3 Heater unit controls to the heater unit is supplied. Refer to Figure 4.3.2 Indicators. 1. FLOW PUMP ON/ OFF: Turns the flow pump in the Figure 4.3.2 Indicators heater unit on or off.
  • Page 26 Operations Voyager Operation and Maintenance Manual 8. SET POINT DISPLAY: Displays the current set point 11. DELIVERY PRESSURE GAUGE: Displays the value for the heater unit. amount of pressure build up from the delivery system. 9. SET POINT UP: When pressed increases the set point value of the heater unit.

  • Page 27: Safety Features

    Voyager Operation and Maintenance Manual Operations 14. RESERVOIR FILL PORT: This is where the 2. SAFETY SHIELD - HEAT ROLLER: This shield operator would fill the reservoir with water if the covers the main heat transfer roller. When the safety reservoir site glass is at less than the half mark.
  • Page 28 Operations Voyager Operation and Maintenance Manual 5. TABLE LIMIT SWITCHES: Limits the travel of the sheet table from lowering or raising. 6. UPPER UNWIND ARM LATCH: Designed to secure the upper part of the unwind shaft arm in the raised position while loading a roll of film.
  • Page 29 Voyager Operation and Maintenance Manual Application 5.0 Application 5.1 Loading the sheets The first thing to do is switch on electrical power at the Main Power Switch. Turn on the compressed air WARNING supply and check the supplied pressure at the Air Pressure Regulator.
  • Page 30 Application Voyager Operation and Maintenance Manual c. Slide the feeding head unit to safe position. f. Load the sheets onto the sheet table. d. Fold the top sheet in half and place on sheet table. g. While raising the table, adjust the feed head to rear of the pile.
  • Page 31 Voyager Operation and Maintenance Manual Application c. Press laminator start. 5.2 Feeding head unit At this point you should have loaded sheets onto the table. Making adjustments to the feeding head unit are quick and easy if the steps are followed precisely.
  • Page 32 Application Voyager Operation and Maintenance Manual f. Set the height of the feeding head unit so the pile height h. Adjust the two sheet brushes for slight pressure on the is about 1/8 inch below the feeder gate. sheet stack. i.

  • Page 33: Loading The Film

    Voyager Operation and Maintenance Manual Application When the film roll is properly positioned on the 5.3 Loading the film laminator, the film extends beyond the cut lines. Both edges of the film should lie on the un-printed margins of the sheet. Film will never extend beyond the edge of the sheet because any film exposed to either laminating roller will leave melted adhesive stuck on the roller.
  • Page 34 Application Voyager Operation and Maintenance Manual b. Lift the upper unwind arm and secure with the latch. f. Place the unwind arm back into its saddle and lower the upper unwind arm. c. Swing the unwind arm out enough for you and another person to load the roll of film.
  • Page 35 Voyager Operation and Maintenance Manual Application g. Measure the same distance for the roll of laminate. 5.4 Adjusting the slitter WARNING Caution should always be exercised adjusting the film slitter. Sharp blade can cut you! For application where the film is too wide, slitter is provided to cut the film to the correct width as it is pulled off the film roll.
  • Page 36 Application Voyager Operation and Maintenance Manual b. Loosen the set screws in the two collars of the slitter. You can vary the distance the slitter blade sticks out of the blade holding block. To change the amount of the blade protruding from the block, simply loosen the set screws, slide the blade out or in, and tighten the set screw.
  • Page 37 Voyager Operation and Maintenance Manual Application b. For polyester films, the temperature will be in the range 5.5 Heating of 240 to 260 F ( 115 to 127 C ). c. For GBC LAY-FLAT Films, the starting point The heat is supplied by a 24 kw water heater, temperature will be between 240 to 280 F ( 115 to which transfers heat to its very smooth outer surface for...
  • Page 38 Application Voyager Operation and Maintenance Manual b. Set the temperature for the heat roller. 5.6 Threading Before you thread the film around the heat roller, confirm that the roller is not too hot for your film and the nip pressure and film tension are at reasonable settings for beginning your lamination.
  • Page 39 Voyager Operation and Maintenance Manual Application d. Guide the film under the bow roller and allow the film i. Engage the unwind shaft clutch. to hang about half way over the heat roller. j. Set the unwind brake pressure to 5 p.s.i. (Refer to image above) just enough to hold the film in place.
  • Page 40 Application Voyager Operation and Maintenance Manual m. Press LAMINATOR STOP when the sheet reaches p. Press and hold the E-STOP RESET while pressing the transport wheel. NIP then press JOG FORWARD until about 4 feet of web has passed through the main roller nip. then n.
  • Page 41 Voyager Operation and Maintenance Manual Application s. Guide the web through the snapping rollers. w. Press LAMINATOR START. x. Turn KNIFE & SNAP to “ KNIFE ” position. t. Pull the web taunt and lower the pull roller. y. Adjust the knife cutting position so that the cut is at the edge of the top sheet overlap.

  • Page 42: Film Tension

    Application Voyager Operation and Maintenance Manual There are various ways of adjusting the film tension. 5.7 Over view 1. First adjust the bow to smooth the film out across the bow roller as much as possible, prior to applying the brake tension.
  • Page 43 Voyager Operation and Maintenance Manual Application If the sheet wrinkles going into the nip, decrease Snap rollers the nip pressure. The action of the Snap Rollers is controlled by two flow control valves at the rear of the machine. By limiting the amount of airflow, the speed of the roller When you must adjust the nip pressure, remember closing can be controlled.

  • Page 44: Shutting Down

    Application Voyager Operation and Maintenance Manual 5.8 Shutting down Top web views At the end of the run, take the following Top web views are provided so that you may receive a visual image of the completed web outline. steps: The web views are separated into three views;...

  • Page 45: Periodical Maintenance

    Voyager Operation and Maintenance Manual Maintenance 6.0 Maintenance 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. This section provides instructions for proper cleaning, inspection and lubrication of the equipment.
  • Page 46 Maintenance Voyager Operation and Maintenance Manual This page intentionally left blank. Page 1 - 44 © GBC Films Group April 2000...

  • Page 47: Troubleshooting

    Voyager Operation and Maintenance Manual Troubleshooting The word qualified is defined as; 7.0 TROUBLESHOOTING Qualified ; An outline of the diagnosis and correction of problems that may occur during laminator operation. This section also suggests ways to prevent problems and increase efficiency.
  • Page 48 Troubleshooting Voyager Operation and Maintenance Manual Chart 7.1 Troubleshooting chart Trouble Cause / Action a. Top of paper stack is breaking light beam 1. Table will not automatically compensate in run mode. b. Raise the light sending stick. a. Spring clips, brushes not allowing suction cups to lift, reducing amount of grip b.
  • Page 49 Voyager Operation and Maintenance Manual Troubleshooting Trouble Cause / Action a. Bow roller is out of adjustment b. Brake tension is too loose 4. Film is wrinkling c. Chrome roller is dirty d. Heat is to high e. Extremely poor film quality WARNING A heat roller that has recently been in use may still be hot eneough to burn you!
  • Page 50 Troubleshooting Voyager Operation and Maintenance Manual Trouble Cause / Action CAUTION In some cases, guards may have to be removed. Ensure the guards replaced when problem has been resolved. a. Sheets no feeding into nip smoothly b. Sheets have absorbed too much moisture c.
  • Page 51 Voyager Operation and Maintenance Manual Troubleshooting Trouble Cause / Action a. Heat setting too high b. Film brake tension too high c. Decurl bar angle is too low 7. Product Curling End to End d. Draw roller tension is uneven side to side or Side to Side e.
  • Page 52 Troubleshooting Voyager Operation and Maintenance Manual Trouble Cause / Action a. Snap adjusting valves ( flow controls ) not properly adjusted. b. Skew wheel applying too much or too little bow to the c. Exit roller is not applying enough draw pressure to the left side of the web 10.
  • Page 53 Voyager Operation and Maintenance Manual Troubleshooting Cause / Action Trouble WARNING Air preesure up to 100 psi and above may be applied to the machine. Troubleshooting should be left to qualified technicians! 12. Pneumatic Malfunctions Most pneumatic problems are caused by water or oil present in the system.
  • Page 54 Troubleshooting Voyager Operation and Maintenance Manual Trouble Cause / Action a. Booster pump not producing enough pressure b. Controller not turned on or a no power condition 16. Booster Pump Functions but Circulating Pump does not c. Blown fuse. d. Circulating pump breaker inside has popped a.

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