GBC VOYAGER Instruction Manual
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GBC VOYAGER Instruction Manual

GBC VOYAGER Instruction Manual

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GBC Voyager Laminator
Instruction Manual

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  • Page 1 GBC Voyager Laminator Instruction Manual...
  • Page 2 GBC VOYAGER™ OPERATION & MAINTENANCE MANUAL © March 2000 GBC Films Group Do not duplicate without written permission. GBC Pro - Tech 4151 Anderson Road DeForest, WI 53532 Revision : Ph: ( 608 ) 246 - 8844 Fx: ( 608 ) 246 - 8645...

  • Page 3: Installation Precautions

    1. The GBC Voyager System must only be installed by a GBC employed technician. 2. Any moving or uninstalling 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 © GBC Films Group April 2000...
  • Page 5 This section describes the controls and To help you operate and maintain your laminator instruments, gives instruction for loading and threading film, efficiently and safely, GBC provides this operators manual. and provides complete procedures for starting, operating and shutting down 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

    ( 1 ) year parts and 90 days labor from the date of installation. This warranty is the only warranty made by GBC Films Group and cannot be modified or amended. THE WARRANTY MADE HEREIN IS IN...
  • Page 10 • Any commissioning or service engineer must be of competent nature, trained and qualified to GBC Pro- Tech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-Tech.
  • Page 11 Fabricated from 3/8 inch ( 10 mm) steel. The Congratulations on your purchase of the GBC rigid, heavy-duty body improves reliability of operation. Film Products Voyager one-sided laminator. The Voyager operates at high speeds with polyester, polypropylene and GBC LAY-FLAT ® thermal lamination films. With its...

  • Page 12: Components Of The Laminator

    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 water to chrome roller with quick chrome roller and the bottom, unheated counter-pressure and easy controls, and a self-diagnostic at start-up.
  • Page 13 Voyager Operation and Maintenance Manual Introduction Emergency Stop Button Speed Control Pressing this button causes the laminating and pull Turning the knob adjusts the speed at which the rollers to separate and all the rollers to stop. rollers turn. Upper Roll Temp Controller...
  • 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 helps to draw the film through needed for a finished product. The unused film remains the 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

    100 fpm ( 30.5 m/min. ) Product Range: 80 lb. C2S stock to 18 pt. board maximum Films: 1.2 mil to 1.7 mil OPP, PET, GBC LAY-FLAT ® Rollers: Top: Water-heated chrome roller with 3 RMS Bottom: Hyplon rubber-coated 1-Sided Slitter: When available film is too wide, slitter can cut film to the proper size.
  • 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, resets the machine after an E-STOP has been pressed. Your new GBC Voyager™ Laminator is a durable 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 3.
  • 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 down position. When pressed and the total sheets or sheets per minute. Total sheets can be reset light extinguishes, the nip roller is in the up 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.
  • Page 22 Operations Voyager Operation and Maintenance Manual 6. KNIFE ADJUST: Moves the table and knife from 9. DRAW ROLLER GUIDES: Guides the sheets after one side to the other side when turned. the snap 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.
  • 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

    REVERSE buttons are pressed simultaneously. 4.4 Safety features 1. EMERGENCY STOPS: Three exist around the Voyager laminator. Two are located on the control side of the machine and the third is located on the drive side on top of the electrical box.
  • 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 You will obtain the best lamination by using the minimum roller temperature, nip pressure, film tension and brake required to do the job. Read the Over view to obtain a better understanding of the Voyager before proceeding. © GBC Films Group April 2000...
  • Page 30 Application Voyager Operation and Maintenance Manual c. Slide the feeding head unit to safe position. f. Adjust the left and right table sheet guides so the crease of the folded sheet aligns with the center table sheet guide. d. Load the sheets onto the sheet table.
  • 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 suction h. Adjust the two sheet brushes for slight pressure on the cups come down and kiss the top sheet. sheet stack. i. Adjust the four sheet clips for slight pressure on the CAUTION sheet stack.

  • Page 33: Loading The Film

    Exposed adhesive should be facing times during the laminating process! away from the heated roller. 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.
  • 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 37 240 to 260 F ( 115 to 127 C ). c. For GBC LAY-FLAT Films, the starting point The heat is supplied by a 24 k W water heater, temperature will be between 250 to 280 F ( 121 to 138 which transfers heat to its very smooth outer surface for C ).
  • Page 38 WARNING GBC Films Group recommends that you use the following procedure to thread the film through the Caution should always be exercised laminator. Threading may be done in other ways, but this...
  • 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.
  • Page 41 Voyager Operation and Maintenance Manual Application s. Guide the web through the snapping rollers. v. Close the pull roller safety shield. w. Press LAMINATOR START. t. Pull the web taunt and lower the pull roller. x. Turn KNIFE & SNAP to “ KNIFE & SNAP ”...

  • 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...

  • 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 solvent. 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

    • Any commissioning or service engineer must be of competent nature, trained and qualified to GBC Films Group standards to fulfill that job. This person will have completed and passed the full service training course from GBC Films Group.
  • Page 48 Troubleshooting Voyager Operation and Maintenance Manual Chart 7.1 Troubleshooting chart Trouble Cause / Action a. Top of paper stack is not breaking light beam 1. Table will not automatically compensate in run mode. b. Stack too low to gate - Raise head a.
  • 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...
  • 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 d. Draw roller tension is too high 7. Product Curling End to End e.
  • Page 52 Troubleshooting Voyager Operation and Maintenance Manual Trouble Cause / Action a. Draw roller pressure too tight b. Knife timing is too early 10. Web Separates in Wrong c. Knife is knicking too far into the lap Lap Position d. Lap is too large, leading edge is folding under and catching on the knife, brush etc.
  • 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! 13. 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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