GBC Voyager Instruction Manual

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GBC Voyager Laminator

Instruction Manual

GBC VOYAGER™ OPERATION

& MAINTENANCE MANUAL

Do not duplicate without written permission.

GBC Pro - Tech

4151 Anderson Road

DeForest, WI 53532

Revision : Ph: ( 608 ) 246 - 8844

Part number : 930 - 047

Fx: ( 608 ) 246 - 8645

V oyager Operation and Maintenance Manual

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!

Installation

1. The GBC V oyager 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.

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.

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Installation

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V oyager Operation and Maintenance Manual

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V oyager Operation and Maintenance Manual

Manual

1.0 THE MANUAL

T o help you operate and maintain your laminator

efficiently and safely , GBC provides this operators manual.

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 4.0 OPERATION

This section describes the controls and instruments, gives instruction for loading and threading film, and provides complete procedures for starting, operating and shutting down the laminator.

Section 5.0 Application

Detailed here are the processes for loading the sheets, setting the feed head unit, loading the film, adjusting the slitter, heating, threading, an over view of operation and shutdown.

Section 2.0 INTRODUCTION TO THE

LAMINATOR

This section describes the features and benefits of the GBC VOYAGER ™, lists optional equipment, and explains the purpose of each part of the laminator.

Section 3.0 SPECIFICATIONS

Provided here are the detailed specifications for

the GBC V oyager .

Section 6.0 Maintenance

Provided here are details on how to keep your

machine running smoothly and efficiently .

Section 7.0 Troubleshooting

This section will assist you in basic and non-basic

troubleshooting in the event a problem should occur .

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Manual

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V oyager Operation and Maintenance Manual

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. Therefore, General Binding Corporation assumes no liability for damages incurred directly or indirectly from errors, omissions, or discrepancies between the laminator and this manual.

Disclaimer

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Disclaimer

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V oyager Operation and Maintenance Manual

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V oyager Operation and Maintenance Manual

1.3 Warranty

GBC Films Group warrants the equipment sold is free from defects in material and workmanship for a period of one ( 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.

GBC Films Group’s sole and exclusive liability and the customer’s sole and exclusive remedy under this warranty shall be, at GBC Films Group’s option, to repair or replace any such defective part or product. These remedies are only available if GBC Films Group’s examination of the product discloses to GBC Films Group’ s satisfaction that such defects actually exist and were not caused by misuse, neglect, attempt to repair , unauthorized alteration or modification, incorrect line voltage, fire, accident, flood, or other hazard.

Warranty

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.

1.3.1 Limited Warranty

This warranty specifically does not cover damage 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 initial one year period from the date of delivery .

1.3.2 Exclusions to the Warranty

This warranty specifically does not cover;

1. Damage to the laminating rolls caused by knives, razor

blades, other sharp objects or failure caused by adhesives.

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Warranty

2. Damage to the machine caused by lifting, tilting and/ or

any attempt to position the machine other than rolling on the installed castors on evensurfaces.

3. Improper use of the machine.

4. Damage due from unqualified person(s) servicing the

machine.

V oyager Operation and Maintenance Manual

Qualified

• Any engineer that has experience with electrical and mechanical design of lamination equipment. The engineers should be fully aware of all aspects of safety with regards to lamination equipment.

• Any commissioning or service engineer must be of competent nature, trained and qualified to GBC ProT ech standards to fulfill that job. This person will have completed and passed the full service training course from GBC Pro-T ech.

• Any GBC T echnician, GBC Specialist, and / or GBC Pro-T ech Technician that has been through the GBC Pro-T ech service training course.

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V oyager Operation and Maintenance Manual

Introduction

2.0 INTRODUCTION TO THE LAMINATOR

Congratulations on your purchase of the GBC

Film Products V oyager one-sided laminator . The V oyager operates at high speeds with polyester, polypropylene and GBC LA Y-FLA T ® thermal lamination films. W ith its high-quality performance and dependability , the V oyager offers the premier laminating capabilities required by today’ s printing and graphics arts industries.

Curl Control

Built-in breaker bar assembly decurls the product.

Control Construction

Fabricated from 3/8 inch ( 10 mm) steel. The

rigid, heavy-duty body improves reliability of operation.

Film Supply Shaft

Mechanical drop-lock chuck that pivots out for

ease of film loading.

2.1 FEATURES

Heated Roller

High-gloss chrome roller is given a 3 RMS micro

finish for superior product quality

Range of Films

Laminator runs polyester, polypropylene and

GBC Lay-Flat thermal films.

W arm-up Time

W arm-up is fast, taking at most 20 minutes.

T emperature Control

Controller provides easy service and accurate control of heat with ability to quickly decrease temperature setting.

WARNING

Speed

One-sided lamination at up to 100 fpm, limited

by the speed of the sheet separator.

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

V oyager Operation and Maintenance Manual

2.2 COMPONENTS OF THE LAMINATOR

Laminating Rollers

The laminating rollers consist of the top, heated chrome roller and the bottom, unheated counter-pressure roller.

Electric Eye Gap Detector

Stops the system automatically if a sheet is misfed.

Heating Unit

Provides heated water to chrome roller with quick

and easy controls, and a self-diagnostic at start-up.

Leveling Feet

Eight adjustable leveling feet are provided to assure proper setup of the laminator.

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Film Supply Shaft

Drop luck manual chuck, that pivots out for ease

of film loading.

V oyager Operation and Maintenance Manual

Introduction

Emergency Stop Button

Pressing this button causes the laminating and pull

rollers to separate and all the rollers to stop.

Nip Pressure Controls

The “On-Off” switch applies air pressure to the laminating rollers. The adjusting knob varies the pressure, and the gauge shows the air pressure.

Speed Control

Turning the knob adjusts the speed at which the

rollers turn.

Upper Roll Temp Controller

This unit displays the actual chrome roller temperature and also allows the operator to adjust the operating temperature of the heat roller, up or down.

FWD/REV Controls

This switch is used to reverse the roll direction

for ease of cleaning and maintenance.

Main Power Switch

Switches on or off, all the power to the laminator and heating unit.

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Introduction

V oyager Operation and Maintenance Manual

Film Slitter

This device cuts the film on-line, to the width needed for a finished product. The unused film remains on the core for ease of disposal.

Bow Roller

Pull Rollers

This pair of rollers helps to draw the film through the laminator, maintaining the web tension across the decurl unit.

Snapping Rollers

This pair of rollers snaps the film enabling the images to be separated after the web has been knicked.

This roller helps to remove wrinkles from the film and increases the dwell time of film on the heated chrome roller. Increased dwell time permits operation at a lower roller temperature.

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.

Knicker Assembly

Places a knick into the web at the set interval.

This allows for the snapping rollers to separate the web.

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V oyager Operation and Maintenance Manual

Introduction

Control panel - Laminator

This panel allows the operator to control the

laminator section in a central location.

Control panel - Heater

Air Pressure Regulator

This control sets the incoming air pressure.

This panel allows the operator to control the

heating section in a central location.

Control panel - Feeder

This panel allows the operator to control the

feeding section in a central location.

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Introduction

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V oyager Operation and Maintenance Manual

3.0 SPECIFICATIONS

Specifications

W orking Widths:

Working Lengths:

Core Size:

Maximum Film Roll Diameter:

Maximum Speed:

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. )

Product Range:

Films:

Rollers:

1-Sided Slitter:

Safety Features:

80 lb. C2S stock to 18 pt. board maximum

1.2 mil to 1.7 mil OPP , PET , GBC LAY-FLAT ®

T op: W ater-heated chrome roller with 3 RMS Bottom: Hyplon rubber-coated

When available film is too wide, slitter can cut film to the proper size.

Safety covers and Emergency stops

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Specifications

V oyager Operation and Maintenance Manual

Electrical Requirements:

Product W arranty:

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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V oyager Operation and Maintenance Manual

Operations

4.0 OPERATION

Operating procedures given in this manual are presented as suggestions for the operator’s consideration. An operator experienced in the art of lamination may prefer different procedures under certain conditions.

Y our new GBC V oyager™ 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 professional quality laminating.

4.1 Laminator controls

1. EMERGENCY STOP ( E-STOP ): When pressed,

stops the machine from operation, raises the heating roller .

2. EMERGENCY STOP RESET: When pressed, resets the machine after an E-STOP has been pressed.

3. SHEET SIZE selector: Enables the operator to select the sheet size ( Short / long ).

This section will explain the controls of the laminator, the feeder and the heating unit. Any control not described within this section is done so intentionally . These controls are not for operator manipulation.

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

4. KNIFE/ KNIFE & SNAP selector: Enables the operator to engage the knife only , knife and snap or neither.

5. JOG FORW ARD: Engages the machine in a forward direction for the duration of the press. When a safety shield is raised, JOG FOR W ARD and E-ST OP RESET must be pressed simultaneously .

6. JOG REVERSE: Engages the machine in a reverse direction for the duration of the press. When a safety shield is raised, JOG REVERSE and E-STOP RESET must be pressed simultaneously .

7. LAMINATOR STOP: When pressed, stops all motion to the machine.

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.

8. LAMINA TOR ST AR T : When pressed, engages all

motion on the machine.

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Operations

V oyager Operation and Maintenance Manual

9. NIP UP/ DOWN: When pressed and illuminates, the

nip roller is in the down position. When pressed and the light extinguishes, the nip roller is in the up position.

10. V ACUUM PUMP selector: Engages or disengages the vacuum pump.

11. LAMINATOR SPEED dial: Adjusts the machine speed. Automatically adjusts the feeder to compensate for the laminator speed change.

12. SHEET EXIT BLOWER dial: Adjusts the amount of air flow comes out the sheet blower valve.

13. SHEET COUNTER: Can be selected to display total sheets or sheets per minute. T otal sheets can be reset back to zero.

14. HOUR METER: Keeps track of the total amount of operating time on your machine.

15. NIP PRESSURE GAUGE: Indicates the amount of pressure presented at the main roller nip.

16. NIP PRESSURE ADJUST dial: Adjusts the amount of pressure presented at the main roller nip.

Figure 4.1.1 Control panel - Laminator

1 2 3 4 5 6 7 8 9

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11 12 13 14 15 16

V oyager Operation and Maintenance Manual

Operations

Other controls on the laminator

1. MAIN POWER ON/ OFF: Engages power to the

machine or removes power to the machine.

OFF ON

2. AIR PRESSURE REGULATOR: Adjusts the amount of incoming air to the machine.

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 the knife when turned.

3. BOW ROLLER ADJUST : Increases film tension or decreases film tension when turned.

5. DECURLING ANGLE ADJUST : when turned can

either add a curling angle or decrease the curling angle of the web.

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Operations

V oyager Operation and Maintenance Manual

6. KNIFE ADJUST : Moves the table and knife from

one side to the other side when turned.

7. PULL ROLLER NIP ADJUST : Raises or lowers the upper pull roll when turned.

9. DRA W ROLLER GUIDES: Guides the sheets after the snap onto the catch table.

10. DRA W CONTROL ROLLER: Adjusts the angle of the sheet exiting the laminator.

8. SNAPPING ADJUST : The right adjust dial controls the control side snapping speed and strength. The left adjust dial controls the drive side snapping speed and strength.

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11. LATERAL FILM ADJUST: Moves the unwind

shaft from one side to the other side when turned.

V oyager Operation and Maintenance Manual

Operations

12. UNWIND BRAKE ON/ OFF: Engages air or

disengages air to the pneumatic brake to the unwind shaft. See image below .

13. PRESSURE ADJUST : Adjusts the amount of air pressure supplied to the pneumatic brake.

Pressure adjust

Clutch ON/ OFF

Pressure guage

4.2 Feeder controls

1 T ABLE UP: Raises the sheet table while pressed. When

released, the sheet table stops. See image below .

2. T ABLE DOWN: When pressed, starts the sheet table to lower . Press again to stop the travel of the sheet table.

Table Up

Table Down

E-STOP

Unwind shaft controls

14. PRESSURE GAUGE: Indicates the amount of air pressure being supplied to the pneumatic brake. See image above.

15. FILM SLITTER PRESSURE ADJUST : Adjusts the amount of pressure applied to the blade pressed against the roll of film. The closer to the roll of film the more pressure applied.

Feeder controls

3. EMERGENCY STOP: When pressed, stops the machine from operation, raises the heating roller. See image above

4. BAFFLE HANDLES: Adjusts the amount of air flow in the conveyor .

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Operations

V oyager Operation and Maintenance Manual

5. CONTROL SIDE TABLE SHEET GUIDE ADJUST : When turned, moves the control 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 sheet clips.

8. LATERAL FEEDING HEAD UNIT ADJUST:

Moves the feeding head unit back or forth.

INFORMATION

Only one handle is provided and

can be used on both adjusters.

6. DRIVE SIDE T ABLE SHEET GUIDE ADJUST : When turned, moves the drive side table sheet guide

closer or farther from the center.

9. FEEDING HEAD UNIT HEIGHT ADJUST:

Adjusts the height of the feeding head suctions cups.

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V oyager Operation and Maintenance Manual

Operations

4.3 Heater unit controls

1. FLOW PUMP ON/ OFF: Turns the flow pump in the heater unit on or off. Refer to Figure 4.3.1 Switches.

2. MANUAL AIR VENT : When presses, engages the

air venting system. When released, reverts to the off position. Refer to Figure 4.3.1 Switches.

Figure 4.3.1 Switches

5. POWER INDICA TOR LIGHT : Illuminates if power to the heater unit is supplied. Refer to Figure 4.3.2 Indicators.

Figure 4.3.2 Indicators

3. FEEDER PUMP ON/ OFF: Turns the system

pressure pump on or off. This should be turned on first at 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.

6. FLOW PUMP INDICATOR LIGHT: When illuminated indicates the flow pump is on. See image above. Refer to Figure 4.3.2 Indicators.

7. FLOW TEMPERA TURE DISPLA Y : Displays the flow temperature for delivery ( Default ) or return.

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Operations

V oyager Operation and Maintenance Manual

8. SET POINT DISPLA Y : Displays the current set point

value for the heater unit.

9. SET POINT UP: When pressed increases the set point value of the heater unit.

11. DELIVER Y PRESSURE GAUGE: Displays the amount of pressure build up from the delivery system.

12. RETURN PRESSURE GAUGE: Displays the amount of pressure build up from the return system.

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.

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13. RESERVOIR SITE GLASS: Indicates the volume

of heat transfer medium in the heater unit.

V oyager Operation and Maintenance Manual

Operations

14. RESERVOIR FILL PORT: This is where the

operator would fill the reservoir with water if the reservoir site glass is at less than the half mark.

4.4 Safety features

2. SAFETY SHIELD - HEA T 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. SAFETY SHIELD - PULL ROLLERS: This shield covers the knife section as well as the pull rollers. 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 .

1. EMERGENCY STOPS: Three exist around the

V oyager laminator . T wo are located on the control side of the machine and the third is located on the drive side on top of the electrical box.

4. SHIELD INTERLOCKS: Keys on the safety shields must be inserted into the interlocks for the laminator to operate in auto run mode.

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Operations

5. T ABLE 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.

V oyager Operation and Maintenance Manual

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.

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V oyager Operation and Maintenance Manual

Application

5.0 Application

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.

WARNING

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 supply and check the supplied pressure at the Air Pressure Regulator. Y ou need 100 psi ( 700 kp).

To load the sheets, take the following steps:

a. Lower the table.

The laminator will only operate if all

E-STOPs are unlatched, safety shields

are in the fully closed position and the

E-STOP RESET is not flashing.

Before you begin laminating, check all safety

devices and controls for proper operation.

Y ou 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.

b. Adjust the table sheet guides apart enough to accommodate the sheet size to be loaded.

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Application

V oyager Operation and Maintenance Manual

c. Slide the feeding head unit to safe position.

d. Load the sheets onto the sheet table.

f. Adjust the left and right table sheet guides so the crease

of the folded sheet aligns with the center table sheet guide.

g. Raise the table.

e. Fold the top sheet in half and replace back on top of

the sheet stack.

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INFORMATION

The eletric eye will stop the table at the

right height when pressing table up

V oyager Operation and Maintenance Manual

Application

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 .

To load the sheets, take the following steps:

a. Slide the feeding head unit forward toward the sheet

stack.

c. Press laminator start.

INFORMATION

Do not turn the VACUUM PUMP on.

You only want the feeding head

unit to move, not feed sheets.

b. Stop when the sheet stack tabs make slight contact with the back of the sheets.

d. Set laminator speed to 15.

e. Use the feeding height adjust to set the feeding head

unit height.

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Application

V oyager Operation and Maintenance Manual

f. Set the height of the feeding head unit so the suction

cups come down and kiss the top sheet.

h. Adjust the two sheet brushes for slight pressure on the sheet stack.

CAUTION

Do not allow the suction cups to jam

down into the sheet stack!

g. Press laminator stop.

i. Adjust the four sheet clips for slight pressure on the

sheet stack.

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V oyager Operation and Maintenance Manual

Application

5.3 Loading the film

CAUTION

Ensure the roll of laminate is loaded

properly on the unwind shaft.

Exposed adhesive should be facing

away from the heated roller.

When the film roll is properly positioned on the laminator, the film extends beyond the cut lines. Both edges of the film should lie on the unprinted 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 .

The rollers must be kept free of adhesive at all times during the laminating process!

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.

WARNING

Always use safe and proper lifting practices when lifting heavy objects. You can become

seriously injured or crushed.

The film roll ( or the portion of a slit roll that will be used ) should be mounted onto the film shaft. Position the product being laminated to obtain the desired margin at the edge of the sheets.

Slight shifts of film position can happen during a lamination run. These shifts can cause problems, if adequate unprinted margins were not allowed for at the edges of the sheet. If the film has been started very near the edge of the sheet to cover the cut lines, it may shift enough to cause adhesive to stick to the rollers. On the right side, applying film too close to the edge of the sheet can interfere with proper operation of a separator. Also, if the right edge of the film is sticking to ink instead of paper, operation of a snapping roller may not be satisfactory.

T o position the film roll, take the following steps:

CAUTION

Before threading begins, ensure the

heat transfer roller is not too hot for

the film being used.

a. Place a sheet at the location where you want it to feed

in for lamination.

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Application

V oyager Operation and Maintenance Manual

b. Lift the upper unwind arm and secure with the latch.

c. Swing the unwind arm out enough for you and another

person to load the roll of film. refer to image above.

d. Remove the one core end and the core gripper .

f. Place the unwind arm back into its saddle and lower

the upper unwind arm.

f. T o correctly position the left edge of the film, measure the distance from the left-hand inner face of the laminator to the edge of the sheet.

WARNING

Always use safe and proper lifting practices when lifting heavy objects. You can become

seriously injured or crushed.

e. Slide the roll of film on the unwind shaft with regards to the laminate used.

CAUTION

If the edge of the film is set in too far

from either edge of the sheet, the sheet

may be damaged due to insufficient

mechanical support from the film.

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V oyager Operation and Maintenance Manual

Application

g. Measure the same distance for the roll of laminate.

INFORMATION

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.

If not exactly centered, lateral film

adjustment can be made during the

webbing process.

INFORMATION

If the edge of the film is adhered to ink

a oppose to paper, the snapping quality

may be less than acceptable.

T o position the slitter, take the following steps:

a. Determine the distance from the left-hand inner face of

the laminator to the point on the sheet where you want the drive side edge of the film to lie.

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Application

V oyager Operation and Maintenance Manual

b. Loosen the set screws in the two collars of the slitter .

c. Slide the Slitter to the location that will let it cut through

your marked point.

Y ou can vary the distance the slitter blade sticks out of the blade holding block. T o 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 .

The blade holding block generally should be at a right angle with the slitter frame, however, you can vary the angle at which the blade meets the roll. T o change the 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 swinging the cylindrical weight toward the slitter support bar ( to decrease pressure ) or away from the bar ( to increase pressure ).

d. Slide the collars so they are snug against the slitter frame and tighten the set screws.

Try to avoid removing the slitter blade from a cut once you have been slitting. If you must adjust or withdraw the blade and then resume slitting, move the slitter slightly in toward the middle of the sheet. Trying to put the blade back exactly where you were slitting before, usually procedures very thin slivers of film ( “angel hair” ) that cause problems with the laminator and the product.

WARNING

To avoid injury when the slitter is not in

use, move the blade completely inside

the holder and secure in place.

Adjust the slitter blade and pressure on the blade, so that the blade cuts the film cleanly and the wheel that rides on the roll does not wrinkle or mark the film. If the film roll has imperfections, you may need more pressure and/or more blade extension.

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V oyager Operation and Maintenance Manual

Application

5.5 Heating

The heat is supplied by a 24 k W water heater, which transfers heat to its very smooth outer surface for optimum heat transfer to the film. The heat has a selfcontained controller which maintains a very precise temperature. With 24,000 watts of heating power , the system heats very rapidly and remains at +/- 5 oF ( +/ - 2

C ) of set temperature at full speed with the full range of paper stocks and sizes. The closed-loop water heat system provides both large amounts of available heat at the nip, yet prevents large temperature swings up or down from the set.

The temperature control unit is easy to use, and

performs a self-diagnostic during start-up.

b. For polyester films, the temperature will be in the range of 240 to 260 oF ( 115 to 127 oC ).

c. For GBC LAY-FLAT Films, the starting point temperature will be between 250 to 280 oF ( 121 to 138

C ).

Thicker paper, darker colors and higher speed of

operation result in a need for higher temperatures.

At the upper end of their usable temperature ranges, films tend to get soft and “neck” ( get narrower because of stretching ). in extreme cases become wrinkly . Polypropylene is especially likely to suffer these distortions.

INFORMATION

When using or ,

- must be pressed in conjunction.

There are a few rules of thumb that you may use

as a starting point in selecting the roller temperature.

a. For polypropylene films, the temperature will be in the range of 200 to 240 oF ( 90 to 115 oC ).

When shutting the system down for the day , bring temperature of closed-loop system down to at least 180

F before removing power to the unit.

Cooling is accomplished by domestic water and a heat exchanger, which allows instant change over of films that require lower temperatures. Cooling for shutdown is only a matter of minutes.

WARNING

Touching the heat roller during operation

or soon after shutdown can result in

severe burns !

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Application

V oyager Operation and Maintenance Manual

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.

GBC Films Group recommends that you use the following procedure to thread the film through the laminator. 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.

b. Set the temperature for the heat roller .

WARNING

Caution should always be exercised

when using the laminator with

the safety shields raised.

You can be seriously HURT or INJURED!

T o thread the laminator, take the following steps:

a. Switch on power at the Main Power Switch.

c. When the heat roller has become hot enough to laminate

the film, raise the heat roller safety shield.

CAUTION

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CAUTION! Heat roller is HOT !

V oyager Operation and Maintenance Manual

Application

d. Guide the film under the bow roller and allow the film

to hang about half way over the heat roller.

e. Adhere one sheet to the activated film on the heat roller.

i. Engage the unwind shaft clutch.

j. Set the unwind brake pressure to 5 p.s.i. Refer to image

above Just enough to hold the film in place.

f. Guide the free end of the sheet into the main nip rollers.

k. Turn VACUUM PUMP to “ ON ”

l. Press LAMINA TOR STAR T .

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Application

V oyager Operation and Maintenance Manual

m. Press LAMINA TOR ST OP when the sheet reaches

the transport wheel.

n. Raise the pull roller safety shield

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.

o. Close the main roller safety shield.

INFORMATION

The E-STOP RESET must be

pressed and held in step " p ".

Page 1 - 38

r. Guide the web through the pull rollers.

V oyager Operation and Maintenance Manual

Application

s. Guide the web through the snapping rollers.

t. Pull the web taunt and lower the pull roller .

v. Close the pull roller safety shield.

w. Press LAMINA TOR STAR T .

x. Turn KNIFE & SNAP to “ KNIFE & SNAP ”

position.

u. Turn the knife adjust wheel so that approximately 1/2 in. of the blade is over the web.

y. Adjust the knife cutting position so that the cut is at

the edge of the top sheet overlap.

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Application

V oyager Operation and Maintenance Manual

5.7 Over view

An over view is provided to explain how certain adjustments are determined and to give you, the operator, a more insightful view of an adjustment.

Nip pressure

Many factors affect the choice of the nip pressure. Factors you should consider may include: kinds of material in film and paper stock, thickness of adhesive, paper grain length and grain direction, as well as thickness and size of sheet. Laminating thick sheets may call for high pressure to minimize “tenting” at the end of the sheet. Paper will not tolerate as much nip pressure after it has been exposed to high humidity .

There are various ways of adjusting the film tension.

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. Apply film tension by turning the air pressure adjusting knob on the control panel. Wrinkles in the film will give a “waterfall” -like appearance to the film near the point where it meets the chrome roller.

3. By slowly turning the adjusting knob, adjust tension so the “waterfall” extends no more than halfway around the chrome roller.

Breaker bar

If you are using material like foam board or corrugated board, that must be protected from crushing, you can apply just enough air pressure to overcome the resistance of the springs and bring the chrome roller into contact with the sheets.

Film tension

Several factors may affect the choice of film tension. These factors include the speed of operation, size of the film roll, and use of the slitter.

Because the action of the brake at the Film Supply Shaft stretches the film before it is applied, the tension in the film tends to bow the laminated product upward. T o counteract the bowing tendency , the laminator “breaks” the paper. That is, while the laminated sheets are still hot, they are pulled over the edge of a breaker bar to stretch the film more and impart a downward curl to the product. Thick sheets may not require breaking.

Pull rollers

The Pull Rollers, located after the knicking section of the laminator, run slightly faster than the laminating rollers, to keep the web tight as it goes over the breaker bar . During any laminating operation, the pull rollers are applied by rotating the lever attached to the lower pull roller .

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V oyager Operation and Maintenance Manual

Application

Snap rollers

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 closing can be controlled. Limit the amount of air flow for the roller to close, and snap the sheets, with the operator side closing slightly ahead of the drive side.

Skew wheel assemblies

This assembly consist of 2 Exit rollers on the operator’s side. Pull the web out straight and one angle roller assembly on drive side. Skew the web to the right, causing the side to bow upward. This bow is controlled by the amount of angle and pressure ( which are adjustable ) that is applied by the skew wheel.

If the sheet wrinkles going into the nip, decrease

the nip pressure.

When you must adjust the nip pressure, remember

that this adjustment can change the amount of under lap.

Do-earing at the breaker bar indicates that the

amount of under lap needs to be reduced.

Check often during the lamination operation to see whether film tension is correct. T oo much tension can cause curl or necking. As the film rolls get smaller, the tension needs adjustments to keep getting the same results. Changing speed of operation may require a change in tension.

The amount of web bow should be just high enough to allow sheet separation by snap rollers. This bow allows a flatter left to right closing of the snap roller giving a cleaner separated edge to the sheet.

Adjustments during a run

When you are increasing 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 tension was set without slitting, applying the

slitter will probably result in the need to adjust the tension.

Heat from the laminated web warms the breaker bar assembly . After the assembly has warmed up, you may need to adjust the breaker bar to obtain the best break.

The tendency of the web to curl is affected by laminating temperature and film tension, therefore adjustments in those machine settings may result in a need to adjust the breaker bar. Another factor that affects curling, is moisture in the sheet.

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Application

V oyager Operation and Maintenance Manual

Top web views

T op web views are provided so that you may receive a visual image of the completed web outline. The web views are separated into three views; Feeder, Laminator, and Exit.

Feeder

5.8 Shutting down

At the end of the run, take the following steps:

a. Press LAMINA T OR STOP.

b. Raise the pull roller.

c. Separate the main rollers.

Laminator

Exit

d. Cool heater to 180 oF.

e. Turn MAIN POWER to “ OFF ”.

f. Turn off the compressed air at the Air Pressure

Regulator.

T aking air pressure off the laminating rollers when they are not in use, prevents the development of a flat spot on the counter-pressure roller. W ith no pressure in the pneumatic cylinders, gravity holds the rollers apart.

Page 1 - 42

V oyager Operation and Maintenance Manual

Maintenance

6.0 Maintenance

This section provides instructions for proper

cleaning, inspection and lubrication of the equipment.

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!

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 ScotchBrite, to remove the adhesive.

T o prevent damage to roller surfaces, never use metal tools or abrasive cleaners to clean either of the Laminating Rollers.

6.2 Periodical Maintenance

6.1 Daily Cleaning

The Laminating Rollers must be kept free of adhesive throughout the laminating process.

Clean the Chrome Roller with a soft rag and mineral spirits, preferably while the roller is still warm.

Lightly oil chains and idler sprockets once a month.

Oil all bushings once a month.

T o prevent rust, a light film of WD40 should be applied to all bare metal parts as necessary .

Lubricate all rollers at the grease fittings on the bearings every six months.

A Chrome Roller that has recently been in use may still be hot enough to burn you.

In some cases, guards may have to be removed. Be sure to replace them when maintenance has been completed.

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Maintenance

This page intentionally left blank.

V oyager Operation and Maintenance Manual

Page 1 - 44

V oyager Operation and Maintenance Manual

7.0 TROUBLESHOOTING

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 .

To avoid injury to yourself or damage to equipment, please read and understand the instructions in this manual before you attempt to install, operate, or service the laminator!

Troubleshooting

The word qualified is defined as;

Qualified ;

• Any engineer that has experience with electrical and mechanical design of lamination equipment. The engineers should be fully aware of all aspects of safety with regards to lamination equipment.

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!

Refer to Chart 7.1 T roubleshooting starting on page 1-44.

• 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.

• Any GBC T echnician, GBC Specialist, and / or GBC Films Group T echnician that has been through the GBC Pro-T ech service training course.

An important feature of the Titan 165/ 110

laminator are the safety latches and the interlocks. The front safety shield (Figure 1.2.1) and the feed table (Figure 1.2.2) are both equipped with safety latches. When a safety latch is not in the locked position, the motor is disabled.

WARNING

Any procedure requiring the removal of a

cabinet cover or guard should be performed

by a qualified technician only.

Page 1 - 45

Troubleshooting

Chart 7.1 Troubleshooting chart

V oyager Operation and Maintenance Manual

Trouble

1. Table will not automatically compensate in run mode.

2. Feed head will not pick up or advance sheets.

Cause / Action

a. T op of paper stack is not breaking light beam

b. Stack too low to gate - Raise head

a. Spring clips, brushes not allowing suction cups to lift, reducing

amount of grip

b. Blower air on foot needs to be increased by opening valve, air must slightly lift leading edge of sheet.

c. V ent hole on air pump is plugged, reducing the vacuum clean it.

d. Check for disconnected or broken air lines

e. Missing or cracked suction cups

3. Lay Varying

a. Vacuum on feed table needs to be adjusted up or down.

b. Upper infeed wheels not properly adjusted to head stop.

Adjust them so that the infeed wheels contact lower infeed wheels when the the head stops are flush within feed tray . Wheels must spin with little contact.

c. Sheet paddles allowing paper to hop over head-stops or causing the sheets to stop at head-stops before the wheels come lower .

d. Loose drive chains - check and tighten.

e. Worn or broken drive train parts on the feeder or on the

laminator - Replace.

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V oyager Operation and Maintenance Manual

Troubleshooting

Trouble

4. Film is wrinkling

Cause / Action

a. Bow roller is out of adjustment

b. brake tension is too loose

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!

5. Film Quality & Adhesion

a. Heat is not properly set for film type

T oo High - film melts, stretches, bubbles

T oo Low - silvering, milky , no adhesion

b. Bow Roller is not adjusted correctly, allowing an air pocket

between film and roller

c. Film has absorbed moisture or is aged

d. Dyne level too low for product

e. Dirty or damaged heat or nip rollers

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Troubleshooting

V oyager 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. Job is running too fast to dry out moisture content of the

sheets

6. Product Wrinkling in Nip

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. W orn or damaged nip roller

i. W orn or damaged heat roller

INFORMATION

Changing grain direction of sheets

may remove wrinkles.

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V oyager Operation and Maintenance Manual

Troubleshooting

Trouble

7. Product Curling End to End or Side to Side

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

e. Draw roller tension is uneven side to side

f. Roller bearing worn or broken at heat, draw or snap

roller

g. W orn draw roller or guide cylinder

h. Snap roller closing not adjusted properly

8. Knife Not Working or Working Erratically

9. Knife Function OK but Missing the Lap

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. Maladjusted cushioning valve or flow control unit

e. W orn or broken knife mechanism

f. Prox. switch or Read switch not properly adjusted

or aligned.

a. Film too close to edge side of sheet

b. Knife adjust not properly set for higher speed -

advance the setting

c. Guide Pin/Knife spacing not properly set for type of paper

d. Knife position of edge of web needs

e. Lap setting too high or too low

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Troubleshooting

V oyager Operation and Maintenance Manual

Trouble

10. Web Separates in Wrong Lap Position

1 1. Snap Rollers Activating but Not Separating or Partially Separating

Cause / Action

a. Draw roller pressure too tight

b. Knife timing is too early

c. Knife is knicking too far into the lap

d. Lap is too large, leading edge is folding under and catching

on the knife, brush etc.

a. Snap adjusting valves ( flow controls ) not properly adjusted.

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. Insufficient nip pressure applied at laminating process

e. Insufficient nip pressure applied at nip or draw roller

12. Electrical Malfunctions Component Not Functioning

f. Knicking knife not cutting film at lap or cutting into paper

after knicking lap. This condition can happen is lap varies greatly .

g. Full bleed of ink and / or coating of sheets

h. W orn snap roller, exit roller or skew wheel

ELECTRICAL

SHOCK

Electrical troubleshooting should be

left to qualified technicians!

Electrical shock hazard!

a. Fuse or circuit breaker blown

b. Disconnected wire

c. Component opened electrical

Page 1 - 50

d. Push reset button

V oyager Operation and Maintenance Manual

Troubleshooting

Trouble

13. Pneumatic Malfunctions

Cause / Action

WARNING

Air preesure up to 100 psi and above may be

applied to the machine. Troubleshooting

should be left to qualified technicians!

Most pneumatic problems are caused by water or oil present in the system. This type or liquid contamination causes impaired air flow , sticking or internal air components, and premature wear of not only pneumatics, but excessive wear of the components that they operate.

Heat Malfunctions

14. Power Applied, but Will Not Run

15. Low Water Pressure From Booster Pump

a. Low water level in tank

b. Thermo-safety switch open or activated

c. Motor overload switch needs resetting

d. Blown fuses

e. Booster pump motor burn out

f. Unit needs power phasing

a. V enting valve stuck open

b. Pressure regulating valve maladjusted of stuck open

c. Pump rotating in wrong direction

d. W ater leak

Page 1 - 51

Troubleshooting

V oyager Operation and Maintenance Manual

Trouble

16. Booster Pump Functions but Circulating Pump does not

17. Temperature Shows a Certain Number but will not Reach Set Point

Cause / Action

a. Booster pump not producing enough pressure

b. Controller not turned on or 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. Controller malfunction

d. T emperature Probe malfunction

18. Temperature Takes a Long

19. Temperature Delay Jumping Up & Down in Temperature

a. Heating element burn out- will not hold temperature while

running

b. V enting valve is stuck open- steam coming out of tank vent after reaching set point

c. Malfunctioning controller or temp. probe

d. Relief valve from heat exchange is leaking water; always

come out of drain

a. Malfunctioning probe

b. Malfunctioning controller

c. Closed-loop system needs venting

d. Controller must be auto-tuned; follow instructions on top

of unit

20. Water Leaks in ClosedLoop System

Page 1 - 52

a. Repair all leaks by tightening or replacing seals, gaskets

and components as necessary .

GBC Voyager Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual