Voyager 3
OPERATION MANUAL
®
Part Number: 930-032 REV: A REV DATE: 04-02-04
©2004 GENERAL BINDING CORPORATION ALL RIGHTS RESERVED.
Do not duplicate without written permission.
Operations Manual
Voyager 3
Voyager 3
2004 General Binding Corporation
I
TABLE OF CONTENTS
1.0 Safety
1.1 Explanation of symbols 1-1
1.2 General Rules of safety 1-2
1.3 Emergency Stops 1-4
1.4 Safety Shields 1-4
1.5 Pneumantics 1-5
1.6 Heat 1-5
1.7 Safety labels 1-6
1.8 Know Your laminator 1-10
2.0 Warranty
2.0 Limited 90-day warranty 2-1
3.0 Specifications
3.1 Machine Specification 3-1
3.2 Feeder Specifications 3-2
3.3 Feeder Pump and Specifications 3-3
3.4 Heater 3-4
4.0 Installation
4.1 Pre-installation 4-1
4.1.1 Suggested Floor Layout 4-3
4.1.2 Connections 4-4
4.2 Receiving the crates 4-5
4.3 Uncrating 4-5
4.4 Positioning the components 4-6
4.4.1 Component placement 4-8
4.5 Safety Checklist 4-9
5.0 Operations
5.1 Feeder 5-3
5.2 Laminator 5-6
5.2.1 Control Panel 5-7
5.2.2 Unwind controls 5-10
5.3 Stacker 5-15
5.4 V acumn pressure 5-16
5.5 Heater 5-16
6.0 Applications
6.1 Start-up procedure 6-1
6.2 Shut down procedure 6-3
7.0 Maintenance and troubleshooting
7.1 Daily cleanng 7-1
7.2 Periodical Maintenance 7-1
7.3 Troubleshooting 7-2
8.0 Appendix
Appendix A — Heater Manuals 8-3
Appendix B — Pump Manual 8-5
Appendix C — Diagrams 8-7
2004 General Binding Corporation
II
Operations Manual
Voyager 3
Voyager 3
2004 General Binding Corporation
III
The information in this publication is provided for reference and is believed to be
accurate and complete. GBC is not liable for errors in this publication or for incidental or
consequential damage in connection with the furnishing or use of the information in this
publication, including, but not limited to, any implied warranty of fitness or merchantability
for any particular use.
GBC reserves the right to make changes to this publication and to the products
described in it without notice. All specifications and information concerning products are
subject to change without notice.
Reference in this publication to information or products protected by copyright or
patent does not convey any license under the rights of GBC or others. GBC assumes no
liability arising from infringements of patents or any other rights of third parties.
This publication is copyrighted © 2003 by GBC. All rights reser ved. The information
contained in this publication is proprietary and may not be reproduced, stored, transmitted,
or transferred, in whole or in part, in any form without the prior and express written
permission of GBC.
2004 General Binding Corporation
IV
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-1
1.0 Safety
CAUTION:Do not attempt to operate y our
Voyager 3 Laminator until you completely
read and understand this and all related
Operations Manual.
Your safety, as well as the safety of others, is important to GBC. This section contains important safety
information pertaining to the Voyager 3 Laminator
which must be adhered to while operating, cleaning
and performing basic maintenance in and around
the machine.
For important safety information regarding the
Becker Pump, Soma Feeder or Sterlco
Water Temperature Control Unit, read the
operation manual provided by each of the components manufacturer.
FCC NOTE
This equipment has been tested and found to
comply with the limits for a
Class A digital device, pursuant to Part 15 of
the FCC Rules.These limits
are designed to provide reasonable protection
against harmful interference
when the equipment is operated in a commercial environment.
This equipment generates, uses, and can radiate radio frequency energy and,
if not installed and used in accordance with the
Operator Manual, may cause
harmful interference to radio communications.
Operation of this equipment in
a residential area is likely to cause harmful
interference in which case the
user will be required to correct the interference
at his/her own expense.
CA
UTION: CHANGES OR MODIFICATIONS NOT EXPRESSLY
APPROVED BY GENERAL BINDING CORPORATION COULD VOID
YOUR AUTHORITY TO OPERATE
THE EQUIPMENT.
Canada Class A Notice - Avis Canada,
Classe A
This Class A digital apparatus complies with
Canadian ICES-3.
Cet appareil numérique de la classe A est conforme à la norme
NMB-003 du Canada.
1.1 Explanation of symbols
INFORMA
TION:
This symbol used to
inform you of important information pertaining to the current subject.
CA
UTION: When you see this symbol,
use caution to avoid harm to you, or others around you.
W
ARNING: This symbol is used to inform
you of a dangerous situation and tells you
how to avoid harm to you, others around
you or to the equipment
ELECTRICAL HAZARD: This symbol is
used to prevent an electrical shock condition that may be caused by an operators
action or machine function.
CA
UTION: When you see this word without a sym-
bol, it means the action described may result in
machine damage.
If for any reason you are unsure of what a symbol
represents, contact your local sales/service representative for further explanation.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-2
1.2 General rules of safety
ELECTRICAL HAZARD: Do not operate
the laminator if power cord is damaged or
frayed.You can be severely shocked, electrocuted or cause a fire.
ELECTRICAL HAZARD:
Employ a
licensed electrician to provide electrical
requirements for the laminator.
ELECTRICAL HAZARD:
Employ a
licensed plumber to provide tap and
drain requirements for the laminator.
ELECTRICAL HAZARD
: Do not use liquid or aerosol cleaners on the laminator.
Do not spill liquid of any kind on the laminator.You can be severely shocked, electrocuted or cause a fire.
ELECTRICAL HAZARD:
Never disconnect any cable on the laminator
while power is supplied. Servicing
should be left to qualified service representatives only.
ELECTRICAL HAZARD:
Do not attempt
to repair or service the laminator.
Servicing should be left to qualified service
representatives only.
W
ARNING: Do not operate this laminator
if you are not physically, psychologically or
emotionally fit. Do not operate this
machine until you have been trained and
read this manual in it’s entirety.
W
ARNING: Do not wear ties, loose fitting
clothes 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.
W
ARNING: Never tamper with the safety
devices to increase the laminator’s production capacity. In the event a safety
device should fail, never attempt to
bypass it for operation. Consult a service
representative immediately.
W
ARNING: To prevent injury to others
working around the laminator, only one
person may control the functions of the
laminator during operation or servicing.
CA
UTION: The operating environment
must be free of dust, flammable liquids
and vapors.
Operations Manual: Safety
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2004 General Binding Corporation
Page 1-3
CAUTION:Vapor build up or stored flammable liquids can cause a fire.Excessive
dust can damage the laminator.
CA
UTION: Exercise extreme caution
when working around or replacing the
film cutter blade.This blade is sharp and
cut you.
CA
UTION: Keep feet away from the feed-
er pile table when lowering to ground
level.
CA
UTION: Avoid contact with the heat
roller during webbing, operation, un-webbing, changing film or after heat has been
removed from the laminator.
CA
UTION: Always observe all warning
labels placed at various points on the
laminator.If you do not completely understand a label, contact your local service
representative for further explanation.
CA
UTION: Always follow proper shut-
down procedure as described in this
manual when turning the laminator off.
CA
UTION: Only use materials specified
in this manual for cleaning of the laminator and routine maintenance.
CA
UTION: The laminator may only be
moved by a qualified service representative.Improper disconnection or reconnecting can result in injury to you and/ or damage to the laminator.
CA
UTION: Never use this machine for
any other purpose than its intended
design and function.You may be injured.
The following actions can result in
machine damage.
CAUTION: Do not make any modifications to this
laminator.Unauthor ized changes will void your warranty and may cause extensive repairs or create
poor output quality.
CA
UTION: Do not locate the laminator where air is
blowing directly on the machine. The air flow can
cool the rollers unevenly and result in poor output
quality.
CA
UTION: Only use acceptable materials through
this laminator. Unacceptable materials may cause
damage to the rollers or cause poor output quality.
CA
UTION: Do not place the laminator on uneven
surfaces.This will effect the operation of the laminator and will result in poor output quality.
INFORMA
TION: Any concer ns for safety
or operation should be brought to the
attention of your local service representative immediately.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-4
Jog/Slow Speed w/Guard Open
1.3 Emergency stops (E-Stop)
The Voyager 3 is equipped with three E-Stops. One
is located on the feeder next to the feeder pile table
controls, the second is located on the laminator control panel and the third is located on the top of the
laminator electrical box.
To engage an E-Stop, press the E-Stop in.When any
one of the three E-Stops is engaged, all functions of
the machine are stopped and the main pressure
roller is lowered.
To continue operation, all E-Stops must be in the up
position.To release an E-Stop, pull button out.
The Jog and Reset buttons must be held simultaneously to allow the slow speed jogging with the safety guard open. Speed is monitored by relay for safety purposes.
1.4 Safety shields
The two safety shields, one covering the main roller
and the second covering the separator section, perform the same function as an emergency stop.
Both safety shields have a key switch. Once the key
is removed from the switch, all functions of the
machine are stopped and the main pressure roller is
lowered.
To disengage the main roller safety shield switch,
pull up on the safety shield handle located on the
operator side of the laminator.
W
ARNING: Burn hazard, chrome cylinder
stays hot.
To disengage the separator safety shield switch,
slide the shield back towards the stacker table and
raise.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-5
1.5 Pneumatics
The pneumatic system used to provide upward
pressure on the pressure roller and the snap roller is
capable of producing great amount of forces. This
force is applied to any object presented in the opening (called the nip) between the two rollers.
CA
UTION: Objects other than media, film or
approved substrates, will cause irreparable damage
to the rollers if caught in the nip.
Use care in raising the lower pressure roller and/ or
engaging the snap roller. Before engaging either of
these rollers, ensure that nothing is in the nip areas.
Know how to react quickly in an emergency. If any
problem or danger should occur, depress any of the
E-Stops, all functions of the machine are stopped
and the main pressure roller is lowered.
1.6 Heat
The heater can raise the main roller temperature
well of over 200°F ( 100°C ).At these temperatures,
you can become severely burned.
W
ARNING: Do not make contact with the
main roller when heat is applied. You may
become severely burned if not avoided.
W
ARNING: After heat is removed from the
main roller, a void contact with the roller for at
least two hours. Heat is still present.
W
ARNING: Use extreme caution when the
main roller safety shield is raised and heat is
supplied.
WARNING: DO NOT operate unless you
have been fully trained. DO NOT operate
until you have read the OPERATING
INSTRUCTIONS completely.
CA
UTION Maximum Air Pressure: Do not
exceed the air pressure specified on this label.
W
ARNING Moving Parts: Keep hands and
fingers awa y.Y ou ma y be crushed and/ or cut.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-6
1.7 Safety labels
Posted at various locations on the Voyager 3
Laminator are important safety labels. Pay careful
attention to these labels at all times! Figure 1.7.1
illustrates the location of each of these labels.
W
ARNING READ MANUAL: Read and
understand the Operations Manual before
attempting to run this machine.
W
ARNING Hazardous Voltage: Do not open
these cabinets.This machine is to be serviced
only by trained and authorized personnel.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-7
CAUTION HOT SURFACE/ PINCH POINT:
Surface may be hot. Do not touch. Keep
hands and fingers away from pinch point.
CA
UTION PINCH POINT:
Keep hands and
clothing away from pinch point.
W
ARNING: Do not operate without all
guards in place. You may be seriously
injured.
W
ARNING BLADE HAZARD: Sharp blade,
keep hands and fingers away. The sharp
blade can crush and cut.
CA
UTION HOT SURFACE: Do not touch.
CA
UTION HEAVY OBJECT: Exercise safe
lifting practices when handling.
W
ARNING ELECTRICAL SHOCK HAZARD:
Live voltage present.Do not touch wires. Use
proper lock out/ tag out procedures.
W
ARNING SHARP EDGE: Keep hands and
fingers away. The sharp blade can crush
and cut.
W
ARNING FORK LIFT HERE:
For safe
moving of the laminator, only place fork lift
paddles where indicated on the machine.
You may become seriously hurt or cause
irreparable damage to the equipment.
WARNING: Shar p edge. Keeps hands and
fingers away. Sharp edge can cut.
W
ARNING: Keep hands and fingers away.
The gate can crush.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-8
CAUTION: Max load and height. Do not exceed.
Main Power Switch
WARNING
SHARP EDGE
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-9
WARNING
ACHTUNG
MISE EN GARDE
Moving parts
can
crush and cut.
Do not operate
!!!
with door open
WARNING
!!!
ACHTUNG
MISE EN GARDE
MUCHO
Fig. 1.7.1N/ABJT
DWG SCALE : DWG :
GBC Films Group
Safety label placement
GBC Votager 3
4151 Anderson Road, DeForest, WI 53532
3-3-04
TITLE :
DATE : DRAWN BY :
+ 1D
TO BE
ANGLES
FINISH
125
This print is the property of GBC Films Group. The information thereon is remitted in confidence.
.050+ .020
1/64
.010
TOL.
+
+ .005
+
+
WARNING
!!!
ACHTUNG
TOLERANCE
UNLESS OTHERWISE SPECIFIED
MISE EN GARDE
X
XX
X/X
XXX
REVISION
XXXX
CHECKED BY : GBC FILMS GROUP
SHOWN
DIM. AS
WARNING
ACHTUNG
MISE EN GARDE
!!!
Moving parts
can
crush and cut.
Do not operate
with door open
WARNINGATTENTION
HOT ROLLS.
PINCH POINT.
Keep hands
and clothing
away.
WARNING
!
ROULEAUX
CHAUDS.
POINT DE
PINCEMENT.
Tenir mains et
vetements a
l'ecant.
!
CUIDADO
ROLLOS MUY
CALIENTES.
PUNTO DE
PINCHAMIENTO.Mantener
manos
y articulos de
vestir a
distancia
WARNUNG !
!
HEISSE
ROLLEN
Klemmgefahr
zwischen
Rollen
Hande und
Kleidung
ferhalten
ACHTUNG
MISE EN GARDE
!!!
WARNING!
Do not
operate
without all
guards in
place
Carefully read Operator's
Manual before handling
this machine. Observe
instructions and safety
rules when operating.
PROPRIETARY
GBC PRO-TECH CLAIMS PROPRIETARY RIGHTS TO THE
MATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE
FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE
REPRODUCED,
COPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR
MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTEN
ATTENTION
Ne pas
utilizer
sans les
capots
installes.
!
WARNINGATTENTION
HOT ROLLS.
PINCH POINT.
Keep hands
and clothing
away.
CUIDADO
!
MUCHO
No operer
sin
cubiertas
SHARP EDGE
WARNING
!
!
ROULEAUX
CHAUDS.
POINT DE
PINCEMENT.
Tenir mains et
vetements a
l'ecant.
CUIDADO
!
MUCHO
ROLLOS MUY
CALIENTES.
PUNTO DE
PINCHAMIENTO.Mantener
manos
y articulos de
vestir a
GEFAHR!
DANGER
!
HAZARDOUS
VOLTAGE
To be serviced only
by trained and
authorized personnel.
Lockout power before
servicing
CAUTION
Pinch point
between
rollers.
MUCHO CUIDADO
WARNIN G
ATTENTION
DO NOT operate until you have
WARNUNG
read the OPERATING
INSTRUCTIONS completely.
NE P AS utiliser sans une bonne
formation.
NE P AS utiliser avant de lire le
MODE D'EMPLOI.
NO OPERAR sin entrenamiento
adecuado.
NO OPERAR sin leer las
INSTRUCTIONES de OPERACION.
Die Maschine nur bedienen, wenn
man dafur vollig ausgebildet ist.
Maschine nicht bedienen bis die
Gebrauchsanweisung vollstandig
!!!
gelesen wird.
!
ATTENTION
Pont de
pincement
!
MUCHO
CUIDADO
!
Punto de
pinchamientoentre los
WARNUNG !
Klemmgefahr
zwishen
!
DO NOT operate unless
you have been fully trained
C
PERMISSION FROM GBC PRO-TECH
CAUTIONATTENTION
Pinch point
between
rollers.
Keep
hands
and
clothing
MUCHO
away.
Pont de
pincement
entre les
rouleaux.
Eloigner
mainsetvetements.
!
CUIDADO
!
Punto de
pinchamientoentre los
rodillos.
Mantener
manos
y prendas a
distancia.
WARNUNG !
Klemmgefahr
zwishen
rollen.
Hande und
kleidung
fernhalten.
!
Keep
hands
and
clothing
away.
entre les
rouleaux.
Eloigner
mainsetvetements.
rodillos.
Mantener
manos
y prendas a
distancia.
rollen.
Hande und
kleidung
fernhalten.
distancia
WARNUNG !
!
HEISSE
ROLLEN
Klemmgefahr
zwischen
Rollen
Hande und
Kleidung
ferhalten
instaladas.
WARNUNG
!
Nicht ohne
geschlossene
schutzvor-
richtung
bedienen
AVERTISSEMENT
!
Lame
dangereuse
.
N'approchez pas
les
mains.
SHARP EDGE
WARNING
!
ADVERTENCIA
! WARNIN G !
Riesgo de
cortaduras.
Mantener las
Blade hazard.
Keep hands
manos
alejadas.
clear.
Operations Manual: Safety
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 1-10
1.8 Know your laminator
To help you relate to the components referred to in
this manual, take the time to get to know what and
where key components are on your new laminator.
Over view
Feeder
Operations Manual: Safety
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2004 General Binding Corporation
Page 1-11
Laminator
Separator
Operations Manual: Safety
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2004 General Binding Corporation
Page 1-12
Operations Manual: Warranty
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 2-1
2.0 Limited 90-Day Warranty
GBC warrants to the original purchaser for a period
of one year parts and ninety days labor, after installation that this laminator is free from defects in workmanship and material under normal use and ser vice. GBC’s obligation under this limited warranty is
limited to replacement or repair, at GBC’s option, of
any part found defective by GBC without charge for
material or labor.
THIS LIMITED WARRANTY IS IN LIEU OF ALL
OTHER WARRANTIES EXPRESSED OR
IMPLIED. WARRANTIES OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE
ARE EXPRESSLY EXCLUDED. ANY REPRESENTATIONS OR PROMISES INCONSISTENT WITH,
OR IN ADDITION TO, THIS LIMITED WARRANTY
ARE UNAUTHORIZED AND SHALL NOT BE
BINDING UPON GBC. IN NO EVENT SHALL GBC
BE LIABLE FOR ANY SPECIAL, INCIDENTAL,
OR CONSEQUENTIAL DAMAGES,WHETHER OR
NOT FORESEEABLE.
This limited warranty shall be void if the laminator
has been misused; mishandled; damaged by negligence, by accident, during shipment, or due to exposure to extreme conditions; repaired, altered,
moved, or installed by anyone other than GBC or its
authorized agents; or if incompatible film was used.
GBC’s obligation under this limited warranty does
not include routine maintenance, cleaning, adjustment, normal cosmetic or mechanical wear, nor
freight charges.
Without limiting the generality of the previous paragraph, GBC’s obligation under this limited warranty
does not include:
1. Damage to the rollers caused by knives, razors,
or other sharp tools; by any foreign objects falling
into the working area of the laminator; or by cleaning the laminator with solutions or materials that
harm its surfaces;
2. Damage caused by adhesives;nor
3. Damage caused by lifting, tilting or attempting to
position the laminator other than rolling it on its castors across even surfaces.
FOR EUROPEAN UNION RESIDENTS ONLY:This
guarantee does not affect the legal rights which consumers have under applicable national legislation
governing the sale of consumer goods.
Operations Manual: Warranty
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2004 General Binding Corporation
Page 2-2
Operations Manual: Specifications
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2004 General Binding Corporation
Page 3-1
3.0 Specifications
3.1 MACHINE SPECIFICATION
Maximum Speed: 150 ft/min = 10,000, 8.5 x 11 in. sheets/ hr.
(45.7 meters/min = 10,000, 21.6 x 28 cm sheets/ hr.)
Minimum sheet sizes: 8.5 x 11 in. with the 8.5 side forward
(21.6 x 28 cm with the 21.6 side forward)
Maximum sheet size: 30 x 40 in. with the 30 side forward
(76.2 x 101.6 cm with the 76.2 side forward)
Max. Feeder Loading: 30 in. (7600 mm), 1940 lb (880 Kg)
Overlap Variation: Electronic lap control, 1/8 +/- 5/64 in. (3 +/- 2 mm )
Paper range: 80lb text C1S* to 14pt cover (115 to 300 g/m2)
Films: OPP Films: PET Films: Lay Flat Films
9325 CLR 8200 CLR 8500 LF
8300 CLR 8200 DEL 8500 LF DEL
8300 DEL 1.7 NAP2 CLR 1.7 NAP5 LF
8700 DEL 1.7 NAP2 DEL
Film Orientation: Adhesive in
Film Core Diameter: 3 in. (76.0 mm)
Maximum Film Roll Diameter: 15.5 in. (394 mm)
Air Requirement:
Operating Air pressure: 80-90 psi, (5.6-6.3 bar), (560-630 kPa)
Air flow: Max. operating pressure 116 psi (8 bar), (800 kPa)
10-13 CFM (17-22 m
3
/h)
Water Requirement: Tap and drain water
Power Requirement European Version: 400 Volt AC, 3-Phase, 50 Hz, 75 Amps
Power Requirement US Version: 230 Volt AC, 3-Phase, 60 Hz, 100 Amps
Short Circuit Interrupt Capacity: Isc = 350 amperes
Sound Pressure: LpA = 76.6+2.5 = 79.1 dbA
Sound Power: L WA = 94.8+2.5 = 97.3 dbA
Operations Manual: Specifications
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2004 General Binding Corporation
Page 3-2
Ambient Air Temp: 5°-40° C
Humidity Rating: 30%-95% (Non-Condensing)
Altitude Rating: 1000 Meter Minimum
3.2 Feeder Specifications
Minimum sheet sizes: 8.5” x 11” (21.6 x 28 cm) (8.5” side forward)
Maximum sheet size: 30”x 40” (76.2 x 101.6 cm) (30” side forward)
Paper range: 80lb text C1S to 14pt cover (115 to 300 g/m2)
Operating Speed: 0 - 10 000 sheets/hr for all paper types listed under
paper range and for sheet lengths according “Chart
#1 in Sec. H”
Max. Paper Load Height: 30 in (7600 mm)
In-feed pile weight: 1940 lb (880 kg )
Laminator Connection Height: 33.5 in (850 mm) (Angle 10˚ or less)
Operation: Continuous
1 Revolution of input shaft = 1 feeder head cycle
= 1 gate cam revolution = conveyor movement 197 mm
Rotation of feeder input shaft: Counter clockwise (looking from DRIVE side)
Sheets overlap on conveyor: 197 mm (recommended)
Feeder Head: Two system feeder head (recommended)
Type: lifting suckers (recommended)
- forwarding suckers (recommended)
Blowers: Blower design for feeding with short side forward.
(Sheet direction is opposite than on printing presses)
(1) foot blower and (2) cushion blowers
(2) front side blowers on the side guides
Adjustments: Horizontal linear mechanism for 11 – 40” paper
with sheet length scale
Vertical feeder head height adjustment
min.
3
/4” (19 mm)
Operations Manual: Specifications
Voyager 3
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2004 General Binding Corporation
Page 3-3
Other: Vacuum and blower adjustments
Conveyor:
Type: Vacuum style conveyor
Length: Min. 40” (101.6 cm)
Vacuum sections : Max. 4” (101.6 mm)
from downstream edge of feeder conveyor
with possibility to close two external sections
Belts: 3.2” (80mm) wide “Habasit” belts for vacuum conveyor
Lifting Mechanism:
Type: Lifting mech. with removable feeder table
design for 2000 lb (907 kg) load capacity
Moving increments:
1
/8” (3 mm) per increment in up direction
with full load and empty table as well
Other: Feeder will be supplied with one (1) removable table
Pile height sensor: Operating on all colors and reflective materials
Gating mechanism: Gating mechanism related to feeder head function
located between paper stock and conveyor
Paddles: (4) Paddles holding sheets from top on the conveyor
Clutch: Not required
Leveling pads: Adjustable pads M 20 with 1” adjustment
Air requirements:
Pressure: Min. 7 psi (.5 bar) (50 kPa)
Vacuum: Min. 6 psi (.5 bar) (40 kPa)
Consumption: 40 m3/h
Electrical plug connections: (1) plug for connection between feeder and laminator
(1) plug for air pump
Power Requirement: Power supplied by the laminator
3.3. Feeder Air Pump Specifications
Capacity at 50 Hz: 24 CFM (40 m3/h)
Pressure: Max.9 psi (.6 bar) (60 kPa)
Vacuum: Max 9 psi (.6 bar) (60 kPa)
Operations Manual: Specifications
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2004 General Binding Corporation
Page 3-4
Motor power: 1.85 kW (informative)
RPM at 50 Hz: 1420 (informative)
Adjustments: Vacuum and pressure adjustments
Power Requirement: Power supplied by the laminator
Note: Air pump design equal or similar to Becker air pump T 4.40 DSK
3.4 Heater
(For heater specifications see heater manual).
4.0 Installation
CAUTION: The GBC Voyager 3 can only be
installed by a trained GBC Service
Representative.
Before a Voayger 3 Laminator can be installed, there
are a few requirements that must be met.Make certain that each of the requirements listed in the following pre-installation checklist are met prior to
installation.
CA
UTION: Failure to follow the pre-installa-
tion check list can result in damage to the
laminator.
As a customer, you are responsible for ensuring the
crates are uncrated and the components are set in
proper position as illustrated in Figure 4.1.1
Suggested Floor Layout.The installation time is outlined to allow for maximum hands on training with
the operators.
4.1 Pre-installation
Are the doorways and hallways wide enough
for the laminator to be moved to the installation site?
Is there ample room for the laminator? The
laminator occupies 16 ft. by 6 ft.of floor space
(488 cm x 183 cm).
A safe work area constitutes enough room to
work with the materials at hand while being
free to move around the laminator without
interference from the laminator. You must
allow a minimum of 5 ft. (152 cm) in front of
the feeder and on the operator side, and a
minimum of 2 ft. (61 cm) behind the stacker
and drive side of the laminator.Refer to Figure
4.1.1 Floor layout.
Is the environment appropriate for the
laminator? A controlled environment is recommended.
CA
UTION: The operating environment must
be free of dust, flammable liquids and
vapors.
The laminator requires a clean, dust and
vapor free environment to operate properly.
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-1
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-2
CA
UTION:
Do not locate the laminator where
air can blow directly on the machine.The air
flow can cool the rollers unevenly and result
in poor quality output.
Have you contacted a certified electrician to
install a receptacle for the laminator ensuring
that adequate power and correct circuit
breaker is being supplied?
The laminator and heater requires 380 Volt
AC, 50/ 60 Hz, 50 amps, Delta three phase
(four wire) power. For US, a transformer is
required to step up power from 230 Volt
3 Phase to 380 Volt 3 Phase AC. Refer to
Figure 4.1.2 connections.
For heater requirements, consult the heater
manual for your unit.
INFORMA
TION: The vacuum/ pump, feeder
and heater units will draw it’s electrical power
from the laminator.
Is tap and drain water available?
Water supply should be hard plumbed with a
3/4 in. (1.9 cm) NPT supply and drain. Refer
to Figure 4.1.2 connections.
Is proper air pressure available?
Air pressure required is 80-90 psi min.
(0.56-0.63 Mpa) with an air flow of 10-13 cfm
(280-360 liters/ min.). Refer to Figure 4.1.2
connections.
CA
UTION: Tripping Hazard. If connections
are not dropped from the ceiling, all lines and
hoses must be covered to pre v ent trip hazard.
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-3
Figure 4.1.1 Suggested Floor Layout
6 ft.
(183 cm)
> 2 ft.
(61 cm)
> 5 ft.
(152 cm)
(Recommended)
- T ap water
Water:
Air:
- 8 Bar Max
(112 psi / 800 MPa)
- Drain return
GBC Films Group
- 10-12 CFM
(280-360 liters/ min.)
This print is the property of GBC Films Group. The information thereon is remitted in confidence.
TOLERANCE
UNLESS OTHERWISE SPECIFIED
4151 Anderson Road, DeForest, WI 53532
FINISH
TOL.
SHOWN
DIM. AS
Figure 4.1.1N/ASNF
DWG SCALE : DWG :
Suggested Floor Layout
GBC Voya ger 3
10/31/02
TITLE :
DATE : DRAWN BY :
+ 1D
TO BE
ANGLES
125
.050+ .020
1/64
.010
+
+ .005
+
+
X
XX
X/X
XXX
XXXX
REVISION
CHECKED BY : GBC FILMS GROUP
4 ft.
(122 cm)
(Heater)
Electrical drop
Water supply drop
(Laminator)
Electrical drop
16 ft.
(488 cm)
> 5 ft.
(152 cm)
Laminator Requirements
Electrical (Europe):
- 400 Vac
- 50 hz
- 75 amps
- 3 phase (four wire)
Electrical (US):
- 230 to 400 Vac
- 60 hz
- 100 amps
- 3 phase (four wire)
Transformer Required
Heater Requirements
See Heater Manual For
Details.
- 230 to 400 Vac
- 3 phase (four wire)
3.5 ft.
(107 cm)
Air supply drop
C
REPRODUCED,
PROPRIETARY
PERMISSION FROM GBC PRO-TECH
GBC PRO-TECH CLAIMS PROPRIETARY RIGHTS TO THE
FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE
COPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR
MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTEN
MATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE
> 2 ft.
(61 cm)
Detail A-A
Align heater with
edge of feeder motor
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-4
Figure 4.1.2 Connections
Figure 4.1.2N/ABJT
DWG SCALE : DWG :
Supply
Drain
GBC Films Group
4151 Anderson Road, DeForest, WI 53532
Connections
GBC Voyager 3
3-3-04
TITLE :
DATE : DRAWN BY :
+ 1D
TO BE
ANGLES
FINISH
125
This print is the property of GBC Films Group. The information thereon is remitted in confidence.
.050+ .020
1/64
.010
TOL.
+
+ .005
+
+
TOLERANCE
X
UNLESS OTHERWISE SPECIFIED
XX
X/X
XXX
XXXX
SHOWN
DIM. AS
REVISION
CHECKED BY : GBC FILMS GROUP
05/13/03 Rev. A Elec. / Air conn.
REPRODUCED,
PROPRIETARY
GBC PRO-TECH CLAIMS PROPRIETARY RIGHTS TO THE
FOR ENGINEERING INFORMATION ONLY AND SHALL NOT BE
MATERIAL DISCLOSED ON THIS DRAWING. IT IS ISSUED IN CONFIDENCE
C
PERMISSION FROM GBC PRO-TECH
COPIED OR DISCLOSED IN WHOLE OR IN PART, OR USED FOR
MANUFACTURE OR FOR ANY OTHER PURPOSE WITHOUT WRITTEN
Power In
(From Transformer - US)
(From Drop - Europe)
legs
three hot
ground
NOTE: See Wiring Diagram for connection details
A
air
connect
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-5
4.2 Receiving the crates
The GBC Voyager 3 is shipped in two crates. Both
crates should arrive at the same time on your
docks.
INFORMA
TION: ALL SHIPMENTS ARE EX-
WORKS. At our dock, title passes to the
buyer. Please review your insurance coverage prior to shipment, as you are responsible
for all subsequent freight charges and risks.
INFORMA
TION:
Before signing the BILL OF
LADING, you should be sure to inspect the
crates and/ or pallets for signs of damage or
missing items; if applicable, make note of
this on the BILL OF LADING.
W
ARNING:
The GBC Voyager 3 Laminator
is a large and heavy piece of equipment.It is
necessary to employ LICENSED RIGGERS
ONLY to move the laminator components.
CA
UTION: The GBC Voyager 3 Laminator is
not designed to be tipped up side down or
sideways in any way. Such action disturbs
the exact alignment of the rolling parts of the
machine and may require costly and extensive realignment.
4.3 Uncrating
CAUTION: Do not attempt to remove the
sides of the crate by yourself. You can be
seriously injured and/ or cause damage to
the laminator components.
Below is an example of a typical crated unit.Your
crate may have some minor differences but should
uncrate in the same manner.
CA
UTION: Do not use a knife or other sharp
objects to remove shrink wrap or pre masking from around the laminator. You can
cause irreparable damage to the rollers.
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-6
4.4 Positioning the components
All components are positioned by the center line of
the laminator. The components should be positioned in the following order; Laminator, stacker
table, f eeder, conveyor, vacuum/ pump and then the
water heater. Refer to Figure 4.4.1 Component
Placement.
W
ARNING:
Always consult your licensed
riggers before attempting to move the components. You may be seriously injured and/
or cause damage to the machine.
W
ARNING: Do not attempt to move the
components of the GBC Voyager 3 across
anything other than a flat level surface without trained and qualified riggers.
It is recommended to move each component in the
following manner but you should consult the
licensed riggers for alternative methods that best fit
your situation and surroundings.
W
ARNING: To safely move the components,
use as many people necessary to assist in
keeping the components stable during
movement.
CA
UTION:
Exercise safe lifting practices to
avoid serious injury to yourself and the
equipment.
Laminator
Once the laminator has been safely removed from
the crate, you can move the laminator into position
by using a pallet jack or forklift.
To move the laminator , approach the laminator from
the front and guide the forks under the laminator
where indicated on the laminator.
Stacker table
The stacker table can be easily carried by two people and attached to the laminator once the laminator has been set into position.
To attach the stacker table, position the stacker
table hooks onto the stacker tab le support rod located at the back of the laminator.
Fork Lift
Stacker table hook
Stacker table
support rod
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-7
Feeder
Once the feeder has been safely removed from the
crate, you can move the feeder into position by
using a pallet jack or forklift.
To move the feeder, approach the feeder from the
front and guide the forks under the feeder where
indicated on the cross beams.
Set the back of the feeder approximately 48 in.(122
cm) from the front of the laminator.This will provide
sufficient space for the installation of the conveyor.
INFORMA
TION: Do not remove the cross
beams. They will be removed at the time of
installation.
Conveyor
The conveyor can be easily carried by two people
and set down on the floor between the feeder and
the laminator. The belt drive gear end of the conveyor should be on the feeder end. The conveyor
will be connected at the time of installation.
Vacuum/ pump
The vacuum/ pump can moved by placing it on to a
pallet jack and moved to the set up location.
Set the vacuum/ pump next to the control panel on
the operator side of the laminator. The vacuum/
pump will be connected at the time of installation.
Water heater/ reservoir tank
The water heater and reservoir tank are equipped
with castors and can be rolled over flat surf aces and
placed next to the laminator.
Set the water heater and reservoir tank next to the
electrical box on the drive side of the laminator.The
water heater and reservoir tank will be connected
at the time of installation.
CA
UTION: Tripping Hazard. Position water
heater so that hoses from heater do not
cause a tripping hazard.
CAUTION: Ensure all accessory items are
placed with the GBC Voyager 3. Do not
attempt to connect any component after
positioning has been completed.
Fork Lift
48 in.
(122 cm)
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-8
Figure 4.4.1 Component placement
CAUTION: Position water
heater as close as possible
to Laminator to prevent trip-
ping hazard.
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-9
4.5 Safety Checklist
Once installation is complete, perform the following
steps to ensure that all the safety features of the
machine are operating properly.
E-Stop on Feeder – Does E-stop remove
power from machine at main contactor? Do
you hav e to press the Reset button to re-apply
power to machine?
E-Stop on Operators Station – Does E-stop
remove power from machine at main contactor? Do you hav e to press the Reset button to
re-apply power to machine?
E-Stop on Electrical Cabinet - Does E-stop
remove power from machine at main contactor? Do you hav e to press the Reset button to
re-apply power to machine?
Snapping Cover – Open the cover while the
machine is running. Does the machine stop?
Laminator Cover - Open the cover while the
machine is running. Does the machine stop?
Check Jog Speed – With the main roll safety
guard open, press and hold the RESET and
JOG Forward buttons. In this condition, the
machine speed should not exceed 1
meter/min. To check the speed, mark the
chrome roll with a piece of tape and time the
machine for 1 minute.Ensure the chrome roll
does not rotate more than 1-3/4
rotations/minute.
Operations Manual: Installation
Voyager 3
Voyager 3
2004 General Binding Corporation
Page 4-10
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