GBC Laminator 930 032 User Manual

®
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.  
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Voyager 3  
Operations Manual  
TABLE OF CONTENTS  
1.0 Safety  
1.1 Explanation of symbols  
1-1  
1-2  
1-4  
1-4  
1-5  
1-5  
1-6  
1-10  
1.2 General Rules of safety  
1.3 Emergency Stops  
1.4 Safety Shields  
1.5 Pneumantics  
1.6 Heat  
1.7 Safety labels  
1.8 Know Your laminator  
2.0 Warranty  
2.0 Limited 90-day warranty  
2-1  
3.0 Specifications  
3.1 Machine Specification  
3.2 Feeder Specifications  
3.3 Feeder Pump and Specifications  
3.4 Heater  
3-1  
3-2  
3-3  
3-4  
4.0 Installation  
4.1 Pre-installation  
4-1  
4-3  
4-4  
4-5  
4-5  
4-6  
4-8  
4-9  
4.1.1 Suggested Floor Layout  
4.1.2 Connections  
4.2 Receiving the crates  
4.3 Uncrating  
4.4 Positioning the components  
4.4.1 Component placement  
4.5 Safety Checklist  
5.0 Operations  
5.1 Feeder  
5-3  
5.2 Laminator  
5-6  
5-7  
5.2.1 Control Panel  
5.2.2 Unwind controls  
5.3 Stacker  
5.4 Vacumn pressure  
5.5 Heater  
5-10  
5-15  
5-16  
5-16  
6.0 Applications  
6.1 Start-up procedure  
6.2 Shut down procedure  
6-1  
6-3  
7.0 Maintenance and troubleshooting  
7.1 Daily cleanng  
7-1  
7-1  
7-2  
7.2 Periodical Maintenance  
7.3 Troubleshooting  
8.0 Appendix  
Appendix A — Heater Manuals  
Appendix B — Pump Manual  
Appendix C — Diagrams  
8-3  
8-5  
8-7  
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Voyager 3  
Operations Manual  
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 reserved. 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.  
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Voyager 3  
Operations Manual: Safety  
1.0 Safety  
CAUTION: CHANGES OR MODIFI-  
CATIONS NOT EXPRESSLY  
APPROVED BY GENERAL BIND-  
ING CORPORATION COULD VOID  
YOUR AUTHORITY TO OPERATE  
THE EQUIPMENT.  
CAUTION: Do not attempt to operate your  
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 impor-  
tant 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.  
Canada Class A Notice - Avis Canada,  
Classe A  
This Class A digital apparatus complies with  
Canadian ICES-3.  
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 compo-  
nents manufacturer.  
Cet appareil numérique de la classe A est con-  
forme à la norme  
NMB-003 du Canada.  
1.1 Explanation of symbols  
FCC NOTE  
INFORMATION: This symbol used to  
inform you of important information per-  
taining to the current subject.  
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 commer-  
cial environment.  
CAUTION: When you see this symbol,  
use caution to avoid harm to you, or oth-  
ers around you.  
WARNING: 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  
This equipment generates, uses, and can radi-  
ate 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  
ELECTRICAL HAZARD: This symbol is  
used to prevent an electrical shock condi-  
tion that may be caused by an operators  
action or machine function.  
user will be required to correct the interference  
at his/her own expense.  
CAUTION: 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 repre-  
sentative for further explanation.  
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Voyager 3  
Operations Manual: Safety  
WARNING: 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.  
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, elec-  
trocuted or cause a fire.  
WARNING: Do not wear ties, loose fitting  
clothes or dangling jewelry while operat-  
ing or servicing the laminator.These items  
can get caught in the nip and choke you or  
you can be crushed or burned.  
ELECTRICAL HAZARD: Employ  
licensed electrician to provide electrical  
requirements for the laminator.  
a
WARNING: Never tamper with the safety  
devices to increase the laminator’s pro-  
duction capacity. In the event a safety  
device should fail, never attempt to  
bypass it for operation. Consult a service  
representative immediately.  
ELECTRICAL HAZARD: Employ a  
licensed plumber to provide tap and  
drain requirements for the laminator.  
ELECTRICAL HAZARD: Do not use liq-  
uid or aerosol cleaners on the laminator.  
Do not spill liquid of any kind on the lami-  
nator. You can be severely shocked, elec-  
trocuted or cause a fire.  
WARNING: To prevent injury to others  
working around the laminator, only one  
person may control the functions of the  
laminator during operation or servicing.  
ELECTRICAL HAZARD: Never discon-  
nect any cable on the laminator  
while power is supplied. Servicing  
should be left to qualified service repre-  
sentatives only.  
CAUTION: The operating environment  
must be free of dust, flammable liquids  
and vapors.  
ELECTRICAL HAZARD: Do not attempt  
to repair or service the laminator.  
Servicing should be left to qualified service  
representatives only.  
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Voyager 3  
Operations Manual: Safety  
CAUTION: Vapor build up or stored flam-  
mable liquids can cause a fire. Excessive  
dust can damage the laminator.  
CAUTION: The laminator may only be  
moved by a qualified service representa-  
tive. Improper disconnection or reconnect-  
ing can result in injury to you and/ or dam-  
age to the laminator.  
CAUTION: Exercise extreme caution  
when working around or replacing the  
film cutter blade. This blade is sharp and  
cut you.  
CAUTION: Never use this machine for  
any other purpose than its intended  
design and function. You may be injured.  
CAUTION: Keep feet away from the feed-  
er pile table when lowering to ground  
level.  
The following actions can result in  
machine damage.  
CAUTION: Do not make any modifications to this  
laminator. Unauthorized changes will void your war-  
ranty and may cause extensive repairs or create  
poor output quality.  
CAUTION: Avoid contact with the heat  
roller during webbing, operation, un-web-  
bing, changing film or after heat has been  
removed from the laminator.  
CAUTION: 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.  
CAUTION: Always observe all warning  
labels placed at various points on the  
laminator. If you do not completely under-  
stand a label, contact your local service  
representative for further explanation.  
CAUTION: Only use acceptable materials through  
this laminator. Unacceptable materials may cause  
damage to the rollers or cause poor output quality.  
CAUTION: Always follow proper shut-  
down procedure as described in this  
manual when turning the laminator off.  
CAUTION: Do not place the laminator on uneven  
surfaces. This will effect the operation of the lamina-  
tor and will result in poor output quality.  
CAUTION: Only use materials specified  
in this manual for cleaning of the lamina-  
tor and routine maintenance.  
INFORMATION: Any concerns for safety  
or operation should be brought to the  
attention of your local service representa-  
tive immediately.  
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Voyager 3  
Operations Manual: Safety  
Jog/Slow Speed w/Guard Open  
The Jog and Reset buttons must be held simultane-  
ously to allow the slow speed jogging with the safe-  
ty guard open. Speed is monitored by relay for safe-  
ty purposes.  
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 con-  
trol panel and the third is located on the top of the  
laminator electrical box.  
1.4 Safety shields  
The two safety shields, one covering the main roller  
and the second covering the separator section, per-  
form the same function as an emergency stop.  
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.  
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.  
WARNING: Burn hazard, chrome cylinder  
stays hot.  
To continue operation, all E-Stops must be in the up  
position. To release an E-Stop, pull button out.  
To disengage the separator safety shield switch,  
slide the shield back towards the stacker table and  
raise.  
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Voyager 3  
Operations Manual: Safety  
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  
1.5 Pneumatics  
The heater can raise the main roller temperature  
well of over 200°F ( 100°C ). At these temperatures,  
you can become severely burned.  
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 open-  
ing (called the nip) between the two rollers.  
WARNING: Do not make contact with the  
main roller when heat is applied. You may  
become severely burned if not avoided.  
WARNING: After heat is removed from the  
main roller, avoid contact with the roller for at  
least two hours. Heat is still present.  
WARNING: Use extreme caution when the  
main roller safety shield is raised and heat is  
supplied.  
CAUTION: Objects other than media, film or  
approved substrates, will cause irreparable damage  
to the rollers if caught in the nip.  
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Voyager 3  
Operations Manual: Safety  
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.  
WARNING: DO NOT operate unless you  
have been fully trained. DO NOT operate  
until you have read the OPERATING  
INSTRUCTIONS completely.  
WARNING READ MANUAL: Read and  
understand the Operations Manual before  
attempting to run this machine.  
CAUTION Maximum Air Pressure: Do not  
exceed the air pressure specified on this label.  
WARNING Hazardous Voltage: Do not open  
these cabinets.This machine is to be serviced  
only by trained and authorized personnel.  
WARNING Moving Parts: Keep hands and  
fingers away.You may be crushed and/ or cut.  
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Voyager 3  
Operations Manual: Safety  
CAUTION HOT SURFACE/ PINCH POINT:  
Surface may be hot. Do not touch. Keep  
hands and fingers away from pinch point.  
CAUTION HEAVY OBJECT: Exercise safe  
lifting practices when handling.  
CAUTION PINCH POINT: Keep hands and  
clothing away from pinch point.  
WARNING ELECTRICAL SHOCK HAZARD:  
Live voltage present. Do not touch wires. Use  
proper lock out/ tag out procedures.  
WARNING: Do not operate without all  
guards in place. You may be seriously  
injured.  
WARNING SHARP EDGE: Keep hands and  
fingers away. The sharp blade can crush  
and cut.  
WARNING BLADE HAZARD: Sharp blade,  
keep hands and fingers away. The sharp  
blade can crush and cut.  
WARNING 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.  
CAUTION HOT SURFACE: Do not touch.  
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Voyager 3  
Operations Manual: Safety  
WARNING  
SHARP EDGE  
WARNING: Sharp edge. Keeps hands and  
fingers away. Sharp edge can cut.  
CAUTION: Max load and height. Do not exceed.  
WARNING: Keep hands and fingers away.  
The gate can crush.  
Main Power Switch  
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Voyager 3  
Operations Manual: Safety  
R E V I S I O N  
O U P  
G B C F I L M S G R C H E C K E D B Y  
:
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Voyager 3  
Operations Manual: Safety  
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  
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Voyager 3  
Operations Manual: Safety  
Laminator  
Separator  
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Voyager 3  
Operations Manual: Safety  
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Voyager 3  
Operations Manual: Warranty  
2.0 Limited 90-Day Warranty  
GBC warrants to the original purchaser for a period  
of one year parts and ninety days labor, after instal-  
lation that this laminator is free from defects in work-  
manship and material under normal use and serv-  
ice. GBCs obligation under this limited warranty is  
limited to replacement or repair, at GBCs option, of  
any part found defective by GBC without charge for  
material or labor.  
Without limiting the generality of the previous para-  
graph, GBCs 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 clean-  
ing the laminator with solutions or materials that  
harm its surfaces;  
THIS LIMITED WARRANTY IS IN LIEU OF ALL  
OTHER WARRANTIES  
EXPRESSED  
OR  
2. Damage caused by adhesives; nor  
IMPLIED. WARRANTIES OF MERCHANTABILITY  
OR FITNESS FOR A PARTICULAR PURPOSE  
ARE EXPRESSLY EXCLUDED. ANY REPRESEN-  
TATIONS 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.  
3. Damage caused by lifting, tilting or attempting to  
position the laminator other than rolling it on its cas-  
tors across even surfaces.  
FOR EUROPEAN UNION RESIDENTS ONLY: This  
guarantee does not affect the legal rights which con-  
sumers have under applicable national legislation  
governing the sale of consumer goods.  
This limited warranty shall be void if the laminator  
has been misused; mishandled; damaged by negli-  
gence, by accident, during shipment, or due to expo-  
sure to extreme conditions; repaired, altered,  
moved, or installed by anyone other than GBC or its  
authorized agents; or if incompatible film was used.  
GBCs obligation under this limited warranty does  
not include routine maintenance, cleaning, adjust-  
ment, normal cosmetic or mechanical wear, nor  
freight charges.  
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Voyager 3  
Operations Manual: Warranty  
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Voyager 3  
Operations Manual: Specifications  
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:  
Maximum sheet size:  
8.5 x 11 in. with the 8.5 side forward  
(21.6 x 28 cm with the 21.6 side forward)  
30 x 40 in. with the 30 side forward  
(76.2 x 101.6 cm with the 76.2 side forward)  
Max. Feeder Loading:  
Overlap Variation:  
Paper range:  
30 in. (7600 mm), 1940 lb (880 Kg)  
Electronic lap control, 1/8 +/- 5/64 in. (3 +/- 2 mm )  
80lb text C1S* to 14pt cover (115 to 300 g/m2)  
Films:  
OPP Films: PET Films:  
Lay Flat Films  
8500 LF  
8500 LF DEL  
1.7 NAP5 LF  
9325 CLR  
8300 CLR  
8300 DEL  
8700 DEL  
8200 CLR  
8200 DEL  
1.7 NAP2 CLR  
1.7 NAP2 DEL  
Film Orientation:  
Adhesive in  
Film Core Diameter:  
Maximum Film Roll Diameter:  
Air Requirement:  
3 in. (76.0 mm)  
15.5 in. (394 mm)  
Operating Air pressure:  
Air flow:  
80-90 psi, (5.6-6.3 bar), (560-630 kPa)  
Max. operating pressure 116 psi (8 bar), (800 kPa)  
10-13 CFM (17-22 m3/h)  
Water Requirement:  
Tap and drain water  
Power Requirement European Version:  
Power Requirement US Version:  
Short Circuit Interrupt Capacity:  
Sound Pressure:  
400 Volt AC, 3-Phase, 50 Hz, 75 Amps  
230 Volt AC, 3-Phase, 60 Hz, 100 Amps  
Isc = 350 amperes  
LpA = 76.6+2.5 = 79.1 dbA  
L WA = 94.8+2.5 = 97.3 dbA  
Sound Power:  
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Voyager 3  
Operations Manual: Specifications  
Ambient Air Temp:  
Humidity Rating:  
Altitude Rating:  
5°-40° C  
30%-95% (Non-Condensing)  
1000 Meter Minimum  
3.2 Feeder Specifications  
Minimum sheet sizes:  
Maximum sheet size:  
Paper range:  
8.5x 11(21.6 x 28 cm) (8.5side forward)  
30x 40(76.2 x 101.6 cm) (30side forward)  
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:  
In-feed pile weight:  
30 in (7600 mm)  
1940 lb (880 kg )  
Laminator Connection Height:  
Operation:  
33.5 in (850 mm) (Angle 10˚ or less)  
Continuous  
1 Revolution of input shaft = 1 feeder head cycle  
= 1 gate cam revolution = conveyor movement 197 mm  
Rotation of feeder input shaft:  
Sheets overlap on conveyor:  
Feeder Head:  
Counter clockwise (looking from DRIVE side)  
197 mm (recommended)  
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 40paper  
with sheet length scale  
Vertical feeder head height adjustment  
3
min. /4(19 mm)  
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Voyager 3  
Operations Manual: Specifications  
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 Habasitbelts for vacuum conveyor  
Lifting Mechanism:  
Type:  
Lifting mech. with removable feeder table  
design for 2000 lb (907 kg) load capacity  
1
Moving increments:  
/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  
Operating on all colors and reflective materials  
Pile height sensor:  
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  
Not required  
Clutch:  
Leveling pads:  
Adjustable pads M 20 with 1adjustment  
Air requirements:  
Pressure:  
Min. 7 psi (.5 bar) (50 kPa)  
Min. 6 psi (.5 bar) (40 kPa)  
40 m3/h  
Vacuum:  
Consumption:  
Electrical plug connections:  
Power Requirement:  
(1) plug for connection between feeder and laminator  
(1) plug for air pump  
Power supplied by the laminator  
3.3. Feeder Air Pump Specifications  
Capacity at 50 Hz:  
Pressure:  
24 CFM (40 m3/h)  
Max. 9 psi (.6 bar) (60 kPa)  
Max 9 psi (.6 bar) (60 kPa)  
Vacuum:  
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Voyager 3  
Operations Manual: Specifications  
Motor power:  
1.85 kW (informative)  
1420 (informative)  
RPM at 50 Hz:  
Adjustments:  
Vacuum and pressure adjustments  
Power supplied by the laminator  
Power Requirement:  
Note: Air pump design equal or similar to Becker air pump T 4.40 DSK  
3.4 Heater  
(For heater specifications see heater manual).  
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Voyager 3  
Operations Manual: Installation  
4.0 Installation  
4.1 Pre-installation  
CAUTION: The GBC Voyager 3 can only be  
installed by  
Representative.  
a
trained GBC Service  
Are the doorways and hallways wide enough  
for the laminator to be moved to the installa-  
tion site?  
Before a Voayger 3 Laminator can be installed, there  
are a few requirements that must be met. Make cer-  
tain that each of the requirements listed in the fol-  
lowing pre-installation checklist are met prior to  
installation.  
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.  
CAUTION: 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 out-  
lined to allow for maximum hands on training with  
the operators.  
Is the environment appropriate for the  
laminator? A controlled environment is recom-  
mended.  
CAUTION: 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.  
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Voyager 3  
Operations Manual: Installation  
CAUTION: 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.  
INFORMATION: The vacuum/ pump, feeder  
and heater units will draw its 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.  
CAUTION: Tripping Hazard. If connections  
are not dropped from the ceiling, all lines and  
hoses must be covered to prevent trip hazard.  
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Voyager 3  
Operations Manual: Installation  
Figure 4.1.1 Suggested Floor Layout  
R E V I S I O N  
O U P  
G B C F I L M S G R C H E C K E D B Y  
:
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Voyager 3  
Operations Manual: Installation  
Figure 4.1.2 Connections  
R E V I S I O N  
:
G B C F I L M S C G H R E O  
C
U
K E D B Y  
P
c o n n / . A i r l e E c .  
A . R e v  
0 5 / 1 3 / 0 3  
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Voyager 3  
Operations Manual: Installation  
4.2 Receiving the crates  
4.3 Uncrating  
The GBC Voyager 3 is shipped in two crates. Both  
crates should arrive at the same time on your  
docks.  
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.  
INFORMATION: ALL SHIPMENTS ARE EX-  
WORKS. At our dock, title passes to the  
buyer. Please review your insurance cover-  
age prior to shipment, as you are responsible  
for all subsequent freight charges and risks.  
Below is an example of a typical crated unit. Your  
crate may have some minor differences but should  
uncrate in the same manner.  
INFORMATION: 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.  
WARNING: 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.  
CAUTION: 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 exten-  
sive realignment.  
CAUTION: Do not use a knife or other sharp  
objects to remove shrink wrap or pre mask-  
ing from around the laminator. You can  
cause irreparable damage to the rollers.  
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Voyager 3  
Operations Manual: Installation  
4.4 Positioning the components  
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.  
All components are positioned by the center line of  
the laminator. The components should be posi-  
tioned in the following order; Laminator, stacker  
table, feeder, conveyor, vacuum/ pump and then the  
water heater. Refer to Figure 4.4.1 Component  
Placement.  
To move the laminator, approach the laminator from  
the front and guide the forks under the laminator  
where indicated on the laminator.  
WARNING: Always consult your licensed  
riggers before attempting to move the com-  
ponents. You may be seriously injured and/  
or cause damage to the machine.  
Fork Lift  
WARNING: Do not attempt to move the  
components of the GBC Voyager 3 across  
anything other than a flat level surface with-  
out 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.  
Stacker table  
The stacker table can be easily carried by two peo-  
ple and attached to the laminator once the lamina-  
tor has been set into position.  
To attach the stacker table, position the stacker  
table hooks onto the stacker table support rod locat-  
ed at the back of the laminator.  
WARNING: To safely move the components,  
use as many people necessary to assist in  
keeping the components stable during  
movement.  
Stacker table hook  
CAUTION: Exercise safe lifting practices to  
avoid serious injury to yourself and the  
equipment.  
Stacker table  
support rod  
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Voyager 3  
Operations Manual: Installation  
Conveyor  
Feeder  
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 con-  
veyor should be on the feeder end. The conveyor  
will be connected at the time of installation.  
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.  
Fork Lift  
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.  
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.  
Water heater/ reservoir tank  
The water heater and reservoir tank are equipped  
with castors and can be rolled over flat surfaces and  
placed next to the laminator.  
48 in.  
(122 cm)  
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.  
CAUTION: Tripping Hazard. Position water  
heater so that hoses from heater do not  
cause a tripping hazard.  
INFORMATION: Do not remove the cross  
beams. They will be removed at the time of  
installation.  
CAUTION: Ensure all accessory items are  
placed with the GBC Voyager 3. Do not  
attempt to connect any component after  
positioning has been completed.  
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Voyager 3  
Operations Manual: Installation  
Figure 4.4.1 Component placement  
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Voyager 3  
Operations Manual: Installation  
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 have 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 contac-  
tor? Do you have 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 contac-  
tor? Do you have 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.  
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Voyager 3  
Operations Manual: Installation  
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