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AGL Encore Maxim Operator's Manual

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OPERATORS MANUAL
FOR
Encore Maxim
801 Burton Blvd. DeForest WI 53532
Ph: 608-846-7016 Fax: 608-846-1024
E-mail: info@aglaminators.com

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  • Page 1 OPERATORS MANUAL Encore Maxim 801 Burton Blvd. DeForest WI 53532 Ph: 608-846-7016 Fax: 608-846-1024 E-mail: info@aglaminators.com...

  • Page 2: Table Of Contents

    Table of Contents Table of Contents Chapter 1 Installation Selecting Area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Uncrating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Leveling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 Electrical Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2...

  • Page 3: Chapter 1 Installation

    The sides of the laminator should also be easily accessible in case service or maintenance is required. AGL approximates this area should be about 7-8 feet in front and back of the machine and 3-4 feet on either end. This is only a suggestion, your plant and the products to be laminated will be the determining factor.

  • Page 4: Electrical Connection

    Installation Electrical Connection Refer to the Electrical Requirements under Specifications for the proper requirements for your laminator. All connections to components and terminal blocks should be checked for tightness before initial startup. This will help avoid and electrical problems caused by connections that may have loosened due to vibration during shipping.

  • Page 5: Chapter 2 Specifications

    Specifications Machine Dimensions Width: 89” Height: 50” Depth: 43” with tables extended, 35" with tables folded down Weight: 2800 lbs. Electrical Requirements 220/230 VAC single phase, 50/60 Hz, 60 Amp service Pneumatic Requirements Approximately 2-3 cfm at 90 psi line pressure supplied via your cleaned/dried/regulated plant air. Material Capacity Upper Rear Station: 7.0”...

  • Page 6: Chapter 3 Safety

    Safety IMPORTANT READ THIS SECTION BEFORE OPERATING YOUR LAMINATOR General Machine Safety The following messages are written here for your safety, all operators and others around the laminator should read, understand and follow these messages. 1. Read and understand all the safety instructions. 2.

  • Page 7: Chapter 4 Operation

    Operation General 1. Power: A switch in the lower right rear switches the main power on and off. The switch is labeled clearly so the operator can tell if the power is on or off. 2. Reset: A reset button is used to start the machine initially and restart the machine after an E-stop condition has occurred.

  • Page 8: Right Front Control Panel, Figure 1

    Operation Right Front Control Panel The right front control panel looks like the figure below. Figure 1 Right Front Control Panel Main Roller Controls: The rocker switch will open and close the main nip rollers. The switch will illuminate when the rolls are selected to close.

  • Page 9: Left Front Control Panel, Figure 2

    Operation Left Front Control Panel The left front control panel looks like the figure below. Figure 2. Left Front Control Panel Cooling Fans: Your machine is equipped with lower cooling fans, the rocker switch will turn the cooling fans on and off. When the fans are turned on, the rocker switch will illuminate.

  • Page 10: Rear Control Panel, Figure 3

    Operation Rear Control Panel Figure 3. Rear Control Panel Pull Roller Controls: The rocker switch will open and close the main nip rollers. The switch will illuminate when the rolls are selected to close. The pressure guage is an indicator of how much pressure is being supplied to the pull roll cylinders.

  • Page 11: Top Control Panel, Figure 4

    Operation Top Control Panel Figure 4. Top Control Panel The top control panel is used to control the speed and direction of the machine. There are three buttons located to the left of the panel and a potentiometer wheel on the right. The potentiometer wheel controls the speed setting of the machine.

  • Page 12: Web Tension Adjust, Figure 5

    Operation Web Tension adjust The brakes on your machine are located on the unwind shafts near the left hand side of the machine. The brakes use compression of the delrin block on the shaft to create back tension on the web. For best results when laminating use the least amount of tension as possible for your application.

  • Page 13: Loading And Positioning Film

    Operation Laminator Setup Your laminator has been designed to make the setup and lamination process as easy and repeatable as possible, however, there will be techniques that make this phase easier that you will only learn by using the machine. Do not get frustrated if the setup process takes longer than you expected, the process will get quicker and easier the more you use your laminator.

  • Page 14: Encapsulation Process, Figure 7

    Operation Webbing the Laminator The term webbing means routing the film through the laminators’ idlers and nip rolls and thus creating a web. The easiest way to web the machine up after loading the film is by using a piece of feeder stock.
  • Page 15 Operation Encapsulation Process 1. Load thermal film on the rear upper and lower unwind stations. Turn the brake to zero. 2. Set temperature on upper and lower nip rolls and allow rolls to balance at temperature. 3. Set the shim wheels to “0” on both the nip rolls and pull rolls. The nip section can pull you into laminator! Do not place fingers into the nip section when the rolls are rotating.

  • Page 16: Pressure Sensitive Top And Bottom Process, Figure 8

    Operation Pressure Sensitive Top and Bottom Process Figure 8. Pressure Sensitive Top and Bottom Process Web Diagram 4-10...
  • Page 17 Operation Pressure Sensitive Top and Bottom Process 1. Load film on the rear upper and lower front unwind station. Note that the lower front station cannot be used for a pressure sensitive film with a release liner. Turn the brake to zero. 2.

  • Page 18: Pressure Sensitive Process, Reverse, Figure 9

    Operation Pressure Sensitve Process (Reverse) Sometimes mounting processes are required to be run between encapsulation processes. Since the nip rolls will be very warm due to the encapsulation process it is not possible to run a cold mounting process without letting the roll cool down. This could be a very long wait depending on the temperatures used for the encapsulation process.
  • Page 19 Operation Pressure Sensitive Process (Reverse) 1. Load film on the rear upper unwind station. Turn the brake to zero. 2. Set the shim wheels to “0” on the pull rolls and 1" on the nip rolls, place a piece of feeder stock into the pull rolls with plenty of stock hanging out the front.

  • Page 20: Process Output Trouble Shooting

    If the web breaks between the laminating opening and the rewind station, reduce the rewind clutch tension. Web breaks will occur from faulty material. The AGL laminator will not correct this; the material must be replaced.
  • Page 21 Operation Wrinkles in Product 1. Check the adhesive stock for wrinkles while operating. If wrinkles exist, this is a manufacturing material defect, and must be cut out of the roll. A laminator will not correct material defects. 2. String the web straight and square between the unwind and the windup shafts. If it is not straight and square, the tension will not be even across the web and will cause wrinkling.

  • Page 22: Process Control Chart

    Operation PROCESS CONTROL CHART Process: Product: Material Top: Material Bottom: Other Material: Date Settings Documented: Front Control Settings Speed (Ft/min): Direction: Forward Reverse Nip Roll: Down Shim Dial Setting: Roll Pressure: (PSI) Top Temp. Setting: Deg. F Top Roll Heater: Bottom Temp.
  • Page 23 Operation 4-17...

  • Page 24: Chapter 5 Maintenance

    The nip rolls should be cleaned as often as necessary, the frequency will vary on the products used and the processes being run. AGL recommends a mild detergent solution or denatured alcohol with a 100% lint free cloth to clean the rolls. Your film manufacturer can recommend solvents that will remove the adhesive from silicone and neoprene rolls without causing damage to the coverings.

  • Page 25: Roller Open And Close Rate

    Maintenance Roller open and close rate The rollers must open and close evenly to prevent excessive wear on the cylinders and bearings. This rate is set at the factory, but can be adjusted in the field. Follow the procedure below to adjust either the pull rolls or nip rolls.
  • Page 26 AGL offers no warranty for the laminated product and/or process that the machine produces and as such will not be liable for any special, indirect or consequential damages.
  • Page 27 AGL-64-K4678 PULL ROLL ASSEMBLY AGL-64-K4687-1 DRIVE ASSEMBLY, ENCORE MAXIM AGL-64-K4760-1 UNWIND w/ LED DISPLAY, ASSEMBLY, ENCORE SERIES AGL-64-K4743-1 PRODUCT WINDUP ASSEMBLY, ENCORE MAXIM & DHR AGL-64-K4731-1 LINER WINDUP ASSEMBLY, ENCORE AGL-64-K4748 IDLER ASSEMBLY AGL-64-K4693 EASY WEB INFEED TABLE ASSY, AGL-64-K4706...
  • Page 29 Bill Of Material Part #: AGL-64-K4803-1 Appl #: Assy #: AGLD4802-1 BOM Rev: 4/7/2003 Model #: Rev: Rev: Date: MAIN MACHINE FRAME, ENCORE SERIES Description: Item: Part #: Description: Qty: AGL-XX-D4798-1 RH. SIDEPLATE WELDMENT, ENCORE SERIES AGL-XX-D4797-1 LH. SIDEPLATE WELDMENT, ENCORE SERIES...
  • Page 31 Rev: Rev: Date: NIP ROLL ASSEMBLY Description: Item: Part #: Description: Qty: AGL-64-D1113 NIP ROLL SUB ASSY, AGL 64 AGL-64-C1116 HEATING ELEMENT, AGL 64 AGL-64-B1117 BEARING GIB AGL-XX-B4674 HOUSING, BEARING, UPPER ROLL AGL-64-B1121-1 RH. PHOTOEYE MTG. BRKT, AGL64 AGL-XX-B1070 BRACKET, SLIP RING STOP...
  • Page 32 Part #: AGL-64-K4677 Appl #: Assy #: AGLC4675 BOM Rev: Model #: Rev: Rev: Date: 12/23/2002 Description: NIP ROLL ASSEMBLY Item: Part #: Description: Qty: 000035-03 SHCS, #10-32UNF, 3/8 LG, BLACK 012396-32 BEARING, THRUST, WASHER, 2 DIA BORE, .03 THICK...
  • Page 34 Bill Of Material Part #: AGL-64-K4678 Appl #: Assy #: AGLC4679 BOM Rev: 9/23/2002 Model #: Rev: Rev: Date: PULL ROLL ASSEMBLY Description: Item: Part #: Description: Qty: AGL-64-B0842 UPPER PULL ROLL SUB ASSY AGL-64-B0018 LOWER PULL ROLL AGL-64-B2244-1 PULL ROLL GUIDE BLOCK, AGL64R/64i 001317-16 KEY, 0.188 SQ, 2.00 LG, CRS...
  • Page 35 Part #: AGL-64-K4678 Appl #: Assy #: AGLC4679 BOM Rev: Model #: Rev: Rev: Date: 9/23/2002 Description: PULL ROLL ASSEMBLY Item: Part #: Description: Qty: 012378-04 SSS, BRASS TIP, 1/4-20UNC, 1/4" LG. 000131-08 SSS, CUP PT, 1/4-20UNC, 1/2 LG, BLACK...
  • Page 37 Part #: AGL-64-K4687-1 Appl #: Assy #: AGLC4686-1 BOM Rev: 4/2/2003 Model #: Rev: Rev: Date: DRIVE ASSEMBLY, ENCORE MAXIM Description: Item: Part #: Description: Qty: AGL-XX-B4684 IDLER TENSIONER, 1.675 LG. AGL-XX-B4685 IDLER TENSIONER, 2.69 LG. AGL-XX-B4964 SPROCKET MOD. (ALTER MARTIN #35B15) AGL-64-B0928-1 IDLER TENSIONER, 3.63 LG.
  • Page 38 Appl #: Assy #: AGLC4686-1 BOM Rev: Model #: Rev: Rev: Date: 4/2/2003 Description: DRIVE ASSEMBLY, ENCORE MAXIM Item: Part #: Description: Qty: 012415-08 WASHER, LOCK, 8mm DIA, SPLIT, BLACK OXIDE 012141-117 CHAIN, #35, 117 PITCHES 012416-07 WASHER, FLAT, SAE, 5/16 DIA, 11/16 OD, 11/32 ID, BLACK OXIDE To order call Advanced Greig Laminators, Inc.
  • Page 40 Bill Of Material Part #: AGL-64-K4760-1 Appl #: Assy #: AGLD4759-1 BOM Rev: 4/7/2003 Model #: Rev: Rev: Date: UNWIND w/ LED DISPLAY, ASSEMBLY, ENCORE SERIES Description: Item: Part #: Description: Qty: AGL-XX-B4750 PIVOT BLOCK AGL-XX-B5036 PLUG, TUBE AGL-XX-B4752 PIVOT SHAFT...
  • Page 41 Part #: AGL-64-K4760-1 Appl #: Assy #: AGLD4759-1 BOM Rev: Model #: Rev: Rev: Date: 4/7/2003 Description: UNWIND w/ LED DISPLAY, ASSEMBLY, ENCORE SERIES Item: Part #: Description: Qty: 012227-105 CLAMP, CABLE, 1/4" 002982-04 SPACER, ROUND, #6 ID, .23 OD, .44 LG...
  • Page 43 Part #: AGL-64-K4743-1 Appl #: Assy #: AGLB4744-1 BOM Rev: 3/12/2003 Model #: Rev: Rev: Date: PRODUCT WINDUP ASSEMBLY, ENCORE MAXIM & DHR Description: Item: Part #: Description: Qty: AGL-XX-B4723 BEARING BLOCK, WINDUP AGL-XX-B4724 DRIVE HUB, WINDUP AGL-XX-B4725 IDLER HUB, WINDUP...
  • Page 44 AGLB4744-1 BOM Rev: Model #: Rev: Rev: Date: 3/12/2003 Description: PRODUCT WINDUP ASSEMBLY, ENCORE MAXIM & DHR Item: Part #: Description: Qty: 000722-06 BUSHING, BRONZE, 3/4 ID, 1 OD, 3/4 LG To order call Advanced Greig Laminators, Inc. 608-846-7016 20-Feb-08...
  • Page 46 Bill Of Material Part #: AGL-64-K4731-1 Appl #: Assy #: AGLB4730-1 BOM Rev: 3/12/2003 Model #: Rev: Rev: Date: LINER WINDUP ASSEMBLY, ENCORE Description: Item: Part #: Description: Qty: AGL-XX-B4723 BEARING BLOCK, WINDUP AGL-XX-B4724 DRIVE HUB, WINDUP AGL-XX-B4725 IDLER HUB, WINDUP...
  • Page 48 Bill Of Material Part #: AGL-64-K4748 Appl #: Assy #: AGLB4749 BOM Rev: 10/31/2002 Model #: Rev: Rev: Date: IDLER ASSEMBLY Description: Item: Part #: Description: Qty: AGL-64-B4286 IDLER SHAFT AGL-64-B4287 IDLER SLEEVE 000013-06 SHCS, 3/8-16UNC, 3/4 LG, BLACK To order call Advanced Greig Laminators, Inc. 608-846-7016...
  • Page 50 Bill Of Material Part #: AGL-64-K4693 Appl #: Assy #: AGLD4691 BOM Rev: 9/30/2002 Model #: Rev: Rev: Date: EASY WEB INFEED TABLE ASSY, Description: Item: Part #: Description: Qty: AGL-XX-B4173-1 TABLE END, LH. AGL-XX-B4174-1 TABLE END, RH. AGL-XX-B4175 CONNECTING LINK...
  • Page 51 Part #: AGL-64-K4693 Appl #: Assy #: AGLD4691 BOM Rev: Model #: Rev: Rev: Date: 9/30/2002 Description: EASY WEB INFEED TABLE ASSY, Item: Part #: Description: Qty: 000207-06 WASHER, FLAT, SAE, 1/4 DIA, 5/8 OD, 9/32 ID, ZINC 012355-01 HANDLE, TEE 012336-06 WASHER, FLAT, TEFLON, WHITE, 1/16 THK, .390 ID.
  • Page 53 Bill Of Material Part #: AGL-64-K4706 Appl #: Assy #: AGLC4705 BOM Rev: 10/9/2002 Model #: Rev: Rev: Date: OUTFEED TABLE ASSEMBLY, PIVOTING Description: Item: Part #: Description: Qty: AGL-XX-C4694 TABLE END, RH. OUTFEED AGL-XX-C4695 TABLE END, LH. OUTFEED AGL-64-D4699...
  • Page 54 Part #: AGL-64-K4706 Appl #: Assy #: AGLC4705 BOM Rev: Model #: Rev: Rev: Date: 10/9/2002 Description: OUTFEED TABLE ASSEMBLY, PIVOTING Item: Part #: Description: Qty: 002862-01 TERMINAL, MALE PIN, 14-16AWG, BLUE 001509-03 TERMINAL, RING, INSULATED, 16-14AWG, #10 STUD 000201-03...
  • Page 56 Bill Of Material Part #: AGL-64-K4961 Appl #: Assy #: AGLC4960 BOM Rev: 4/3/2003 Model #: Rev: Rev: Date: COOLING STATION, LOWER, ENCORE Description: Item: Part #: Description: Qty: AGL-64-C4944 FAN CASE 001988-02 FAN, AXIAL, 4-1/2" SQ, 106 CFM, 230V 001987-05 GUARD, FAN, CHROME, 4-1/2"...
  • Page 58 Part #: AGL-64-K4721-1 Appl #: Assy #: AGLC4720-1 BOM Rev: 4/7/2003 Model #: Rev: Rev: Date: PNEUMATIC ASSEMBLY, ENCORE MAXIM & DHR Description: Item: Part #: Description: Qty: 012263-05 TUBING, 1/4" OD, BLACK 001294 REGULATOR, PRESSURE, 1/8NPT 012234-01 GUAGE, PRESSURE, 0-100PSI, 1/8NPT, PANEL MNT, CHROME BEZEL...
  • Page 61 Bill Of Material Part #: AGL-64-K4808-1 Appl #: Assy #: AGLC5135 BOM Rev: 4/3/2003 Model #: Rev: Rev: Date: ELECTRICAL ASSEMBLY, ENCORE MAXIM Description: Item: Part #: Description: Qty: AGL-64-D4807-1 ELECTRICAL SCHEMATIC, ENCORE MAXIM REF. AGL-XX-B4805 POT. MTG. BRACKET AGL-XX-B4806...
  • Page 62 Appl #: Assy #: AGLC5135 BOM Rev: Model #: Rev: Rev: Date: 4/3/2003 Description: ELECTRICAL ASSEMBLY, ENCORE MAXIM Item: Part #: Description: Qty: 001089-02 CABLE TIE, NYLON, WHITE, 5.5" LG 001090-02 CABLE TIE, MOUNT, ADHESIVE-BACKED, 1" SQ 001875-01 FUSE HOLDER, TERMINAL BLOCK, 35MM MTG, (NOW INCLUDES 001881-01)
  • Page 63 Appl #: Assy #: AGLC5135 BOM Rev: Model #: Rev: Rev: Date: 4/3/2003 Description: ELECTRICAL ASSEMBLY, ENCORE MAXIM Item: Part #: Description: Qty: 006017-02 SWITCH, MOMENTARY, BLANK, RED 001352-06 STANDOFF, HEX, M/F, #10-32UNC, 3/4 LG, AL 002523-08 FERRULE, INSULATED, 18AWG, WIDE COLLAR...
  • Page 64 Appl #: Assy #: AGLC5135 BOM Rev: Model #: Rev: Rev: Date: 4/3/2003 Description: ELECTRICAL ASSEMBLY, ENCORE MAXIM Item: Part #: Description: Qty: 002337-06 SOCKET, RELAY, 5-PIN, DIN RAIL MTG 012393 DOUBLE SIDED TAPE 002345-221 RESISTOR, METAL-FILM, 1%, 1/4W, 221 OHM...
  • Page 66 Bill Of Material Part #: AGL-XX-K4816 Appl #: Assy #: AGLB4965 BOM Rev: 11/21/2002 Model #: Rev: Rev: Date: SPEED DISPLAY ASSEMBLY Description: Item: Part #: Description: Qty: 006020-01 SENSOR, MAGNETIC, 8-30VDC,PUSH-PULL 006020-03 RING, MAGNETIC 002855-01 COUNTER & RATE INDICATOR...
  • Page 68 Bill Of Material Part #: AGL-64-K4824 Appl #: Assy #: AGLB4747 BOM Rev: 12/6/2002 Model #: Rev: Rev: Date: MOVABLE IDLER ASSEMBLY, MAXIM Description: Item: Part #: Description: Qty: AGL-64-B4745 MOVABLE IDLER ROLLER AGL-XX-B4746 SHAFT, IDLER ROLLER 012404-01 WASHER, 1.120 OD. x .160 ID. x .03 THK, SST 012405-05 SPRING, COMPRESSION, 1.095 OD, 0.082 THICK, 1.75 LG, MUSIC WIRE...
  • Page 70 Bill Of Material Part #: AGL-64-K4326 Appl #: Assy #: AGLC4327 BOM Rev: 1/17/2002 Model #: Rev: Rev: Date: INFEED BASKET ASSEMBLY Description: Item: Part #: Description: Qty: AGL-64-D4329 INFEED BASKET AGL-XX-B4328 HANGING BRACKET, BASKET 000071-04 BHSCS, #10-32UNF, 1/2 LG, BLACK To order call Advanced Greig Laminators, Inc.
  • Page 71 Bill Of Material Part #: AGL-XX-K2660 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: ACCESSORIES KIT, 44/4400/64 SERIES/6400/6450 Description: Item: Part #: Description: Qty: 012235-01 CUTTER, ZIPPY 012236-01 ROLL ADHESIVE ERASER, PLAIN, SHRINKWRAPPED 001446-04 ALLEN WRENCH, LONG ARM, 3/32, T-HANDLE...
  • Page 73 Bill Of Material Part #: AGL-64-K5033-2 Appl #: Assy #: AGLB5034 BOM Rev: 11/7/2005 Model #: Rev: Rev: Date: INFEED HOLD DOWN, ENCORE, EASY WEB TABLE Description: Item: Part #: Description: Qty: AGL-64-C2904-02 INFEED HOLD DOWN, ENCORE SERIES (WHITE) 000055-04...

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