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Advanced Greig Laminators, Inc. AGL8000S Operator's Manual

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OPERATORS MANUAL
FOR
AGL8000S
801 Burton Blvd. DeForest WI 53532
Ph: 608-846-7016 Fax: 608-846-1024
E-mail: info@aglaminators.com

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Summary of Contents for Advanced Greig Laminators, Inc. AGL8000S

  • Page 1 OPERATORS MANUAL AGL8000S 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 Preface- General Description Chapter 1 Installation Selecting Area……………………………………………………………………………… 1-1 Uncrating……………………………………………………………………………………… 1-1 Leveling……………………………………………………………………………………… 1-1 Electrical Connection…………………………………………………………………………1-2 Pneumatic Connection……………………………………………………………………… 1-2 Recycling Packaging………………………………………………………………………… 1-2 Chapter 2 Specifications Machine Dimensions………………………………………………………………………… 2-1 Electrical Requirements…………………………………………………………………… 2-1 Pneumatic Requirements…………………………………………………………………… 2-1 Material Capacity…………………………………………………………………………… 2-1 Chapter 3 Safety General Machine Safety……………………………………………………………………...

  • Page 3: Preface-General Description

    Preface-General Description Preface Your Advanced Greig Laminators, Inc. (AGL) laminator is a finely engineered and designed piece of equipment. Standard equipment includes a 1 HP DC drive (variable and reversible), air operated brake and clutch, plus an air-operated laminating section with easily adjustable spacer system for controlled laminating nip opening.

  • Page 4: Chapter 1 Installation

    Installation Selecting Area Select an area that has a smooth, level surface for the laminator to set on, this will allow for easier maneuverability of the machine if it requires moving later on. The area should be large enough to allow an operator ample room to properly handle your largest product on the infeed and outfeed sides of the laminator.

  • Page 5: 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 6: Chapter 2 Specifications

    Specifications Machine Dimensions Length: 105” Height: 60” Depth: 57” Weight: 3200 lbs. Electrical Requirements 220/230 VAC single phase, 50/60 Hz, 80 Amp service. Pneumatic Requirements Approximately 2-3 cfm at 90 psi line pressure supplied via your cleaned/dried/regulated plant air. Material Capacity Upper Front Station: 10”...

  • Page 7: 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 8: Chapter 4 Operation

    Operation General 1. Power: A red and yellow power switch 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 9: Right Hand Control Panel, Figure 1

    Operation Right Hand Control Panel The right hand control panel looks like the figure below. Upper Roll Heater Controls: Two position switch turns heater for upper roll on and off. The temperature controller allows the operator to set a desired temperature for the process.

  • Page 10: Left Hand Control Panel, Figure 2

    Operation Left Hand Control Panel The left hand control panel looks like the figure below. Upper Rear Station: The 2 position switch turns the brake on and off. The regulator adjusts the air pressure to the brake changing the web tension. The gauge indicates air pressure which allows for repeatable results.

  • Page 11: Rear Control Panel, Figure 3

    Operation Rear Control Panel Drive Control: STOP button stops the drive from turning thus stopping the rolls. Pull Roller Control: A 2 position switch open and closes the pull rolls. The regulator adjusts the air pressure to the cylinders and the gauge indicates air pressure which allows for repeatable results.

  • Page 12: Laminator Setup

    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 13: Encapsulation Process

    Operation Encapsulation Process 1. Load thermal film on the rear upper and lower unwind stations. Turn the selector switch on these two stations to “Off”. 2. Set the shim wheels to “0”, place a piece of feeder stock into the nip rolls with plenty of stock hanging out the front.

  • Page 14: Pressure Sensitive Process

    Operation Pressure Sensitive Process 1. Load film on the rear upper unwind station. Turn the selector switch to that station to “Off”. 2. Set the shim wheels to “0”, place a piece of feeder stock into the nip rolls with plenty of stock hanging out the front.

  • Page 15: Process Output Trouble Shooting

    Operation Process Output Trouble Shooting Straight waves in output Pull roll creating too much tension Decrease clutch air pressure Film not cooling fast enough Slow feed rate down and turn on cooling system. Waves on one side of output Nip “zero” setting may be incorrect Check nip setting and adjust if necessary.
  • Page 16 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 17: 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 18 Operation 4-11...

  • Page 19: Chapter 5 Maintenance

    Maintenance Maintenance As a result of years of experience, refined engineering and construction techniques, very little time need be lost to maintenance. However, regular maintenance will keep your laminator operating at its optimum level. Removing the enclosure covers to work on machine exposes person to electrocution and moving parts hazard.

  • Page 20: 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 23: Chapter 6 Warranty

    Warranty Warranty and Conditions AGL warrants all models of the laminator’s product line manufactured to be free from defects in workmanship and materials for a period of one year with the exception of operator caused damage, or surface abrasions to the laminating rolls or other obvious caused damage.
  • Page 24 Bill Of Material Part #: AGL-80-K1916-1 Appl #: Assy #: AGLD1915-1 BOM Rev: 1/8/2002 Model #: Rev: Rev: Date: MAIN MACHINE FRAME, AGL8000 Description: Item: Part #: Description: Qty: AGL-80-D1912-1 RH. SIDEPLATE, AGL8000 SERIES AGL-80-D1913-1 LH. SIDEPLATE, AGL8000 SERIES AGL-80-B1918 LOWER TIE BAR, AGL8000 AGL-80-B1917 CROSS TUBE, AGL8000...
  • Page 26 Bill Of Material Part #: AGL-80-K1894-1 Appl #: Assy #: AGLD1889-1 BOM Rev: 1/8/2002 Model #: Rev: Rev: Date: NIP ROLL ASSEMBLY, AGL8000R (BAUMER EYE) Description: Item: Part #: Description: Qty: AGL-80-C1886 NIP ROLL SUB ASSEMBLY, AGL8000 AGL-80-B1797 BEARING GIB, AGL8000 AGL-80-B2092 CENTERING COLLAR, AGL8000 AGL-80-B2103...
  • Page 27 Part #: AGL-80-K1894-1 Appl #: Assy #: AGLD1889-1 BOM Rev: Model #: Rev: Rev: Date: 1/8/2002 Description: NIP ROLL ASSEMBLY, AGL8000R (BAUMER EYE) Item: Part #: Description: Qty: 000055-03 BHSCS, #8-32UNC, 3/8 LG, BLACK 000553-08 PHMS, SLOTTED, #4-40UNC, 1 LG, ZINC 000207-01 WASHER, FLAT, SAE, #4 DIA, 5/16 OD, 1/8 ID, ZINC 000493-01...
  • Page 29 Part #: AGL-80-K3040-1 Appl #: Assy #: AGLD3039-1 BOM Rev: 6/24/2003 Model #: Rev: Rev: Date: DRIVE ASSEMBLY, AGL8000S (PNEUMATIC COUPLER) Description: Item: Part #: Description: Qty: AGL-80-B1804 MOTOR SUPPORT, AGL8000 AGL-80-B1803 MOTOR MOUNTING PLATE, AGL8000 AGL-80-B2097 IDLER TENSIONER, 3.00 LG.
  • Page 30 Appl #: Assy #: AGLD3039-1 BOM Rev: Model #: Rev: Rev: Date: 6/24/2003 Description: DRIVE ASSEMBLY, AGL8000S (PNEUMATIC COUPLER) Item: Part #: Description: Qty: 000493-08 WASHER, LOCK, 3/8 DIA, SPLIT, ZINC 012022-05 GEAR BOX, 60:1 012022-06 OUTPUT SHAFT, 1.25 DIA.
  • Page 32 Part #: AGL-80-K3567-1 Appl #: Assy #: AGLC3568-1 BOM Rev: 5/23/2003 Model #: Rev: Rev: Date: UNWIND/WINDUP ASSEMBLY, AGL8000S/C (PNEUMATIC COUPLER) Description: Item: Part #: Description: Qty: AGL-64-B0003 VERTICAL SHAFT, CANTILEVERED UNWIND AGL-64-B0004 SHAFT BRACE, CANTILEVERED UNWIND AGL-64-B0005 SHAFT SUPPORT, CANTILEVERED UNWIND...
  • Page 33 Part #: AGL-80-K3567-1 Appl #: Assy #: AGLC3568-1 BOM Rev: Model #: Rev: Rev: Date: 5/23/2003 Description: UNWIND/WINDUP ASSEMBLY, AGL8000S/C (PNEUMATIC COUPLER) Item: Part #: Description: Qty: To order call Advanced Greig Laminators, Inc. 608-846-7016 24-Nov-08 Page 2 of 2...
  • Page 35 Bill Of Material Part #: AGL-80-K1866 Appl #: Assy #: AGLD1865 BOM Rev: 1/14/1999 Model #: Rev: Rev: Date: INFEED/OUTFEED TABLE ASSEMBLY, AGL8000 Description: Item: Part #: Description: Qty: AGL-80-C1864 REMOVABLE TABLE, AGL8000 AGL-64-B0082-01 TABLE SUPPORT, RIGHT HAND (LIGHT GREY) AGL-64-B0083-01 TABLE SUPPORT, LEFT HAND (LIGHT GREY) AGL-64-B0923...
  • Page 37 Part #: AGL-80-K1896-3 Appl #: Assy #: AGLC1895-3 BOM Rev: 9/25/2006 Model #: Rev: Rev: Date: PULL ROLL ASSEMBLY, AGL8000S Description: Item: Part #: Description: Qty: AGL-80-B1898 UPPER PULL ROLL SUB ASSEMBLY, AGL8000 AGL-64-B0694-1 STOP, CYLINDER, TAPPED AGL-80-B2014-1 PULL ROLL GUIDE BLOCK, AGL8000...
  • Page 39 Bill Of Material Part #: AGL-80-K1851 Appl #: Assy #: AGL-80-D1850 BOM Rev: 1/5/1999 Model #: Rev: Rev: Date: IDLER ASSY, AGL8000 Description: Item: Part #: Description: Qty: AGL-80-B1806 IDLER SUB ASSY, AGL8000 000343-10 HHCS, 3/8-16UNC, 1-1/4 LG, ZINC 000207-08 WASHER, FLAT, SAE, 3/8 DIA, 13/16 OD, 13/32 ID, ZINC 000493-08 WASHER, LOCK, 3/8 DIA, SPLIT, ZINC...
  • Page 41 Bill Of Material Part #: AGL-80-K2909 Appl #: Assy #: AGLC2910 BOM Rev: 6/20/2000 Model #: Rev: Rev: Date: INFEED HOLD DOWN ASSEMBLY, 8000 SERIES Description: Item: Part #: Description: Qty: AGL-80-D2905 INFEED HOLD DOWN, 8000 SERIES 000055-02 BHSCS, #8-32UNC, 1/4 LG, BLACK To order call Advanced Greig Laminators, Inc.
  • Page 43 Bill Of Material Part #: AGL-80-K5112 Appl #: Assy #: AGLC5111 BOM Rev: 7/2/2003 Model #: Rev: Rev: Date: COOLING STATION, UPPER, AGL8000 SERIES Description: Item: Part #: Description: Qty: AGL-80-C5108 FAN CASE, AGL8000 001988-02 FAN, AXIAL, 4-1/2" SQ, 106 CFM, 230V 001987-05 GUARD, FAN, CHROME, 4-1/2"...
  • Page 45 Bill Of Material Part #: AGL-80-K5114 Appl #: Assy #: BOM Rev: 7/2/2003 Model #: Rev: Rev: Date: ELECTRICAL ASSEMBLY, AGL8000S Description: Item: Part #: Description: Qty: AGL-80-D5113 CONTROL SCHEMATIC, AGL8000S AGL-80-B5116 DECAL PACKAGE, AGL 8000 SERIES AGL-64-A0941 LABEL, TERMINAL BLOCK, AGL 6400/64/64i...
  • Page 46 AGL-80-K5114 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 7/2/2003 Description: ELECTRICAL ASSEMBLY, AGL8000S 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 47 AGL-80-K5114 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 7/2/2003 Description: ELECTRICAL ASSEMBLY, AGL8000S Item: Part #: Description: Qty: 001826-11 POWER SUPPLY, SINGLE, 24VDC, 1.0A 000715-00 WIRE, STRANDED, 18 AWG, BLACK 012142-01 KNOB, FLUTED, 1.06 DIA., 1/4 DIA. SHAFT 001530-003 FUSE, SLO-BLO, 1/4A, 250V, 1/4X1-1/4"...
  • Page 48 AGL-80-K5114 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 7/2/2003 Description: ELECTRICAL ASSEMBLY, AGL8000S Item: Part #: Description: Qty: 002523-10 FERRULE, INSULATED, 12AWG, STD LENGTH, GRAY 002523-02 FERRULE, INSULATED, 14AWG, STD LENGTH, BLUE 002727-01 CONNECTOR, 90 DEG. FLAG DISCONNECT 16-14AWG 002727-02 CONNECTOR, 90 DEG.
  • Page 50 Part #: AGL-80-K3035-1 Appl #: Assy #: AGLC3034-1 BOM Rev: 6/24/2003 Model #: Rev: Rev: Date: PNEUMATIC ASSEMBLY, AGL8000S (PNEU. COUPLER) Description: Item: Part #: Description: Qty: 012262-05 TUBING, 5/32" OD, BLACK 012263-05 TUBING, 1/4" OD, BLACK 001294 REGULATOR, PRESSURE, 1/8NPT 012234-03 GUAGE, PRESSURE, 0-100PSI, 1/8NPT, PANEL MNT.
  • Page 51 Assy #: AGLC3034-1 BOM Rev: Model #: Rev: Rev: Date: 6/24/2003 Description: PNEUMATIC ASSEMBLY, AGL8000S (PNEU. COUPLER) Item: Part #: Description: Qty: 001456-01 FITTING, DOUBLE "Y", 1/4 TUBE - 5/32 TUBE To order call Advanced Greig Laminators, Inc. 608-846-7016 24-Nov-08...
  • Page 53 Bill Of Material Part #: AGL-XX-K2914 Appl #: Assy #: BOM Rev: 6/23/2000 Model #: Rev: Rev: Date: ACCESSORIES KIT, 8000 SERIES 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 001446-11 ALLEN WRENCH, LONG ARM, 1/4 T-HANDLE 012248...
  • Page 54 Bill Of Material Part #: AGL-80-K5462 Appl #: Assy #: AGLC5461 BOM Rev: 4/20/2004 Model #: Rev: Rev: Date: BOARD SUPPORT TABLE ASSEMBLY, AGL8000 Description: Item: Part #: Description: Qty: AGL-80-C2914-1 BOARD SUPPORT TABLE, AGL8000 (2004) 000635-12 SHOULDER SCREW, 3/8 DIA, 1-1/2 LG (5/16-18UNC) 000346-18 HHCS, 7/16-14UNC, 2-1/2 LG, ZINC To order call Advanced Greig Laminators, Inc.

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