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Advanced Greig Laminators, Inc. AGL64i Operator's Manual

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OPERATORS MANUAL
FOR
AGL64i
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. AGL64i

  • Page 1 OPERATORS MANUAL AGL64i 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 1/2 HP DC drive (variable and reversible), manually 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: 88” Height: 60” Depth: 38” Weight: 2100 lbs. Electrical Requirements 220/230 VAC single phase, 50/60 Hz, 60 Amp service. Pneumatic Requirements Approximately 2-3 cfm at 60-90 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 circuit breaker switch is located on the lower right rear of the machine to turn power on and off. 2. Reset: Located on the right rear enclosure, the reset button is used to start the machine initially and restart the machine after an E-stop condition has occurred.

  • Page 9: Front Right Control Panel, Figure 1

    Operation Front Right Control Panel The front right control panel looks like the figure below. Top Roller Controls: Two position switch opens and closes the nip rolls. The regulator adjusts the air pressure to the cylinders that create the pressure on the nip rolls. The gauge indicates air pressure which allows for repeatable results.

  • Page 10: Front Left Control Panel, Figure 2

    Operation Front Left Control Panel The front left control panel looks like the figure below. Upper Roll Heat Control: 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. The controller will maintain that temperature during the process.

  • Page 11: Rear Right Control Panel, Figure 3

    Operation Rear Right Control Panel The rear right control panel looks like the figure below. Top Pull Roller Control: Two position switch opens and closes the pull rolls. The regulator adjusts the air pressure to the cylinders and clutch. The gauge indicates air pressure which allows for repeatable results.

  • Page 12: Reset Panel, Figure 4

    Operation Reset Panel The reset panel looks like the figure below. Reset Switch The momentary pushbutton switch must be pressed and held for 15 seconds after turning on main power and after and emergency stop. Figure 4. Reset Panel Temperature Controls Your laminator has heated rolls that allow you to laminate with thermal films and pressure sensitive films that require heat to activate the adhesive.

  • Page 13: 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 14: Encapsulation Process

    Operation Encapsulation Process 1. Load thermal film on the upper rear and center front unwind stations. Loosen the brake tension by rotating the knob counter clockwise. 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: Curl Cam Option

    Operation Curl Cam Option Your machine may have an option called the curl cam. This is a set of 2 idler rollers that can be pivoted and locked into position. This option is particularly useful when the machine is running thermal films of differing thickness.

  • Page 16: Pressure Sensitive Process

    Operation Pressure Sensitive Process 1. Load film on the rear upper unwind station and front center (if required and only without release liner). Loosen the brake tension by turning counter knob counter clockwise. 2. Set the shim wheels to “0”, or to the correct shim height if a board is being used. Place a piece of feeder stock into the nip rolls with plenty of stock hanging out the front and close the nip rolls onto the piece of feeder stock.

  • Page 17: 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 18 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 19: 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 20 Operation 4-13...

  • Page 21: 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 22: 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 the 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 Date: MASTER BILL OF MATERIALS, AGL64i Description: Item: Part #: Description: Qty: AGL-64-K2528-3 MAIN MACHINE FRAME ASSEMBLY, AGL64i & 64R AGL-64-K0959-1 NIP ROLL ASSEMBLY, AGL64 (BAUMER EYE) AGL-64-K2242-2 PULL ROLL ASSY, AGL64R/64i (SENSOR INSIDE) AGL-64-K2246-1 DRIVE ASSEMBLY, AGL64R/64i AGL-64-K0962-2 UNWIND ASSEMBLY, AGL64I...
  • Page 25 Part #: AGL-64-K2528-3 Appl #: Assy #: AGLD2530-3 BOM Rev: 8/29/2002 Model #: Rev: Rev: Date: MAIN MACHINE FRAME ASSEMBLY, AGL64i & 64R Description: Item: Part #: Description: Qty: AGL-64-D1147-1 RH. ENCLOSURE, AGL64i AGL-64-D1148-1 LH. ENCLOSURE, AGL64i AGL-64-D1149-1 RH. SIDEPLATE, AGL64 SERIES AGL-64-D1150-1 LH.
  • Page 27 Bill Of Material Part #: AGL-64-K0959-1 Appl #: Assy #: AGLD1120-1 BOM Rev: 1/17/2002 Model #: Rev: Rev: Date: NIP ROLL ASSEMBLY, AGL64 (BAUMER EYE) 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-64-B1118...
  • Page 28 Part #: AGL-64-K0959-1 Appl #: Assy #: AGLD1120-1 BOM Rev: Model #: Rev: Rev: Date: 1/17/2002 Description: NIP ROLL ASSEMBLY, AGL64 (BAUMER EYE) Item: Part #: Description: Qty: 000493-01 WASHER, LOCK, #4 DIA, SPLIT, ZINC 000201-01 NUT, HEX, #4-40UNC, ZINC 000007-03 SHCS, #10-24UNC, 3/8 LG, BLACK 001403-32...
  • Page 30 Bill Of Material Part #: AGL-64-K2242-2 Appl #: Assy #: AGLC2241-2 BOM Rev: 2/26/2002 Model #: Rev: Rev: Date: PULL ROLL ASSY, AGL64R/64i (SENSOR INSIDE) Description: Item: Part #: Description: Qty: AGL-64-B0842 UPPER PULL ROLL SUB ASSY AGL-64-B0913-1 STOP, CYLINDER, TAPPED AGL-64-B2244-1 PULL ROLL GUIDE BLOCK, AGL64R/64i AGL-64-B0018...
  • Page 31 Part #: AGL-64-K2242-2 Appl #: Assy #: AGLC2241-2 BOM Rev: Model #: Rev: Rev: Date: 2/26/2002 Description: PULL ROLL ASSY, AGL64R/64i (SENSOR INSIDE) Item: Part #: Description: Qty: 000494-01 WASHER, LOCK, #4 DIA, INT STAR, ZINC 012378-04 SSS, BRASS TIP, 1/4-20UNC, 1/4" LG. 000161-24 SSS, CUP PT, 3/8-24UNF, 1-1/2 LG, BLACK 012415-08...
  • Page 33 Bill Of Material Part #: AGL-64-K2246-1 Appl #: Assy #: AGLD2245-1 BOM Rev: 2/27/2002 Model #: Rev: Rev: Date: DRIVE ASSEMBLY, AGL64R/64i Description: Item: Part #: Description: Qty: AGL-64-B0046 MOTOR SUPPORT BAR AGL-64-B0047 MOTOR MOUNTING PLATE AGL-64-B1109 IDLER SPACER, 2.75 LG AGL 64 AGL-64-B1110 IDLER TENSIONER, 2.75 LG AGL 64 AGL-64-B1111...
  • Page 34 Part #: AGL-64-K2246-1 Appl #: Assy #: AGLD2245-1 BOM Rev: Model #: Rev: Rev: Date: 2/27/2002 Description: DRIVE ASSEMBLY, AGL64R/64i Item: Part #: Description: Qty: 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 000651-05...
  • Page 36 Part #: AGL-64-K0962-2 Appl #: Assy #: AGLD0974-2 BOM Rev: 10/9/2002 Model #: Rev: Rev: Date: UNWIND ASSEMBLY, AGL64I Description: Item: Part #: Description: Qty: AGL-64-B0968-01 VERTICAL SHAFT, 9.75 LG AGL-64-B0968-02 VERTICAL SHAFT, 19.25 LG AGL-64-B0004 SHAFT BRACE, CANTILEVERED UNWIND...
  • Page 37 Appl #: Assy #: AGLD0974-2 BOM Rev: Model #: Rev: Rev: Date: 10/9/2002 Description: UNWIND ASSEMBLY, AGL64I Item: Part #: Description: Qty: 000207-06 WASHER, FLAT, SAE, 1/4 DIA, 5/8 OD, 9/32 ID, ZINC 000055-02 BHSCS, #8-32UNC, 1/4 LG, BLACK 000217-06...
  • Page 39 Bill Of Material Part #: AGL-64-K0963-1 Appl #: Assy #: AGLD0991-1 BOM Rev: 1/15/2002 Model #: Rev: Rev: Date: WINDUP STATIONS, AGL64 SERIES Description: Item: Part #: Description: Qty: AGL-64-B0978 CLUTCH SHAFT AGL-64-B0979 CORE HOLDER, DRIVE SIDE AGL-64-B0980 ADJUSTMENT TUBE AGL-XX-B4005 ADJUSTMENT KNOB, 4.50 DIA.
  • Page 40 Part #: AGL-64-K0963-1 Appl #: Assy #: AGLD0991-1 BOM Rev: Model #: Rev: Rev: Date: 1/15/2002 Description: WINDUP STATIONS, AGL64 SERIES Item: Part #: Description: Qty: 000776-12 BEARING, THRUST, NEEDLE, 3/4 BORE 001358-92 SPRING, CURVED DISC, .80 ID. 1.10 OD. 012027-06 SPRING, COMPRESSION, 1.095 OD.
  • Page 42 Part #: AGL-64-K4318 Appl #: Assy #: AGLC4319 BOM Rev: 1/15/2002 Model #: Rev: Rev: Date: IDLER ROLLER ASSEMBLY, AGL64i Description: Item: Part #: Description: Qty: AGL-64-B2826 IDLER ROLLER, AGL64 SERIES 000639-10 SHOULDER SCREW, 5/8 DIA, 1-1/4 LG (1/2-13UNC) 000741-04 BUSHING, FLANGE, BRONZE, 5/8 ID 3/4 OD 1/2 LG To order call Advanced Greig Laminators, Inc.
  • Page 44 Bill Of Material Part #: AGL-64-K0965 Appl #: Assy #: AGLD0999 BOM Rev: 4/17/1998 Model #: Rev: Rev: Date: WEB COOLING ASSY, AGL 64 Description: Item: Part #: Description: Qty: AGL-64-D0997 FAN PLENUM AGL-64-C0998 COVER, PLENUM AGL-64-C3132 COOLING TUBE, AGL64 AGL-64-B2510 ADAPTER RING, AGL6400 000334-06...
  • Page 46 Item: Part #: Description: Qty: AGL-64-D4609-2 ELECTRICAL SCHEMATIC, AGL64I (NUMATIC VALVE) REF. AGL-64-B5070 DECAL PACKAGE, AGL64I, -01 BLUE, -02 GREEN, -03 BURGUNDY AGL-64-A0941 LABEL, TERMINAL BLOCK, AGL 6400/64/64i AGL-64-C1146-1 SUBPANEL, AGL64 SERIES 002728-01 EMITTER, SERIES 10 002427-04 SWITCH, FOOT, SPDT, MTD. IN GUARD, 16' CABLE...
  • Page 47 Appl #: Assy #: AGLC5303 BOM Rev: Model #: Rev: Rev: Date: 12/11/2002 Description: ELECTRICAL ASSEMBLY, AGL64I Item: Part #: Description: Qty: 001881-01 NOW PURCHASED AS PART OF 001875-01 006021-30 CIRCUIT BREAKER, 2 POLE, 30 AMP, DIN RAIL MNT 001530-008 FUSE, SLO-BLO, 3/4A, 250V, 1/4X1-1/4"...
  • Page 48 AGL-64-K4608-1 Appl #: Assy #: AGLC5303 BOM Rev: Model #: Rev: Rev: Date: 12/11/2002 Description: ELECTRICAL ASSEMBLY, AGL64I Item: Part #: Description: Qty: 002955-01 WIRE DUCT, 1 x 1-1/2, WHITE 144.0 002955-02 WIRE DUCT, 1 x 2-1/4, WHITE 48.0 002955-04 WIRE DUCT, 1-1/2 x 3, WHITE 96.0...
  • Page 49 Appl #: Assy #: AGLC5303 BOM Rev: Model #: Rev: Rev: Date: 12/11/2002 Description: ELECTRICAL ASSEMBLY, AGL64I 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 52 Part #: AGL-64-K2254-2 Appl #: Assy #: AGLC2257-2 BOM Rev: 9/25/2006 Model #: Rev: Rev: Date: PNEUMATIC ASSEMBLY, AGL64I/64R (NUMATIC VALVE) 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 54 Bill Of Material Part #: AGL-64-K4314-1 Appl #: Assy #: AGLD4313-1 BOM Rev: 2/28/2002 Model #: Rev: Rev: Date: EASY WEB INFEED TABLE ASSEMBLY, AGL64i Description: Item: Part #: Description: Qty: AGL-XX-B4173 TABLE END, LH. AGL-XX-B4174 TABLE END, RH. AGL-XX-B4175 CONNECTING LINK...
  • Page 55 Appl #: Assy #: AGLD4313-1 BOM Rev: Model #: Rev: Rev: Date: 2/28/2002 Description: EASY WEB INFEED TABLE ASSEMBLY, AGL64i Item: Part #: Description: Qty: 001398-03 WIRE ROPE, VINYL COATED, 1/8 DIA RED 001399-03 SPLICE, WIRE ROPE, ALUMINUM, 1/8 DIA 001409-04...
  • Page 57 Part #: AGL-64-K4315 Appl #: Assy #: AGLC4316 BOM Rev: 1/15/2002 Model #: Rev: Rev: Date: OUTFEED TABLE ASSEMBLY, AGL64i Description: Item: Part #: Description: Qty: AGL-64-C0955-01 INFEED TABLE, REMOVABLE (LIGHT GREY) AGL-64-B0083-01 TABLE SUPPORT, LEFT HAND (LIGHT GREY) AGL-64-B0082-01...
  • Page 59 Bill Of Material Part #: AGL-64-K4223 Appl #: Assy #: AGLB4222 BOM Rev: 3/6/2002 Model #: Rev: Rev: Date: CURL CAM ASSEMBLY, AGL64 Description: Item: Part #: Description: Qty: AGL-64-B4241 CHILL ROLLER SUB ASSY AGL-XX-B4219 ARM, CHILLER ROLL AGL-XX-B4330 BRACKET, CHILLER ROLL AGL-XX-B4221 SHAFT, CHILLER ROLL 012143-03...
  • Page 61 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 63 Bill Of Material Part #: AGL-64-K5033-1 Appl #: Assy #: AGLB5034 BOM Rev: 6/12/2003 Model #: Rev: Rev: Date: INFEED HOLD DOWN, 64/6400 Description: Item: Part #: Description: Qty: AGL-64-C2904-01 INFEED HOLD DOWN, 64/6400 SERIES (LIGHT GREY) 000055-03 BHSCS, #8-32UNC, 3/8 LG, BLACK 012143-08 PLUNGER, KNURLED KNOB,LOCKING, 1/4-20UNC 000201-03...
  • Page 65 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 001446-11 ALLEN WRENCH, LONG ARM, 1/4 T-HANDLE 012248...

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