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Advanced Greig Laminators, Inc. Patriot Operation Manual

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Operation Manual
Patriot
Advanced Greig Laminators, Inc.
801 Burton Blvd, Deforest, WI 53532
608-846-1025, info@aglinc.com
I

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Summary of Contents for Advanced Greig Laminators, Inc. Patriot

  • Page 1 Operation Manual Patriot Advanced Greig Laminators, Inc. 801 Burton Blvd, Deforest, WI 53532 608-846-1025, info@aglinc.com...

  • Page 2: Table Of Contents

    Chapter 1: Installation Table of Contents Preface ................................I Chapter 1: Installation Selecting Area ..............................1 Uncrating ................................1 Leveling ................................1 Electrical Connection ............................2 Pneumatic Connection ............................2 Recycling Packaging ............................2 Chapter 2: Specifications Machine Dimensions ............................3 Electrical Requirements .............................

  • Page 3: Preface

    Chapter 1: Installation Preface Your Advanced Greig Laminators, Inc. (AGL) laminator is a finely engineered and designed piece of equipment. The nip rolls are the heart and soul of the laminator. To insure a quality end product, the rolls are rigid enough to carry their weight, plus the working pressures against them without deflecting.

  • Page 4: Chapter 1: Installation

    Chapter 1: 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: Recycling Packaging

    Chapter 1: Installation Recycling Packaging If your machine came in a fully enclosed crate, the crate can be stored flat for future use or dismantled and the wood can be recycled. The screws can be kept for future use of the crates or stored for some other use. The shrink wrap is not recyclable and should be thrown away.

  • Page 6: Chapter 2: Specifications

    Chapter 2: Specifications Machine Dimensions Length: 91” Height: 55” Depth: 44” Weight: 2000 lbs. Electrical Requirements 64i: 220/230 VAC single phase, 50/60 Hz, 40 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: 6”...

  • Page 7: Chapter 3: Safety

    Chapter 3: Safety 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. Read and understand all the safety instructions. Keep this manual in a place where it can be easily referenced by all operators. All connections to components and terminal blocks should be checked for tightness before initial startup.

  • Page 8: Chapter 4: Operation

    Chapter 4: Operation General Power: A circuit breaker switch is located on the lower right rear of the machine to turn power on and off. 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

    Chapter 4: Operation Front Right Control Panel The front right control panel looks like the figure below. Figure 1 Front Right Control Panel The Run button will turn the drive on to turn the rollers continuously in the forward direction. Stop The Stop button will stop the drive.

  • Page 10: Front Left Control Panel

    Chapter 4: Operation Front Left Control Panel The front left control panel looks like the figure below. Figure 2. Front Left Control Panel Liner Windup The regulator controls the pressure to the upper front liner windup. Top Roll Heat Control The button turns the heater on and off.

  • Page 11: Rear Right Control Panel

    Chapter 4: Operation Rear Right Control Panel The rear right control panel looks like the figure below. Figure 3. Rear Right Control Panel Product Windup The regulator controls the pressure to the pneumatic clutch on the lower rear windup station. Reset The reset button is used to reset the machine after an estop or at initial power up.

  • Page 12: Temperature Controls

    Chapter 4: Operation 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. The temperature control has a maximum temperature set at the factory. The operator cannot set the temperature above this point.

  • Page 13: Laminator Setup

    Chapter 4: 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 Chapter 4: Operation Lamination Process 1. Load material onto the upper rear and lower front unwind stations. Reduce pressure to the brakes to allow the material to be pulled from the stations. Lift the infeed table and rotate it up and out of the way. 2.
  • Page 15 Chapter 4: Operation Inline Trimming The left Front control panel looks like the figure below. Figure 5. Inline trimmer blade holder 1. Using 5/16 allen wrench loosen bolts (1) that secure body to the shaft. Position the trimmer in the approx- imate position along the shaft.

  • Page 16: Process Output Trouble Shooting

    Chapter 4: 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”...

  • Page 17: Wrinkles In Product

    Chapter 4: Operation Wrinkles in Product 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. 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 18 Chapter 4: Operation PROCESS CONTROL CHART Process: Product: Material Top: Material Bottom: Other Material: Date Settings Documented: Front Control Settings Speed (Ft/min): Shim Dial Setting: Roll Pressure: (PSI) Top Temp. Setting: Deg. F Rear Control Settings Pull Roll: Down Shim Dial Setting: Pull Roll Setting:(PSI) Film Station Settings Upper Rear Unwind:...
  • Page 19 Chapter 4: Operation...

  • Page 20: Chapter 5: Maintenance

    Chapter 5: 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 21: Roller Open And Close Rate

    Chapter 5: 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. Maintenance that requires working on the machine while power and air are connected poses and imminent danger of electrocution or extremities being caught in rotating parts.
  • Page 22 Chapter 5: Maintenance Slip Ring Maintenance It is recommended that during the first year, the slip ring be inspected monthly for connection condition, brush wear and ring cleanliness. After the first year you should have a good idea of how often the slip rings requires maintenance.

  • Page 23: Chapter 6: Warranty

    Chapter 6: 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: Chapter 7: Schematics

    Chapter 7: Schematics Electrical – Drawing #AGL-64-D10229 Pneumatic – Drawing #AGL-64-D10227...
  • Page 25 AGL-64-K10232 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 8/12/2013 Description: MASTER BILL OF MATERIALS, PATRIOT Item: Part #: Description: Qty: 1 AGL-64-K10226 MAIN MACHINE FRAME ASSEMBLY 2 AGL-64-K10192 NIP ROLL ASSEMBLY 3 AGL-64-K10190 PULL ROLL ASSEMBLY...
  • Page 26 6 AGL-64-B0010-04 UPPER CROSS TUBE 7 AGL-64-B10218 LOWER TIE BAR 8 AGL-XX-B10224 HOLE COVER 9 AGL-XX-D10388 COVER DECALS, PATRIOT 10 AGL-XX-B11339 LEVELER BLOCK, PATRIOT 20 000198-15 NUT, HEX, JAM, 1-1/8-12UNF, ZINC 21 000013-12 SHCS, 3/8-16UNC, 1-1/2 LG, BLACK 22 000207-08...
  • Page 28 Bill Of Material Part #: AGL-64-K10192 Appl #: Assy #: AGLC10191 BOM Rev: Model #: Rev: Rev: Date: 8/1/2013 Description: NIP ROLL ASSEMBLY Item: Part #: Description: Qty: 1 AGL-64-D0001 NIP ROLL, 8.0 OD., 64.0 ROLL FACE (COMPLETE) 2 AGL-64-D0001-18 NIP ROLL SUB ASSEMBLY, 8"...
  • Page 29 Part #: AGL-64-K10192 Appl #: Assy #: AGLC10191 BOM Rev: 8/1/2013 Model #: Rev: Rev: Date: Description: NIP ROLL ASSEMBLY Item: Part #: Description: Qty: 48 000553-06 PHMS, SLOTTED, #4-40UNC, 3/4 LG, ZINC 49 000207-01 WASHER, FLAT, SAE, #4 DIA, 5/16 OD, 1/8 ID, ZINC 50 000493-01 WASHER, LOCK, #4 DIA, SPLIT, ZINC 51 000201-01...
  • Page 31 PULL ROLL GUIDE BLOCK, INSIDE SENSORS 4 AGL-64-B0018-1 LOWER PULL ROLL, 60-70 SILICONE 5 001317-16 KEY, 0.188 SQ, 2.00 LG, CRS 6 AGL-XX-B10416 SHIM WHEEL SUPPORT, PATRIOT 7 AGL-64-B0015 SHIM WHEEL 8 AGL-64-B1331-1 EYEBOLT MODIFICATION (ALTER K&L 012031-16) 9 AGL-XX-B10415...
  • Page 32 Part #: AGL-64-K10190 Appl #: Assy #: AGLC10189 BOM Rev: 8/1/2013 Model #: Rev: Rev: Date: Description: PULL ROLL ASSEMBLY Item: Part #: Description: Qty: 20-Sep-16 To order call Advanced Greig Laminators, Inc. 608-846-7016 Page 2 of 2...
  • Page 34 Bill Of Material Part #: AGL-64-K10216 Appl #: Assy #: AGLC10215 BOM Rev: Model #: Rev: Rev: Date: 8/6/2013 Description: DRIVE ASSEMBLY Item: Part #: Description: Qty: 1 AGL-64-B0046 MOTOR SUPPORT BAR 2 AGL-64-B0047 MOTOR MOUNTING PLATE 3 AGL-64-B0048-1 IDLER SPACER, 3.00 LG. 4 AGL-64-B0049-1 IDLER TENSIONER, 3.00 LG.
  • Page 35 Part #: AGL-64-K10216 Appl #: Assy #: AGLC10215 BOM Rev: 8/6/2013 Model #: Rev: Rev: Date: Description: DRIVE ASSEMBLY Item: Part #: Description: Qty: 38 012022-01 GEAR BOX, 60:1,56C, WITH SINGLE OUTPUT SHAFT 39 012214-04 WASHER, RUBBER, 1/4 ID. X 5/8 OD. (SOLD IN PKG OF 100) 40 012495-03 WASHER, RUBBER, 2.25 OD.
  • Page 37 Bill Of Material Part #: AGL-64-K10188 Appl #: Assy #: AGLD10187 BOM Rev: Model #: Rev: Rev: Date: 7/31/2013 Description: UNWIND ASSEMBLY, AIRSHAFT Item: Part #: Description: Qty: 1 AGL-64-B0968-01 VERTICAL SHAFT, 9.75 LG 2 AGL-64-B0004 SHAFT BRACE, CANTILEVERED UNWIND 3 AGL-64-B0005 SHAFT SUPPORT, CANTILEVERED UNWIND 4 AGL-64-B0940...
  • Page 38 Part #: AGL-64-K10188 Appl #: Assy #: AGLD10187 BOM Rev: 7/31/2013 Model #: Rev: Rev: Date: Description: UNWIND ASSEMBLY, AIRSHAFT Item: Part #: Description: Qty: 39 000855-04 FITTING, TUBE, "Y", 1/4 OD TUBE 40 000847-10 FITTING, PIPE, ELBOW, MALE, 1/4 OD, 1/8 NPT 41 000847-06 FITTING, PIPE, ELBOW, MALE, 5/32 OD, 1/8 NPT 42 012388-09...
  • Page 40 Bill Of Material Part #: AGL-64-K10182 Appl #: Assy #: AGLC10181 BOM Rev: Model #: Rev: Rev: Date: 7/31/2013 Description: LINER WINDP ASSEMBLY Item: Part #: Description: Qty: 1 AGL-XX-B8648-1 CLUTCH SHAFT 2 AGL-XX-B8649 BEARING BLOCK 3 AGL-64-B8645 WINDUP SHAFT, AGL64 4 AGL-XX-B8646 SUPPORT, WINDUP SHAFT 6 AGL-XX-B8650...
  • Page 42 Bill Of Material Part #: AGL-64-K10214 Appl #: Assy #: AGLD10213 BOM Rev: Model #: Rev: Rev: Date: 8/6/2013 Description: PRODUCT WINDUP ASSEMBLY Item: Part #: Description: Qty: 1 AGL-64-B0968-01 VERTICAL SHAFT, 9.75 LG 2 AGL-64-B0004 SHAFT BRACE, CANTILEVERED UNWIND 3 AGL-64-B0005-1 SHAFT SUPPORT WITH TAP FOR BRACE 4 AGL-64-B0940...
  • Page 44 Bill Of Material Part #: AGL-64-K10201 Appl #: Assy #: AGLD10200 BOM Rev: Model #: Rev: Rev: Date: 8/1/2013 Description: IDLER ROLLER ASSEMBLY Item: Part #: Description: Qty: 1 AGL-64-B0992 IDLER ROLLER SUB ASSY 5 000343-08 HHCS, 3/8-16UNC, 1 LG, ZINC 6 000493-08 WASHER, LOCK, 3/8 DIA, SPLIT, ZINC 7 000207-08...
  • Page 46 Bill Of Material Part #: AGL-64-K10203-1 Appl #: Assy #: AGLB10202-1 BOM Rev: Model #: Rev: Rev: Date: 8/14/2013 Description: WEB SUPPORT TABLE ASSEMBLY, SMALL Item: Part #: Description: Qty: 1 AGL-64-B10201-1 WEB SUPPORT TABLE, SMALL 2 AGL-64-B10204 EXTRUSION MOD. 1.50 SQ. x 68.00 LG. 5 000061-08 BHSCS, 5/16-18UNC, 1 LG, BLACK 6 000103-04...
  • Page 48 Bill Of Material Part #: AGL-64-K10194 Appl #: Assy #: AGLC10193 BOM Rev: Model #: Rev: Rev: Date: 3/29/2016 Description: INFEED TABLE ASSEMBLY Item: Part #: Description: Qty: 1 AGL-XX-B10195-1 TABLE END, RH. 2 AGL-XX-B10195-2 TABLE END, LH. 3 AGL-64-B10196 EXTRUSION MOD.
  • Page 50 Bill Of Material Part #: AGL-64-K10211 Appl #: Assy #: AGLB10210 BOM Rev: Model #: Rev: Rev: Date: 8/5/2013 Description: REAR TABLE W/ CUTTING SURFACE Item: Part #: Description: Qty: 1 AGL-64-B10205 EXTRUSION MOD. 1.50 SQ x 67.00 LG. 2 AGL-64-B10207 CUTTING MAT WITH HOLES (10 Sheets per Matt) 3 AGL-XX-B10208 END PLATE, RH.
  • Page 52 Bill Of Material Part #: AGL-64-K10228 Appl #: Assy #: AGLD10227 BOM Rev: Model #: Rev: Rev: Date: 8/8/2013 Description: PNEUMATIC ASSEMBLY Item: Part #: Description: Qty: 1 012263-05 TUBING, 1/4" OD, BLACK 2 012262-05 TUBING, 5/32" OD, BLACK - SOLD IN SPOOLS OF 500 (Ft) 3 001294 REGULATOR, PRESSURE, 1/8NPT 4 000847-10...
  • Page 54 Bill Of Material Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 8/12/2013 Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 0 AGL-64-D10229 CONTROL SCHEMATIC REF. 4 AGL-XX-C10231 SUBPANEL 20 002728-01 EMITTER, SERIES 10 21 002427-04 SWITCH, FOOT, SPDT, MTD.
  • Page 55 Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: 8/12/2013 Model #: Rev: Rev: Date: Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 45 001569-030 CIRCUIT BREAKER, CLASS 720, 2 POLE, 240V, 30A 46 001530-010 FUSE, SLO-BLO, 1.0A, 250V, 1/4X1-1/4" 47 001530-020 FUSE, SLO-BLO, 2.0A, 250V, 1/4 X 1-1/4"...
  • Page 56 Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: 8/12/2013 Model #: Rev: Rev: Date: Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 77 000717-24 WIRE, STRANDED, 14 AWG, GREEN/YELLOW 78 002955-01 WIRE DUCT, 1 x 1-1/2, WHITE 144.0 79 002955-02 WIRE DUCT, 1 x 2-1/4, WHITE 48.0 80 002955-04...
  • Page 57 Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: 8/12/2013 Model #: Rev: Rev: Date: Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 109 006033-03 CONNECTOR, BRASS/SETSCREW, 2-14AWG 110 012980-01 STANDOFF, HEX, M/F, M3x.5mm, 12mm LG, NYLON 20-Sep-16 To order call Advanced Greig Laminators, Inc. 608-846-7016 Page 4 of 4...
  • Page 58 Bill Of Material Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 8/12/2013 Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 0 AGL-64-D10229 CONTROL SCHEMATIC REF. 4 AGL-XX-C10231 SUBPANEL 20 002728-01 EMITTER, SERIES 10 21 002427-04 SWITCH, FOOT, SPDT, MTD.
  • Page 59 Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: 8/12/2013 Model #: Rev: Rev: Date: Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 45 001569-030 CIRCUIT BREAKER, CLASS 720, 2 POLE, 240V, 30A 46 001530-010 FUSE, SLO-BLO, 1.0A, 250V, 1/4X1-1/4" 47 001530-020 FUSE, SLO-BLO, 2.0A, 250V, 1/4 X 1-1/4"...
  • Page 60 Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: 8/12/2013 Model #: Rev: Rev: Date: Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 77 000717-24 WIRE, STRANDED, 14 AWG, GREEN/YELLOW 78 002955-01 WIRE DUCT, 1 x 1-1/2, WHITE 144.0 79 002955-02 WIRE DUCT, 1 x 2-1/4, WHITE 48.0 80 002955-04...
  • Page 61 Part #: AGL-64-K10230 Appl #: Assy #: BOM Rev: 8/12/2013 Model #: Rev: Rev: Date: Description: ELECTRICAL ASSEMBLY Item: Part #: Description: Qty: 109 006033-03 CONNECTOR, BRASS/SETSCREW, 2-14AWG 110 012980-01 STANDOFF, HEX, M/F, M3x.5mm, 12mm LG, NYLON 20-Sep-16 To order call Advanced Greig Laminators, Inc. 608-846-7016 Page 4 of 4...
  • Page 63 Bill Of Material Part #: AGL-XX-K10999 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: Description: ACCESSORY KIT, UNIVERSAL Item: Part #: Description: Qty: 1 012236-01 ROLL ADHESIVE ERASER, PLAIN, SHRINKWRAPPED 2 012248 CLOTH, LOW LINT, 12x13 3 012249 ALCOHOL, ISOPROPYL, 1 PINT 70% 4 012235-01 CUTTER, ZIPPY...

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