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AGL AGL8000R Operator's Manual

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OPERATORS MANUAL
FOR
AGL8000R
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 AGL8000R 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

    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 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 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 9: Right Hand Control Panel, Figure 1

    Operation Right Hand Control Panel The right hand control panel looks like the figure below. Nip Roll Switch: This switch will open and close the nip rolls. Fans Switch: This switch turns the web cooling system on and off for web cooling during thermal lamination.

  • 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 3 position switch changes the station between a windup and unwind The regulator adjusts the air pressure to the brake - clutch changing the web tension.

  • Page 11: Rear Control Panel, Figure 3

    Operation Rear Control Panel Drive Control: FWD/REV button toggles the drive between forward and reverse. If the button is lit the machine is in reverse mode. STOP button stops the drive from turning thus stopping the rolls. RUN button switches the laminator from jog mode to run mode. Pull Roller Control: A 2 position switch open and closes the pull rolls.

  • Page 12: Temperature Controls

    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 controls have a maximum temperature set at the factory. The operator cannot set the temperature above this point. The controllers are also set up with an over temp alarm.

  • 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 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 15: 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 16: 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 17 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 18: 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 19 Operation 4-12...

  • Page 20: 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 21: 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 22: Chapter 6 Warranty

    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 23 Description: Item: Part #: Description: Qty: AGL-80-K1916-1 MAIN MACHINE FRAME, AGL8000 AGL-80-K1894-1 NIP ROLL ASSEMBLY, AGL8000R (BAUMER EYE) AGL-80-K1816-1 DRIVE ASSEMBLY, AGL8000R (PNEUMATIC COUPLERS) AGL-80-K3563-1 UNWIND/WINDUP CANTILEVERED STATION, AGL8000R (PNEUMATIC COUPLE AGL-80-K1866 INFEED/OUTFEED TABLE ASSEMBLY, AGL8000 AGL-80-K1896-2 PULL ROLL ASSEMBLY, AGL8000 (BAUMER INSIDE & PNEUMATIC COUPLER)
  • 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...
  • Page 26 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...
  • Page 27 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...
  • Page 29 Part #: AGL-80-K1816-1 Appl #: Assy #: AGLD1815-1 BOM Rev: 5/20/2003 Model #: Rev: Rev: Date: DRIVE ASSEMBLY, AGL8000R (PNEUMATIC COUPLERS) Description: Item: Part #: Description: Qty: AGL-80-B1804 MOTOR SUPPORT, AGL8000 AGL-80-B1803 MOTOR MOUNTING PLATE, AGL8000 AGL-80-B2095-1 IDLER SPACER, 3.00 LG.
  • Page 30 Appl #: Assy #: AGLD1815-1 BOM Rev: Model #: Rev: Rev: Date: 5/20/2003 Description: DRIVE ASSEMBLY, AGL8000R (PNEUMATIC COUPLERS) Item: Part #: Description: Qty: 000343-10 HHCS, 3/8-16UNC, 1-1/4 LG, ZINC 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-K3563-1 Appl #: Assy #: AGLC3564-1 BOM Rev: 5/20/2003 Model #: Rev: Rev: Date: UNWIND/WINDUP CANTILEVERED STATION, AGL8000R (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 34 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)
  • Page 36 Bill Of Material Part #: AGL-80-K1896-2 Appl #: Assy #: AGLC1895-2 BOM Rev: 3/15/2002 Model #: Rev: Rev: Date: PULL ROLL ASSEMBLY, AGL8000 (BAUMER INSIDE & PNEUMATIC COUPLER) Description: Item: Part #: Description: Qty: AGL-80-B1898 UPPER PULL ROLL SUB ASSEMBLY, AGL8000...
  • Page 37 Part #: AGL-80-K1896-2 Appl #: Assy #: AGLC1895-2 BOM Rev: Model #: Rev: Rev: Date: 3/15/2002 Description: PULL ROLL ASSEMBLY, AGL8000 (BAUMER INSIDE & PNEUMATIC COUPLER) Item: Part #: Description: Qty: 000201-01 NUT, HEX, #4-40UNC, ZINC 012378-04 SSS, BRASS TIP, 1/4-20UNC, 1/4" LG.
  • 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...
  • 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-K5110 Appl #: Assy #: AGLC5109 BOM Rev: 7/2/2003 Model #: Rev: Rev: Date: COOLING STATION, LOWER, 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 ELECTRICAL ASSEMBLY, AGL8000R Description: Item: Part #: Description: Qty: AGL-80-D3515-2 CONTROL SCHEMATIC, AGL8000R AGL-80-B5116 DECAL PACKAGE, AGL 8000 SERIES AGL-64-A0941 LABEL, TERMINAL BLOCK, AGL 6400/64/64i AGL-64-C1107 SUBPANEL 001998-03 CONTROLLER, MOTOR, 240V INPUT, 90 or 180VDC OUTPUT 001625-05 CONTROLLER, TEMP, THERMOCOUPLE, PULSED, ALARM...
  • Page 46 AGL-80-K3514-2 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 12/12/2002 Description: ELECTRICAL ASSEMBLY, AGL8000R 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-K3514-2 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 12/12/2002 Description: ELECTRICAL ASSEMBLY, AGL8000R Item: Part #: Description: Qty: 000493-06 WASHER, LOCK, 1/4 DIA, SPLIT, ZINC 002974-01 RELAY, MIDGET, 3PDT, 24VDC 001826-03 POWER SUPPLY, SINGLE, 24VDC, 1.2A...
  • Page 48 AGL-80-K3514-2 Appl #: Assy #: BOM Rev: Model #: Rev: Rev: Date: 12/12/2002 Description: ELECTRICAL ASSEMBLY, AGL8000R Item: Part #: Description: Qty: 002523-06 FERRULE, INSULATED, 6AWG, STD LENGTH, GREEN 002523-05 FERRULE, INSULATED, 10AWG, STD LENGTH, BLACK 002523-10 FERRULE, INSULATED, 12AWG, STD LENGTH, GRAY...
  • Page 50 Part #: AGL-80-K2106-1 Appl #: Assy #: AGLC2107-1 BOM Rev: 5/20/2003 Model #: Rev: Rev: Date: PNEUMATIC ASSEMBLY, AGL8000R (PNEUMATIC 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 Appl #: Assy #: AGLC2107-1 BOM Rev: Model #: Rev: Rev: Date: 5/20/2003 Description: PNEUMATIC ASSEMBLY, AGL8000R (PNEUMATIC COUPLER) Item: Part #: Description: Qty: 012572-04 CONNECTOR, SOLENOID VALVE 000847-05 FITTING, PIPE, ELBOW, MALE, 5/32 OD, 10-32UNF 001456-01 FITTING, DOUBLE "Y", 1/4 TUBE - 5/32 TUBE To order call Advanced Greig Laminators, Inc.
  • 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...

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