AGL AGL8000R Operator'S Manual Download

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OPERATORS MANUAL

FOR

AGL8000R

801 Burton Blvd. DeForest WI 53532

Ph: 608-846-7016 Fax: 608-846-1024

E-mail: [email protected]

Summary of Contents for AGL8000R

Page 1: ...OPERATORS MANUAL FOR AGL8000R 801 Burton Blvd DeForest WI 53532 Ph 608 846 7016 Fax 608 846 1024 E mail info aglaminators com ...

Page 2: ...peration General 4 1 Right Hand Control Panel Figure 1 4 2 Left Hand Control Panel Figure 2 4 3 Rear Control Panel Figure 3 4 4 Temperature Controls 4 5 Laminator Setup 4 6 Loading and Positioning Film 4 6 Web the Laminator 4 6 Encapsulation Process 4 7 Pressure Sensitive Process 4 8 Process Output Trouble Shooting 4 9 Process Control Chart 4 10 PLI Chart 4 12 Chapter 5 Maintenance Nip Roll Sectio...

Page 3: ...essures against them without deflecting The covering is ground straight and concentric to the bearing journals to insure a constant uniform opening at the laminating nip between the top and bottom roll The power transmission from the drive motor to the bottom laminating roll and the release liner windup clutch is with chain The laminating nip section is protected with an electric photo cell and sa...

Page 4: ... the casters With 3 4 people to guide the machine roll the machine into the final position The laminator is a large heavy piece of equipment Do not attempt to move the machine with one person Injury is possible as well as permanent damage to the laminator The laminator should only be rolled on a relatively smooth and level surface Tipping or forcing the machine over large bumbs can destroy the ali...

Page 5: ...eg Laminators Inc will not be responsible for damage caused by incorrect electrical installation Pneumatic Connection Refer to the Pneumatic Requirements under Specifications for the proper requirements for your laminator The air supply should be clean dry and regulated Failure to properly clean and dry the air supplied to the laminator will cause damage to the cylinders brakes and clutches The la...

Page 6: ...r core Thermal 10 Diameter x 79 long x 3 Diameter core Pressure Sensitive Upper Rear Station 10 Diameter x 72 long x 3 Diameter core Thermal 10 Diameter x 79 long x 3 Diameter core Pressure Sensitive Lower Rear Station 10 Diameter x 72 long x 3 Diameter core Thermal 10 Diameter x 79 long x 3 Diameter core Pressure Sensitive Middle Front Station 8 Diameter x 72 long x 3 Diameter core Thermal 8 Diam...

Page 7: ...correct operational procedures Operator Safety Your laminator is designed to protect the operator from injury when used properly Do not operate the machine without all guards and protection devices in place serious injury could occur The nip section can pull you into laminator Do not place fingers into the nip section when the rolls are rotating It is recommended that operators tie long hair back ...

Page 8: ... than 0 when the machine is not in use This will prevent the rolls from forming a flat spot from resting against each other This also applies to the pull rolls Always set the shim wheel to a setting greater than 0 when the machine is not in use This will prevent the roll from coming together and forming a flat spot Permanent damage can be caused to the rolls if this warning is not heeded 6 Fwd Rev...

Page 9: ...osition 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 Drive Control E Stop switch will stop the laminator and open the rolls Speed Pot sets the laminators speed 0 20 FPM FWD REV button toggles the drive between forward and reverse If the butto...

Page 10: ...The regulator adjusts the air pressure to the brake changing the web tension The gauge indicates air pressure which allows for repeatable results Nip Roller Control The open close switch is found on the RH panel but the regulator adjusts the air pressure to the cylinders and the gauge indicates air pressure An E stop switch is located here for easy access to the operator Lower Rear Station The 3 p...

Page 11: ... to run mode 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 Pull Clutch Control The switch turns the clutch on and off The regulator adjusts air pressure to the clutch changing the amount of pull the rollers exert on the web The gauge indicates ai...

Page 12: ...t The operator only needs to press and hold the asterisk key then press the up arrow key to raise the Set Point Temperature or the down arrow to lower the Set Point Temperature The square green LED in the upper left will stay on initially as heater comes up to temperature and flash as the controller pulses electricity to maintain the heat in the rolls The top alarm LED will flash on if the rolls e...

Page 13: ...n 5 Measuring from the sideplates make sure the film is centered on the shaft Once the measurements from each end of film to the sideplates are equal tighten the locking core chuck and core idler down 6 Repeat this process on any other unwind station or rewind using an empty core 7 If the film is a pressure sensitive with a release liner you will need to set up a wind up station This is done by we...

Page 14: ...der the bottom nip roll Tape the film to the feeder stock 5 Replace the infeed table 6 Set the speed potentiometer to a low setting an move to the rear of the machine 7 Set the machine to run in the FWD direction the FWD REV button should not be lit and press the foot switch 8 Guide the feeder stock into the gap between the pull rolls Once the feeder stock has cleared the pull rolls close the pull...

Page 15: ...s and back to the front upper windup station Tape the release liner to the wind up core 5 Set the speed potentiometer to a low setting an move to the rear of the machine 6 Set the machine to run in the FWD direction the FWD REV button should not be lit and press the foot switch 7 Guide the feeder stock into the gap between the pull rolls 8 Turn the heater controls to On and set the desired tempera...

Page 16: ...Check the substrate moisture content and the substrate tension If waves are in the film Low tension between nip pull roll Increase air pressure to pull roll clutch Roll pressure settings Adjust nip and pull roll settings as required Web Breaks Web breaks caused by excess tension If the web breaks between the unwind station and the nip reduce the unwind brake tension If the web breaks between the l...

Page 17: ...thout the use of cylinder spacers or the next smaller spacer may be used or special spacer utilized 3 Material such as Plexiglas or glass sometimes carry a greasy or oily film These materials may need to be cleaned with a solvent prior to lamination 4 Poor lamination can be caused by defective material To correct this replace defective material with higher quality material Bubbles in Product 1 Vis...

Page 18: ...g Deg F Bottom Roll Heater On Off Rear Control Settings Pull Roll Clutch On Off Pull Roll Up Down Pull Roll Clutch Setting PSI Pull Roll Pressure PSI Shim Dial Setting Film Station Settings Upper Rear Station Unwind Off Windup Pressure Setting PSI Upper Front Station Unwind Off Windup Pressure Setting PSI Center Front Station Unwind Off Windup Pressure Setting PSI Lower Rear Station Unwind Off Win...

Page 19: ...Operation 4 12 ...

Page 20: ...e same as the nip rolls Zeroing the Nip 1 Loosen the set screw in the cylinder stop 2 Adjust the cylinder stop clockwise to raise the roll and counter clockwise to lower the roll 3 Check the nip using the 3 steps shown in the Checking the Nip section 4 Once the drag on the pieces of paper has been equalized tighten the setscrew in the cylinder stop Cleaning the Nip Rolls Cleaning the nip rolls may...

Page 21: ...ock the adjustment screw in place with the jam nut Be careful not to turn the adjustment screw as you tighten the nut 5 Replace enclosure covers Lubrication The high temp grease that is packed into the nip roll bearings will begin to pass by the seal as the machine is used in high temperature applications The frequency of high heat processes will determine the frequency of adding grease to the bea...

Page 22: ...lterations by anyone other than persons authorized by AGL Component parts such as controls motors heating elements air cylinders rubber coverings etc which are incorporated into the design and manufacture of our laminators are purchased from reputable manufacturers and suppliers and as such carry their respective warranties Failure of any components purchased by AGL and incorporated in the laminat...

Page 23: ...ILEVERED STATION AGL8000R PNEUMATIC COUPLE 5 AGL 80 K1866 1 INFEED OUTFEED TABLE ASSEMBLY AGL8000 6 AGL 80 K1896 2 1 PULL ROLL ASSEMBLY AGL8000 BAUMER INSIDE PNEUMATIC COUPLER 7 AGL 80 K1851 1 IDLER ASSY AGL8000 8 AGL 80 K2909 1 INFEED HOLD DOWN ASSEMBLY 8000 SERIES 9 AGL 80 K5110 1 COOLING STATION LOWER AGL8000 SERIES 10 AGL 80 K3514 2 1 ELECTRICAL ASSEMBLY AGL8000R 11 AGL 80 K2106 1 1 PNEUMATIC ...

Page 24: ...8 15 6 NUT HEX JAM 1 1 8 12UNF ZINC 21 000358 36 4 HHCS 3 4 10UNC 7 LG ZINC 22 000195 12 4 NUT HEX JAM 3 4 10UNC ZINC 23 001451 4 CASTER SWIVEL 5 DIA 900 LBS 24 000011 08 16 SHCS 5 16 18UNC 1 LG BLACK 25 000007 03 41 SHCS 10 24UNC 3 8 LG BLACK 26 000055 03 20 BHSCS 8 32UNC 3 8 LG BLACK 27 000207 04 41 WASHER FLAT SAE 10 DIA 1 2 OD 7 32 ID ZINC 29 000340 07 14 HHCS 5 16 18UNC 7 8 LG ZINC 30 000493 ...

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Page 26: ...ET AGL8000 12 AGL 80 B2102 1 2 CYLINDER STOP TAPPED 8000 6450 13 AGL 80 B2104 2 CYLINDER MOUNTING PLATE AGL8000 30 001392 15 2 PLUNGER SPRING LEP 3 8 16UNC 5 8 LG 31 000289 16 2 PIN DOWEL 3 8 DIA 2 LG 32 000007 04 2 SHCS 10 24UNC 1 2 LG BLACK 33 000013 08 8 SHCS 3 8 16UNC 1 LG BLACK 34 000041 08 8 SHCS 3 8 24UNF 1 LG BLACK 36 001395 39 2 BEARING FLANGE 4 BOLT 2 7 16 BORE HIGH TEMP 37 000355 17 8 H...

Page 27: ...S SLOTTED 4 40UNC 1 LG ZINC 49 000207 01 4 WASHER FLAT SAE 4 DIA 5 16 OD 1 8 ID ZINC 50 000493 01 2 WASHER LOCK 4 DIA SPLIT ZINC 51 000201 01 2 NUT HEX 4 40UNC ZINC 52 000011 17 12 SHCS 5 16 18UNC 2 1 4 LG BLACK 53 012109 01 2 HEATER ASSY AGL8000 55 000127 08 2 SSS CUP PT 8 32UNC 1 2 LG BLACK 56 012112 32 4 SSS CUP PT 3 4 16UNF 2 LG BLACK 14 Apr 08 Page 2 of 2 To order call Advanced Greig Laminato...

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Page 29: ...LY AGL8000 20 001275 01 3 CHAIN 35 HALF LINK 21 001275 3 CHAIN 35 CONNECTING LINK 23 000157 04 2 SSS CUP PT 1 4 28UNF 1 4 LG BLACK 24 012417 10 7 HHCS 5 16 18UNC 1 1 4 LG BLACK OXIDE 25 012416 07 7 WASHER FLAT SAE 5 16 DIA 11 16 OD 11 32 ID BLACK OXIDE 26 012415 08 7 WASHER LOCK 8mm DIA SPLIT BLACK OXIDE 27 000337 08 4 HHCS 1 4 20UNC 1 LG ZINC 28 000637 10 6 SHOULDER SCREW 1 2 DIA 1 1 4 LG 3 8 16U...

Page 30: ...SHAFT 1 25 DIA 43 000091 08 1 FHSCS 5 16 18UNC 1 LG BLACK 44 000651 07 4 NUT HEX NYLOCK 3 8 16UNC ZINC 45 000207 08 12 WASHER FLAT SAE 3 8 DIA 13 16 OD 13 32 ID ZINC 46 012495 03 4 WASHER RUBBER 2 25 OD X 38 ID X 13 THICK 47 012426 02 8 BUSHING FLANGED RUBBER 21 32 OD X 3 8 ID 48 000343 14 4 HHCS 3 8 16UNC 1 3 4 LG ZINC 49 000207 06 4 WASHER FLAT SAE 1 4 DIA 5 8 OD 9 32 ID ZINC 50 000493 06 4 WASH...

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Page 32: ...DECAL PUSH TO RETRACT 20 012115 05 4 BRAKE CLUTCH COMBO PNEUMATIC COUPLER 21 000059 08 15 BHSCS 1 4 20UNC 1 LG BLACK 22 001356 12 10 BUSHING FLANGED BRONZE 1 1 4 ID 1 1 2 OD 1 1 2 LG 23 000411 20 10 COLLAR SHAFT 1 25 DIA BORE 1 2 WIDE 24 001355 26 10 BEARING TAPPED BASE 1 5 8 BORE 25 000013 10 16 SHCS 3 8 16UNC 1 1 4 LG BLACK 28 000135 08 6 SSS CUP PT 3 8 16UNC 1 2 LG BLACK 30 012265 06 5 SSS NYLO...

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Page 34: ...ASSY AGL8000 10 000009 04 8 SHCS 1 4 20UNC 1 2 LG BLACK 11 000007 04 8 SHCS 10 24UNC 1 2 LG BLACK 12 000129 10 8 SSS CUP PT 10 24UNC 3 4 LG BLACK 13 000207 06 8 WASHER FLAT SAE 1 4 DIA 5 8 OD 9 32 ID ZINC 14 000343 10 2 HHCS 3 8 16UNC 1 1 4 LG ZINC 15 000207 08 2 WASHER FLAT SAE 3 8 DIA 13 16 OD 13 32 ID ZINC 16 000493 08 2 WASHER LOCK 3 8 DIA SPLIT ZINC 17 000207 04 8 WASHER FLAT SAE 10 DIA 1 2 O...

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Page 36: ... 1 LG BLACK 23 000346 08 4 HHCS 7 16 14UNC 1 LG ZINC 24 000493 09 4 WASHER LOCK 7 16 DIA SPLIT ZINC 25 000198 09 4 NUT HEX JAM 1 2 20UNF ZINC 26 000131 08 2 SSS CUP PT 1 4 20UNC 1 2 LG BLACK 27 000764 16 2 BEARING FLANGE 2 BOLT 1 00 DIA BORE 28 012255 07 1 CLUTCH PNEUMATIC 32 TOOTH INPUT 7 8 BORE LOCO PADS 29 000009 08 1 SHCS 1 4 20UNC 1 LG BLACK 30 000195 07 1 NUT HEX JAM 3 8 16UNC ZINC 31 000055...

Page 37: ...C COUPLER Qty Part Item Description Rev BOM Rev B Assy AGLC1895 2 Rev A Date 3 15 2002 41 000201 01 2 NUT HEX 4 40UNC ZINC 42 012378 04 4 SSS BRASS TIP 1 4 20UNC 1 4 LG 43 000165 32 4 SSS CUP PT 1 2 20UNF 2 LG BLACK 14 Apr 08 Page 2 of 2 To order call Advanced Greig Laminators Inc 608 846 7016 ...

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Page 39: ...OM Rev Assy AGL 80 D1850 Rev Date 1 5 1999 1 AGL 80 B1806 4 IDLER SUB ASSY AGL8000 5 000343 10 8 HHCS 3 8 16UNC 1 1 4 LG ZINC 6 000207 08 8 WASHER FLAT SAE 3 8 DIA 13 16 OD 13 32 ID ZINC 7 000493 08 8 WASHER LOCK 3 8 DIA SPLIT ZINC 14 Apr 08 Page 1 of 1 To order call Advanced Greig Laminators Inc 608 846 7016 ...

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Page 41: ...HOLD DOWN ASSEMBLY 8000 SERIES Qty Part Item Description Rev BOM Rev Assy AGLC2910 Rev Date 6 20 2000 1 AGL 80 D2905 1 INFEED HOLD DOWN 8000 SERIES 2 000055 02 4 BHSCS 8 32UNC 1 4 LG BLACK 14 Apr 08 Page 1 of 1 To order call Advanced Greig Laminators Inc 608 846 7016 ...

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Page 43: ...1 001745 18 18 CABLE 3 x 18 AWG TYPE SJT 12 001153 05 1 CORD GRIP BELL MOUTH BLACK 5 8 MTG HOLE 13 000715 24 1 5 WIRE STRANDED 18 AWG GREEN YELLOW 14 001509 15 1 TERMINAL RING INSULATED BRAZED SEAM 18 22 AWG 8 STUD 15 002523 07 3 FERRULE INSULATED 18AWG STD LENGTH WHITE 16 000055 04 32 BHSCS 8 32UNC 1 2 LG BLACK 17 001211 03 32 NUT K LOCK 8 32UNC ZINC 18 001211 01 2 NUT K LOCK 4 40UNC ZINC 19 0006...

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Page 45: ...SOCKET 14 006006 80 1 CIRCUIT BREAKER 2 POLE 80 AMP PANEL MNT 15 001731 03 9 CABLE 3 x 20 AWG SHIELDED 16 002099 10 200 LABEL 50 x 1 50 VINYL SELF LAMINATING 17 001883 05 55 TERMINAL BLOCK 35MM 10 26 AWG GRAY UK5N 02M0381 18 001879 01 28 DIN RAIL 35MM WIDE 7 5MM HIGH 2 MT LG NS35 7 5 19 000716 00 60 WIRE STRANDED 16 AWG BLACK 20 002859 00 24 WIRE STRANDED 8 AWG BLACK 21 002324 01 5 SWITCH KNOB 2 P...

Page 46: ... 001509 08 12 TERMINAL RING INSULATED BRAZED SEAM 12 10 AWG 10 STUD 43 001509 07 16 TERMINAL RING INSULATED BRAZED SEAM 16 14 AWG 6 STUD 44 000557 04 8 PHMS SLOTTED 8 32UNC 1 2 LG ZINC 45 000559 03 4 PHMS SLOTTED 10 24UNC 3 8 LG ZINC 46 000577 02 32 PHMS PHILLIPS 8 32UNC 1 4 LG ZINC 47 002852 01 1 CONTACTOR 3 POLE 80 AMP 240V 48 001509 10 1 TERMINAL RING INSULATED 16 14AWG 1 4 STUD 49 002506 4 SWI...

Page 47: ...ULATED 14AWG STD LENGTH BLUE 73 000717 24 14 00 WIRE STRANDED 14 AWG GREEN YELLOW 74 002955 01 144 0 WIRE DUCT 1 x 1 1 2 WHITE 75 002955 02 48 0 WIRE DUCT 1 x 2 1 4 WHITE 76 002955 04 96 0 WIRE DUCT 1 1 2 x 3 WHITE 77 000343 08 4 HHCS 3 8 16UNC 1 LG ZINC 78 000493 08 4 WASHER LOCK 3 8 DIA SPLIT ZINC 79 002512 03 2 LEGEND DO NOT OPERATE WITHOUT GUARDS IN PLACE 80 002512 04 2 LEGEND CAUTION HOT 81 0...

Page 48: ...CT 12 10AWG 96 002448 01 3 CORD GRIP LIQUID TIGHT 1 2 NPT 0 20 0 35 DIA BLK 97 001087 01 2 NUT LOCK CONDUIT 1 2 99 000055 03 2 BHSCS 8 32UNC 3 8 LG BLACK 100 006004 83 2 RIBBON SWITCH 4 LEADS 4 WIRE YELLOW 83 LG 101 002974 02 1 RELAY MIDGET 1PDT 24VDC 102 002337 06 1 SOCKET RELAY 5 PIN DIN RAIL MTG 103 012393 166 DOUBLE SIDED TAPE 104 002345 221 1 RESISTOR METAL FILM 1 1 4W 221 OHM 105 006030 01 2...

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Page 50: ...NG PIPE TEE BRANCH 1 4 OD 1 8 NPT 13 000851 04 2 FITTING PIPE ELBOW FEMALE 1 4 OD 1 8 NPT 14 000855 01 5 FITTING TUBE Y 5 32 OD TUBE 15 000855 04 8 FITTING TUBE Y 1 4 OD TUBE 16 000845 04 2 FITTING PIPE MALE 5 32 OD 1 8 NPT 17 000847 12 1 FITTING PIPE ELBOW MALE 1 4 OD 1 4 NPT 18 000822 02 1 FITTING PIPE BULKHEAD 1 4 NPT 3 4 16UNC 19 012303 04 2 VALVE SOLENOID 2 POSITION 24VDC EXT PILOT 20 012011 ...

Page 51: ...rt Item Description Rev BOM Rev A Assy AGLC2107 1 Rev A Date 5 20 2003 30 012572 04 2 CONNECTOR SOLENOID VALVE 31 000847 05 2 FITTING PIPE ELBOW MALE 5 32 OD 10 32UNF 32 001456 01 1 FITTING DOUBLE Y 1 4 TUBE 5 32 TUBE 14 Apr 08 Page 2 of 2 To order call Advanced Greig Laminators Inc 608 846 7016 ...

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Page 53: ...Y 2 012236 01 1 ROLL ADHESIVE ERASER PLAIN SHRINKWRAPPED 3 001446 04 1 ALLEN WRENCH LONG ARM 3 32 T HANDLE 5 001446 11 1 ALLEN WRENCH LONG ARM 1 4 T HANDLE 7 012248 1 CLOTH LOW LINT 12x13 8 012249 1 ALCOHOL ISOPROPYL 1 PINT 10 001530 100 2 FUSE SLO BLO 10 0A 250V 1 4X1 1 4 11 X6 1 OPERATORS MANUAL 14 Apr 08 Page 1 of 1 To order call Advanced Greig Laminators Inc 608 846 7016 ...

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