Advanced Greig Laminators, Inc. Patriot User manual

I
Operation Manual
Patriot
Advanced Greig Laminators, Inc.
801 Burton Blvd, Deforest, WI 53532
608-846-1025, [email protected]

Chapter 1: Installation
II
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 ..................................................................................................................................... 3
Pneumatic Requirements................................................................................................................................... 3
Material Capacity ............................................................................................................................................... 3
Chapter 3: Safety
General Machine Safety..................................................................................................................................... 4
Operator Safety.................................................................................................................................................. 4
Chapter 4: Operation
General ............................................................................................................................................................. 5
Front Right Control Panel................................................................................................................................... 6
Front Left Control Panel ..................................................................................................................................... 7
Rear Right Control Panel ................................................................................................................................... 8
Reset Panel....................................................................................................................................................... 9
Temperature Controls......................................................................................................................................... 9
RTS brakes (64i Std, 64T/C optional) ................................................................................................................. 9
Laminator Setup............................................................................................................................................... 10
Loading and Positioning the Film...................................................................................................................... 10
Webbing the Laminator.................................................................................................................................... 10
Encapsulation Process, 64i Model.....................................................................................................................11
Curl Cam Option.............................................................................................................................................. 12
Pressure Sensitive Process, 64i Model............................................................................................................. 13
Pressure Sensitive Process, 64T/C Model........................................................................................................ 14
Process Output Trouble Shooting..................................................................................................................... 15
Web Breaks..................................................................................................................................................... 15
Curl in Product................................................................................................................................................. 15
Wrinkles in Product .......................................................................................................................................... 16
Poor Lamination......................................................................................................................................... 16
Bubbles in Product..................................................................................................................................... 16
Process Control Charts.................................................................................................................................... 16
Chapter 5: Maintenance
Nip Roll Section ......................................................................................................................................... 19
Checking the Nip........................................................................................................................................ 19
Zeroing the Nip Rolls.................................................................................................................................. 19
Cleaning the nip rolls and pull rolls ............................................................................................................. 19
Roller open and close rate.......................................................................................................................... 20
Lubrication ................................................................................................................................................. 20
Chapter 6: Warranty
Warranty and Conditions.................................................................................................................................. 21
Chapter 7: Schematics
Electrical-......................................................................................................................................................... 23
Pneumatic- ...................................................................................................................................................... 24

Chapter 1: Installation
III
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. 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 nip and pull roll sections are protected with an electric photo-cell system.
The AGL design has a rigidly constructed steel frame. All parts are machined to prints, ensuring complete
interchangeability of all parts, manufactured or purchased.
Adjustable air pressure to the laminating nip rolls, pull rolls and clutches is supplied via your regulated, cleaned and
dried air. Use of a lubricator in your air system is not required nor recommended. The oil can actually cause issues
with the laminator. Air must be cleaned and dried, damage to components by moisture is not covered by the
warranty.

Chapter 1: Installation
1
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. 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.
Uncrating
Your new laminator may come in a full crate. The crate is designed to be usable for future shipping if required, so
careful disassembly of the crate is important if the crate is to be reused. The crate is held together by screws
(phillips head) a power screwdriver with a phillips bit is recommended but not required for uncrating. First, remove
the top of the crate, keep the screws for future use on the crate. Next, remove the front of the crate (it is
recommended that two people disassemble the crate, so one person can hold the panels while the other removes
the screws). Move around the crate and remove the remaining panels. Remove the bolts/boards holding the
laminator down to the skid. A fork truck can now lift the laminator off the skid (it is possible to get the laminator out
of the crate after removing only the top and front and the hold down bolts). With 2 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 alignment of the rolls, idlers, and unwind/windup
shafts. This alignment is required for proper lamination. Advanced Grieg Laminators, Inc.’s warranty does
not cover malfunction of the machine due to improper handling of the machine during installation.
Remove the shrink wrap, bands, and protective coverings from the rolls.
Do Not use a knife or other sharp object to remove the shrink wrap from the laminator
and the protective coverings from the rolls. This can cause irreparable damage to the
laminator enclosures and rolls.
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. A
readily accessible disconnect device shall be incorporated into the fixed wiring circuit. The switch on the laminator
is not considered a disconnect device. Consult a qualified, licensed electrician to ensure that the power supply for
the machine is properly installed in your facility. Qualified personnel can remove the RH enclosure cover to allow
access to the terminal strip and grounding lug. Advanced Grieg 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. The laminator is supplied with a 1/4npt port for your final connection.
The air supply to the laminator must be clean and dry. Particles and moisture
can damage the cylinders.

Chapter 1: Installation
2
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. The foam protective coverings over the rolls can be
recycled to be used for other shipping purposes.

Chapter 2: Specifications
3
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” Diameter x 60 long x 3” Diameter core.
Lower Front Station: 8” Diameter x 60 long x 3” Diameter core.
Upper Rear Station: 8” Diameter x 60 long x 3” Diameter core.
Lower Rear Station: 10” Diameter x 60 long x 3” Diameter core.
These are physical dimension restrictions. The weight of the material on any station should never exceed 90 lbs.

Chapter 3: Safety
4
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. Keep this manual in a place where it can be easily referenced by all operators.
3. 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.
4. Use only the recommended power source to run the laminator. Consult a qualified and licensed electrician
if you are unsure of the power supply and the safety features of the supply.
5. If power supply cord is run across the floor, provide adequate protection to the cord to avoid damage from
foot traffic, dropped items or rolling items.
6. Do not attempt to service the laminator without qualified personnel available. Damage to the machine or
injury to you could be caused by moving parts or high voltage.
7. Do not operate the laminator with out all guards in place. If a guard is damaged or not working properly,
replace or repair before returning the machine to operation. If the machine is run without all guards in place
the safety obligation of the manufacturer is null and void.
8. Do not insert fingers, hands, or items into openings in the sideframes. Items may become entangled in
moving parts or in contact with high voltage.
9. Disconnect or lockout power from machine when any service is required and when cleaning the nip rolls.
10. Disconnect or lockout power from the machine and refer to service personnel if the performance of the
machine changes indicating a problem or if machine does not operate normally to 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 and not wear neckties, loose clothing and jewelry since they
can be caught in the nip section and pull the operator into the machine.
Proper equipment such as gloves should be used if the material being
laminated requires it. The nip rolls will lower if there is a loss of air pressure.
The nip section is protected by a photoelectric eye that shoots a light beam across the machine in front of the nip
rolls. When the machine is in continuous run mode, the rolls will stop when the beam is broken by an item too
close to the nip section. However, if the machine is in jog mode, an alarm will sound warning the operator that
he/she is very close to the nip section, but the rolls will not stop rotating. The jog mode is useful for starting prints
into the laminator and smoothing the print corners out as they enter the nip section, but this mode should be used
as sparingly as possible since it puts the operator at a greater risk than the run mode.
When the machine is in jog mode, an alarm will sound to warn the operator but
the rolls will not stop rotating when the light beam is broken. Use this mode
sparingly and with respect.
There are E-stop switches on all four corners of the machine, as well as an E-stop ribbon switch on the front lower
tie bar and depending on model, the rear lower tie bar. The machine will stop and the nip section will open if any of
these switches are tripped. Striking the red mushroom heads on the switches with your palm can activate the four
switches. The ribbon switch can be tripped by using your foot and stepping on the yellow ribbon. The machine
must be reset after and E-stop condition has occurred. Refer to the Operation section for further details.

Chapter 4: Operation
5
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.
3. Speed: A potentiometer is used to control the speed that the laminator will run product through. Your
laminator has the electrical and mechanical capability to run up to 30 feet per minute, but the quality of the
product output is the governing factor in maximum process speed.
4. E-stops: E-stop switches are located at all four corners to allow the operator to stop the machine and open
the nip rolls and pull rolls in case of emergency. The button must be pulled back out before pressing the
reset button to restart the machine.
5. Nip Rolls: The nip rolls are the heart and soul of the laminator and must be cared for properly in order to
give years of quality product output. Always dial the shim wheel to a shim setting greater 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: This button is a lighted button that will determine which direction the machine will run. If the
button is not lit, the machine will run from back to front (Reverse). If the button is lit, the machine will run
from front to back (Forward). The machine can only jog in reverse.
7. Stop: This button will stop the rotation of the nip rolls.
8. Run: This button will allow the machine to run continuously in the forward direction at the speed set by the
potentiometer.
9. Foot Switch: The foot switch will run the laminator in the direction depicted by the Fwd/Rev button and at
the speed set by the potentiometer. The foot switch is always active, this allows an operator to press the
foot switch to get a print started and then press the Run button to transfer to the continuous run mode
without stopping (Forward direction only)
10. Temperature Control with switch: The two position switch allows the operator to turn the heater in the roll on
or off. The temperature controller allows the operator to set a desired temperature for a process. The
switch will illuminate when the heater is on.
11. Brakes: Your laminator is equipped with pneumatic brakes. Adjust the regulator clockwise to increase
pressure and counter clockwise to decrease pressure. The tension is dependent on the air pressure
provided. Higher pressure equals higher tension.
12. Clutches: Your laminator is equipped with pneumatic clutches. Adjust the regulator clockwise to increase
pressure and counter clockwise to decrease pressure. The tension is dependent on the air pressure
provided. Higher pressure equals higher tension.
13. Pull Roll Clutch: Turn the regulator clockwise to increase the pressure to the pull roll clutch and pull roll
cylinders and counter clockwise to decrease pressure to the clutch.

Chapter 4: Operation
6
Front Right Control Panel
The front right control panel looks like the figure below.
Figure 1 Front Right Control Panel
Run
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.
Fwd/Rev
The Fwd/Rev button selects the direction the rollers will turn. When illuminated, the drive is in forward mode. The
machine will only jog (footswitch) in the reverse direction.
Nip Roller Control
The button opens and closes the nip rolls. Illuminated indicates closed rolls. The regulator adjusts the pressure to
the nip cylinders.
Upper and Lower Unwind
The regulators control the pressure to the pneumatic brakes on the upper and lower unwinds.

Chapter 4: Operation
7
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. Iluminated indicates the heater is on. The temperature controller will
maintain the heat at the user set point.

Chapter 4: Operation
8
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. Press and release to reset the
machine.
Pull Roller Control
The regulator controls the pressure to both the clutch that drives the rollers and the cylinders that push the top roller
down. The Open / Close switch will open and close the pull rolls. Illuminated indicates closed rollers.
Stop
The stop button will stop the drive.

Chapter 4: Operation
9
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. The controllers are also set up with an over temp alarm. If
there is a failure and the heater coils heat out of control, the temperature controller will create an e-stop condition.
The temperature controller looks like the graphic shown at the left. 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 exceed the upper
temperature limit set at the factory and then the machine will go into an E-stop
condition. The rolls must be allowed to cool down before restarting machine. The
machine can be restarted by pressing and holding the Reset button for 15 seconds.
If the machine fails again in the same manner, the laminator should be serviced by
qualified personnel.
Temp controller troubleshooting
Your laminator uses a mechanical slip ring to transfer the thermocouple signal and power from outside the roller to
the heater and thermocouple inside the roller. Since the slip ring uses friction brushes as the transfer point, a
common problem is the signal rings can get dirty and cause a faulty or inconsistent signal from the thermocouple
back to the temperature controller. This signal is very small and if it starts bouncing around due to dirty rings or
poor connections it can cause intermittent estop conditions. It is important to maintain the slip ring and the
thermocouple connections in good working condition. Every facilities working conditions, temperature, and
humidity will be different which will affect the slip ring differently. It is recommended that monthly, the signal rings
are cleaned with a contact cleaner and the brushes are checked for wear. If the display on the temperature
controller starts to bounce around it is an indication that the slip ring is dirty.
Airshaft Inflate/Deflate
The upper rear, lower front and lower rear stations are all airshafts. This allows the user to quickly change rolls of
materials on the machine. The switches located just above each shaft on the left end are used to inflate and
deflate the airshafts. Flip the switch down to deflate the shaft and up to inflate the shaft.

Chapter 4: Operation
10
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.
The set up process is comprised of the following steps:
1. Loading and positioning the film.
2. Webbing the laminator.
3. Setting the process controls to initial settings.
4. Warm up time (if required by process)
Loading and Positioning the Film
1. Pull plunger and rotate slightly to hold in unlocked position. Grab the shaft with your fingers and using your
thumb push up the latch an swing the upper rear shaft out for loading.
2. Flip the Inflate/Deflate switch down to deflate the airshaft. Slide the material onto the shaft.
3. Rotate the shaft back into place. Slightly rotate the plunger head so that it locks into the latch.
4. Using the centering ruler on the airshaft, center the material on the airshaft. Flip the Inflate/Deflate switch up
to inflate the shaft and hold the core.
5. Repeat this process on any other unwind station.
6. 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
webbing the film under an idler and separating the film and liner. Once the liner has been separated
from the film, it must be routed up over the second idler and taped to a windup core.
7. The liner wind up core is loaded onto the windup shaft either in the upper front location. Rotate the shaft so
that the pin on the drive side (LH when in front of the machine) is horizontal. Lift the shaft up out of the
holder on the right and move shaft toward the RH cabinet until it clears the drive shaft. Load the core onto the
shaft and replace the shaft into the machine. The product windup is loaded the same as an unwind
shaft described in steps 1-4.
8. Tape the release liner to the core and windup any slack by hand. Feed the film with adhesive around and
through the nip opening. Note: You may require feeder stock to keep the film from sticking to the
lower nip roll.
Webbing the Laminator
The term webbing means routing the film through the laminators’ idlers and nip rolls and thus creating a web. The
easiest way to web the machine up after loading the film is by using a piece of feeder stock. The stock can be
anything that is relatively stiff, but still flexible enough to route around the nip roll. A common example would be tag
board.
The first step in webbing the machine is to have a planned web path configuration. There are two web path
configurations shown for two different processes in this manual. The encapsulation process uses thermal film from
top and bottom to “encapsulate” the substrate being fed into the laminator. This process seals the edges and
protects the substrate. Refer to figure 4 as the webbing process is described below.

Chapter 4: Operation
11
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. With nip rolls open, pull the material from the lower front station up behind the web path idler and in front of
lower nip roll. Thread enough material between the nip rolls to allow you to grab it from the back side.
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 and not wear neckties, loose clothing and jewelry since they
can be caught in the nip section and pull the operator into the machine
3. Grab the material from the back side of the nip and thread it through the open pull rolls. Pull the material taut
and then close the pull rolls to secure the material. Increase pressure to the lower front unwind brake.
4. Lower the infeed table into the standard position. Pull the material from the upper rear station under the
wrap idler and over the top nip roll. Thread the material through the open nip rolls.
5. Pull the material from the back side of the nip and attach to lower material. Close the nip rolls and increase
the pressure to the upper rear unwind station. If you are using a pressure sensitive product with a release
liner, route the release liner up to the upper front windup core.
6. Set the speed potentiometer to a low setting, select Fwd. Move to the rear of the machine.
7. Press the footswitch to run the material through the pull rolls. It may be necessary to open the pull rolls and
manually pull the material taut then reclose the pull rolls.
8. To wind up the product, route the film down to the lower rear windup and tape to the core.
9. Turn the heater controls to “On” and set the desired temperature. While the rolls are heating up use your
process control chart to make all initial settings on the brakes, speed and nip pressure.
10. With rolls at the desired temperature you may feed the substrate into the nip section.
11. If your material is thick and requires a shim setting higher than “0” you will need to use a sacrificial piece of the
substrate when you web up the machine to take up the gap in the nip and pull rolls..
Figure 4. Lamination Proces

Chapter 4: Operation
12
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.
2. Loosen pressure knob (2) to allow the spring to be decompressed.
3. Locate holder/blade in location on shaft for desired cut. Rotate the body (5) about 30 degrees CCW and
tighten the bolts (1) with the 5/16 allen wrench. The body is now secured to the shaft.
4. Using the pressure knob (2) you can force the blade into the anvil roller to ensure a good cut.
5. The blade can be adjusted slightly side to side while running and without loosening body or pressure knob.
Loosen knob (3) and then rotated the adjustment knob (4) to correct position and then tighten knob (3) to
secure the position of the blade.

Chapter 4: Operation
13
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.
Refer to Zeroing the Nip in the maintenance section.
Pull roll “zero” setting may be incorrect Check nip setting and adjust if necessary. Refer
to Zeroing the Nip in the maintenance section. Pay particular attention to sides opposite
the waves.
D-Waves in Product
If waves are in the substrate and not film
Substrate problem 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 excessive tension: If the web breaks between the unwind station and the nip,
reduce the unwind brake tension. 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.
Curl in Product
1. Running a hot mount material in cold-mount machine sometimes creates a curl in the finished
product.
2. Too much web tension: Reduce unwind brake tension.
3. Excessive roll pressure: Reduce upper roll pressure.
4. Wrong spacers being used.

Chapter 4: Operation
14
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.
3. If the web is loose between the unwind and the drive roll, there is not enough tension on the unwind brake.
Increase the tension on the unwind brake to correct.
4. If the web is loose between the windup and the drive roll, there is not enough tension on the windup clutch.
Increase the tension on the windup clutch to correct.
5. If the web gets narrow between the unwind and the drive roll, there is too much tension on the unwind
brake. Decrease the tension on the unwind brake to correct.
6. Top and bottom laminating rolls may not be parallel. Make sure spacer shims are the same size, then zero
the nip. Refer to Zeroing the Nip in the maintenance section.
Poor Lamination
1. All substrate materials must be cleaned and free of dust, dirt, grease, and any other type film.
2. Poor lamination is usually caused by thickness variation in the substrate materials such as plywood, hard
board or other such non-precisely made materials. To overcome this, cylinder spacers may have to be
removed and materials laminated without the use of cylinder spacers, or the next smaller spacer may be
used or special spacer utilized.
3. Materials 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. Visually inspect materials, mounting or overlays for any voids in the adhesive film. If any exist, it cannot be
corrected by any laminating machine - that part of the material should be discarded.
2. Low pressure on nip rolls Increase air pressure to nip rolls. Incorrect shim setting Adjust shim wheel to
correct setting.
3. Nip “zero” setting may be incorrect Check nip setting and adjust if necessary. Refer to Zeroing the Nip in
the maintenance section.
Process Control Charts
In order to consistently output high quality product, the operator must have a definite starting point on the many
process variables. This can be achieved by having the operators document system settings when you have
achieved acceptable quality output. The process control chart will allow any operator to set the machine up for a
given process. Keep in mind that the system variables may require adjusting as the process is being run, but the
chart gives an excellent starting point. Factors such as temperature, humidity, changing film roll diameters all affect
the process, therefore, operator technique in running the machine is inevitable. There is a blank process control
chart located on page 16, copy this page as often as needed for new processes.

Chapter 4: Operation
15
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: Up Down Shim Dial Setting:
Pull Roll Setting:(PSI)
Film Sta
tion Settings
Upper Rear Unwind: PSI Upper Front Rewind: PSI
Lower Front Unwind: PSI Lower Rear Rewind: PSI
Other Instructions:

Chapter 4: Operation
16
AGL6400 LAMINATOR ROLL PRESSURE
0.00 5.00
10.00 15.00 20.00 25.00 30.00
0.00 10.00 20.00 30.00 40.00 50.00 60.00 70.00 80.00 90.00 100.00
AIR PRESSURE, PSI
ROLL PRESSURE, LBS./IN.
LBS/IN.

Chapter 5: Maintenance
17
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. Only trained service personnel
should perform maintenance with any guards or covers removed.
Nip Roll Section
The most critical adjustment of the nip and pull rolls is the “zero” position. This adjustment makes the
top roll parallel to the bottom roll which creates even pressure and pull distribution across the face of the
roll. If the rolls are out of adjustment, the machine will not laminate properly. Zeroing the nip is done at
the factory before shipment, but should be checked at startup and if laminator is not creating quality
output.
Checking the Nip
1. Place two pieces of thin paper (approximately 1.0” wide by 12.0” long) between the upper pressure roll
and the lower roll (about 3.0” from each end).
2. Set the shim dial to the “0” setting and close the upper roll, with a pressure of about 35 psi.
3. Pull gently on both pieces of paper, if both pieces of paper have the same drag, the nip is fine, if the drag
is different, follow the procedure below to correct the setting. The pull rolls are adjusted the same as the
nip rolls.
Zeroing the Nip Rolls
1. Loosen the sets 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 and pull rolls
Cleaning the nip rolls may require the nip rolls to be rotating. Rotate the
rolls at a very slow rate to avoid being pulled into the nip section. Do not
wear neck ties, loose clothing or hanging jewelry that could be pulled into
the nip section.
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. To facilitate the cleanup process,
adhesives should be cleaned from the rolls as soon as possible and while the roll is still warm. A rubber "eraser"
has been included in your accessory kit that can be used to clean the adhesive from the warm rolls. Rub the
eraser over the adhesive with the rolls turning very slowly. The cloth and alcohol can be used to remove the
residue.
Use of incorrect solvents on your nip and pull rolls can cause irreparable damage to the coverings.
AGL. is not responsible for damage to roll coverings caused by these solvents.