AGL Encore Maxim User manual

OPERATORS MANUAL
FOR
Encore Maxim
801 Burton Blvd. DeForest WI 53532
Ph: 608-846-7016 Fa : 608-846-1024
E-mail: [e-mail]

Table of Contents
Table of Contents
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 Specifications
Machine Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Electrical Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1
Pneumatic Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -2-1
Material Capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Chapter 3 Safety
General Machine Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1
Operator Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3-1
Chapter 4 Operation
General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Right Front Control Panel, Figure 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-2
Left Front Control Panel, Figure 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-3
Rear Control Panel, Figure 3 - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - -4-4
Top Control Panel, Figure 4 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-5
Web Tension Adjust, Figure 5 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -4-6
Windup Stations, Figure 6- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Loading and Positioning Film - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
Drop Down Infeed Table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
Web the Laminator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - 4-8
Encapsulation Process, Figure 7 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-8
Pressure Sensitive Top and Bottom Process, Figure 8 - - - - - - - - - - - - - - - - - - - - - 4-10
Pressure Sensitive Process, Reverse, Figure 9 - - - - - - - - - - - - - - - - - - - - - - - - - - -4-12
Process Output Trouble Shooting - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - -4-14
Process Control Chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-16
PLI Chart - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-17
Chapter 5 Maintenance
Nip Roll Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-1
Checking the Nip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-1
Zeroing the Nip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Cleaning the Nip Rolls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Roller Open and Close Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-2
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-2
Electrical Schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-3
Pneumatic Schematic - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5-4
Chapter 6 Warranty
Limited Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Installation
1-1
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 appro imates 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. Ne t,
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 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 the laminator on the fork truck, thread the adjusting bolts into the
lower cross bar, make sure that the bolt heads are about ½” above the caster. Lower the machine down
onto 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 alignment of the rolls, idlers, and unwind/windup shafts. This alignment is
required for proper lamination. Advanced rieg Laminators, Inc.’s warranty does not cover
malfunction of the machine due to improper handling of the machine during installation.
Turn the leveling bolts down until they touch the floor. 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.
Leveling
The laminator has been trammed and burned in at the factory, but to insure the alignment of the machine
it must be leveled in its final position. To level the machine, set a level on the upper front unwind/windup
shaft. Turn the front leveling bolts until the bubble shows that the shaft is level. Repeat this procedure on
the upper rear unwind/windup shaft. Ne t place the level across the upper unwind/windup shafts (front to
rear) and adjust the leveling bolts to achieve a level reading. Repeat this procedure on the other end of
the machine. Be sure to check the left to right level as it may have shifted when leveling from front to
back. Repeat the previous procedures until you have a level reading at all four places. Tighten the jam
nuts on the leveling bolts up tight against the lower cross bar to lock the bolts in place.
Do Not lift the casters more than ½” off the floor. This will cause the
machine to be unstable.

Installation
1-2
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
fi ed wiring circuit. The circuit breaker 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 circuit breaker and
grounding lug. Advanced Grieg Laminators, Inc. will not be responsible for damage caused by incorrect
electrical installation. Before initial startup, check all switches to make sure they are in the off or open
position.
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, valves, and clutches. The laminator is supplied with a
1/4npt port for your final connection located in the lower right rear of the machine.
The air supply to the laminator must be clean and dry. Particles and
moisture can damage the cylinders, brakes and clutches.
Before laminating with your new laminator, the open close rate of the nip and pull rolls must be checked.
Refer to the maintenance section under Roller Open and Close Rate.
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.

Specifications
2-1
Machine Dimensions
Width: 89”
Height: 50”
Depth: 43” with tables e tended, 35" with tables folded down
Weight: 2800 lbs.
Electrical Requirements
220/230 VAC single phase, 50/60 Hz, 60 Amp service
Pneumatic Requirements
Appro imately 2-3 cfm at 90 psi line pressure supplied via your cleaned/dried/regulated plant air.
Material Capacity
Upper Rear Station: 7.0” Diameter 62 long 3” Diameter core. Standard
Upper Front Station: 7.0” Diameter 62 long 3” Diameter core. Standard
Lower Front Station: 7.0” Diameter 62 long 3” Diameter core. Standard
Lower Rear Station: 7.0” Diameter 62 long 3” Diameter core. Standard

Safety
3-1
IMPORTANT
READ THIS SECTION BEFORE OPERATIN 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. 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.
11. Adjust only items specifically covered by the operations portion of this manual. Any other
adjustments may create problems in performance in your machine and may require servicing by
qualified personnel to get machine back in correct working condition.
Operator Safety
Your laminator is designed to protect the operator from injury when used properly. Do not operate the
machine until you have read and understand this manual and 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 in front
and back. 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 switches can be tripped by stepping on the yellow ribbon switch. The machine must be reset after
and E-stop condition has occurred. Refer to the Operation section for further details.

Operation
4-1
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. After the power is turned on, the reset button is held for 15 seconds to allow
the machines electrical controls to reset to initial settings.
3. Speed: A potentiometer thumb wheel located on the top of the RH enclosure 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 15 feet per minute, but the quality of the product output is the governing factor
in ma imum 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-Stop-Rev: There are a set of 3 buttons located on the top of the RH enclosure used to select the
direction of the machine and to stop the machine. When standing in front of the machine, the green
lit button that is farthest away from you is the reverse button, the red lit button is the stop button and
the green lit button closest to you is the forward button.
7. 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 direction button to transfer to the
continuous run mode without stopping.
8. 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.
9. Fan On/Off- This switch will turn on and off the web cooling fans if equipped. The button will
illuminate when the fans are on.
10. Nip Roll open/close- This switch will open and close the nip rolls. When the switch selects the roll to
close the switch will illuminate.
11. Pull Roll open/close- This switch will open and close the pull rolls. When the switch selects the roll to
close the switch will illuminate.
12. Regulators- The regulators are used to control the air pressure to the cylinders for the nip and pull
rolls. The regulator knob is turned clockwise to increase pressure and counter clockwise to decrease
pressure.
13. Guages- The guages on the front and rear panels show the air pressure supplied to the nip and pull
rolls. This will be a very repeatable reading that can be documented for quicker setups on jobs.

Operation
4-2
Right Front Control Panel
The right front control panel looks like the figure below.
Figure 1 Right Front Control Panel
Main Roller Controls:
The rocker switch will open and close the main nip rollers. The switch will illuminate when the rolls are
selected to close. The pressure guage is an indicator of how much pressure is being supplied to the nip
roll cylinders. This pressure is critical to your processes, therefore the pressure guage gives an accurate
repeatable reference for quality product runs on your laminator. The regulator adjusts the pressure to the
nip roll cylinders, clockwise to increase the pressure, counterclockwise to decrease pressure.
Speed/Counter:
The speed display will show the laminator speed in feet per minute. The display can also display linear
feet of material used by pressing the "Sel" button to toggle between the speed and counter display. The
display will show an "R" in the left side if the rate display is selected. If the display is in counter mode, the
counter can be reset by pressing the "Rst" button. The display will go to 0 and begin counting up again.
Power Indicator:
The power indicator light shows that power is supplied to the machine. If an emergency stop occurs, this
light will go out.

Operation
4-3
Left Front Control Panel
The left front control panel looks like the figure below.
Figure . Left Front Control Panel
Cooling Fans:
Your machine is equipped with lower cooling fans, the rocker switch will turn the cooling fans on and off.
When the fans are turned on, the rocker switch will illuminate. An upper cooling station is available.
Heat Controls:
To use the heat control, simply press the rocker switch to the on position. The only other setting the
operator must change is the set point. To do this press and hold the star button and press the up or down
arrow to adjust the setting. The led in the upper left of the control will illuminate and flash if controller is
heating the coil up. The controller also has a built in overtemp alarm system to protect the rollers from
overheating and destroying the roll coverings. If the roller temperature e ceeds the factory preset value,
the machine will go into an emergency stop mode and stop the machine. After the rolls have cooled
down, the operator may attempt to restart the machine by pressing and holding the reset button on the
right rear of the machine. If the rolls cause and emergency stop again, qualified service technicians
should inspect the machine to solve the problem. Do not attempt to override this safety feature.

Operation
4-4
Rear Control Panel
Figure 3. Rear Control Panel
Pull Roller Controls:
The rocker switch will open and close the main nip rollers. The switch will illuminate when the rolls are
selected to close. The pressure guage is an indicator of how much pressure is being supplied to the pull
roll cylinders. This pressure is critical to your processes, therefore the pressure guage gives an accurate
repeatable reference for quality product runs on your laminator. The regulator adjusts the pressure to the
pull roll cylinders, clockwise to increase the pressure, counterclockwise to decrease pressure.
Reset Switch:
This switch is for initial startup and resetting the machine after it has had an emergency stop. The button
must be pressed and held for 15 seconds to allow the machine to go through a diagnostic setup.

Operation
4-5
Top Control Panel
Figure 4. Top Control Panel
The top control panel is used to control the speed and direction of the machine. There are three buttons
located to the left of the panel and a potentiometer wheel on the right. The potentiometer wheel controls
the speed setting of the machine. As you push the wheel away from you (when standing in the front of
the laminator) the speed will increase. There is a numerical display to reference for speed settings. If
equipped, there may also be a digital speed readout on the front display.
Direction buttons:
The panel is shown as it would look when the operator stands in front of the machine. The top button is
for Forward, the middle button is for Stop, and the lower button is for reverse. The buttons can be used in
numerous ways depending on the operation required.
Continuous mode from stop
To start the machine in continuous mode from a stop, press and hold the forward button, or reverse
button for 4 seconds. The button selected will begin to flash and the machine will move in the direction
selected if the photoeye is not blocked. If an object blocks the eye, the machine will return to stop mode.
Jog mode
To start the machine in jog mode, press a direction button, it will illuminate. Press the footswitch and the
machine will begin moving in the direction selected as long as the footswitch is pressed. The photoeye
now only works as warning device. If the operator is holding down the footswitch and an object breaks
the eye, a warning buzzer will sound but the rolls will not stop. This is useful when starting prints, but the
operator must use this with e treme caution as it puts them at a high risk for injury.
Jog to Continuous mode transfer
Follow the above steps in jog mode to start print, then while still holding down the footswitch, press the
illuminated direction button again. The button will begin to flash and now the machine is in continuous
run mode. The operator can step off the footswitch and the machine will continue to run.
Note: Sometimes the trailing edge of the print may curl up and trip the eye when in continuous run mode.
This could stop the machine and lead to a ruined print. If the operator sees this is going to happen,
simply step on the footswitch, if the eye trips the machine will go back to jog mode and can be manually
run to get the print through. Press the direction button again to transfer to continuous run mode.

Operation
4-6
Web Tension adjust
The brakes on your machine are located on the unwind shafts near the left hand side of the machine.
The brakes use compression of the delrin block on the shaft to create back tension on the web. For best
results when laminating use the least amount of tension as possible for your application. The knob on the
block will increase tension when turned clockwise and decrease tension when turned counterclockwise.
The 10 bar LED display located near the brake will move up as tension increases (more lights will be
visible). This is a good reference for repeatable tension settings from process to process. The brake
assembly is shown below.
Figure 5. Brake Assembly
Windup Stations
The windup stations are used to take material up. The liner windup station which is located in front and
above the nip rolls is used to windup the release liner of pressure sensitive film. There is also a product
windup station available that winds up the finished product after it e its the pull rolls. This windup station
is located underneath the pull rolls. The adjustment disc for these stations is located on the right hand
side. The knurled disc is rotated away from the operator to increase the friction drive an toward the
operator to decrease the friction drive. The adjustment disc assembly is shown below:
Figure 6. Windup adjustment assembly

Operation
4-7
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 e pected, 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. Determine the way the film is wound, adhesive inside or outside. This will determine the way it is
placed on the unwind shaft. If the adhesive is wound to the inside, the web will be pulled from the
bottom of the supply roll. The web path configuration figures show the film in this configuration.
2. Pull the plunger on the shaft support out and rotate it slightly so that it stays in the retracted
position. Grasp the shaft and using your thumb lift the shaft locking arm up so that shaft can be
pulled out from support.
3. Loosen the set screw in the core support collar using the allen wrench provided. Slide the core
support collar off the shaft.
4. Slide the roll of film onto the shaft and up onto the locking core chuck. Slide the core support
collar onto the shaft and into the end of the film core.
5. Swing the unwind/windup shaft with film back into the support and rotate the plunger so that it
snaps back into position and locks the shaft locking arm into place.
6. 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.
7. Repeat this process on any other unwind station.
8. 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 and taped to a windup core.
9. The wind up core is loaded by removing the windup tube. Grab the tube and press it back
against the spring loaded cup until the near end clears the drive cup. Place core over tube and
replace back in machine. Center core on windup tube, use a piece of tape to prevent the core
from slipping if required. Keep in mind that the windup cores will rotate the e act same direction
as the lower nip roll.
10. 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.
Infeed Table
The infeed table on your machine is designed to fold down to allow easier webbing access to the bottom
roll of film and the lower roll. In addition to having the table fold out of the way, the lower wrap idler is
attached to the table and moves out of the way as the table is dropped. To web the lower film station,
load film as described above. The operator grasps the T handle located under the infeed table in the
center and pull toward them, being careful not to let go of the handle, the table requires the support of the
operators hand to lower it down into its open position. If the operator does not support the table it will fall
open and over time could cause damage to the machine. To web a thermal film that requires wrap
around the lower roll, reach between the lower nip roll and the idler roll. Caution: Lower roll will be hot,
take care not to contact lower roll with hand or arm!!! Pull the film through the gap and out onto front
edge of the infeed table. Hold onto the film with one hand and raise the infeed table with the other until it
locks into position. To web a pressure sensitive film that does not have a release liner, reach in front of
the idler down to the film and pull the film up to the table. The front edge of the table should be covered
with a scrap piece of substrate to keep the adhesive from sticking to the table. Do not pull the film
between the idler roll and the lower nip roll or the adhesive will stick directly to the idler roll.

Operation
4-8
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 fle ible enough to route around the nip
roll. A common e ample would be tag board.
The first step in webbing the machine is to have a planned web path configuration. There are three
web path configurations shown in this manual. Encapsulation, Pressure sensitive top and bottom,
and pressure sensitive in reverse.
Encapsulation Process:
Figure 7. Encapsulation Process Web Diagram

Operation
4-9
Encapsulation Process
1. Load thermal film on the rear upper and lower unwind stations. Turn the brake to zero.
2. Set temperature on upper and lower nip rolls and allow rolls to balance at temperature.
3. Set the shim wheels to “0” on both the nip rolls and pull rolls.
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
4. Pull the film from the upper rear station down under the idler roller directly behind the nip roll and
over the top of the top nip roll. Be sure film is wetting out on the upper roll.
5. Lower infeed table and pull film between the lower nip roll and idler roll up over table. Hold film
with one hand and close infeed table with other hand.
6. Pulling film taut, place lower film against the wet out adhesive on the upper roll. With nip rolls
open, push film into the nip opening.
7. Select the forward direction, select a low speed setting with the speed adjust wheel, step on foot
switch as the nip rolls are closed. The rolls should pull the film into the nip.
8. Route the film through the chiller rolls (see chiller roll paths) then through the pull rolls.
9. Pull the web tight and close the pull rolls.
10. If your machine is equipped with optional product windup, route the web down to windup core and
tape to core.
11. Using your process sheets, make all the initial settings for your process. Machine is now ready to
laminate. Follow the procedures in operation to start your prints and set machine in run mode.

Operation
4-10
Pressure Sensitive Top and Bottom Process
Figure 8. Pressure Sensitive Top and Bottom Process
Web Diagram

Operation
4-11
Pressure Sensitive Top and Bottom Process
1. Load film on the rear upper and lower front unwind station. Note that the lower front station
cannot be used for a pressure sensitive film with a release liner. Turn the brake to zero.
2. Set temperatures on upper and lower rolls if required by film and allow to balance at temperature.
3. Set the shim wheels to “0” on both the nip rolls and pull rolls, place a piece of feeder stock into
the nip rolls with plenty of stock hanging out the front. Close the nip rolls onto the piece of feeder
stock.
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
4. Pull the film from the upper rear station down under the idler roller directly behind the nip roll and
over the top of the top nip roll. Separate the release liner from the film and stick the film to the
feeder stock.
5. Route the release liner up to the front upper windup station. Tape the release liner to the wind up
core.
6. Lower infeed table and pull film up in front of the idler roll and stick to lower side of feeder stock.
7. Select the forward direction, set the speed adjust wheel to a low setting an move to the rear of the
machine.
8. Using the footswitch, run web to pull rolls and close the pull rolls.
9. With web pulled through laminator, you can now lift the infeed table into its locked position.
10. If your machine is equipped with optional product windup, route the web down to windup core and
tape to core.
11. Using your process sheets, make all the initial settings for your process. Machine is now ready to
laminate. Follow the procedures in operation to start your prints and set machine in run mode.

Operation
4-12
Pressure Sensitve Process (Reverse)
Sometimes mounting processes are required to be run between encapsulation processes. Since the nip
rolls will be very warm due to the encapsulation process it is not possible to run a cold mounting process
without letting the roll cool down. This could be a very long wait depending on the temperatures used for
the encapsulation process. It is possible to run a single side mounting process through the pull rolls in
reverse. The web diagram for this process is shown below:
Figure 9. Pressure Sensitive Process (Reverse)
Web Diagram

Operation
4-13
Pressure Sensitive Process (Reverse)
1. Load film on the rear upper unwind station. Turn the brake to zero.
2. Set the shim wheels to “0” on the pull rolls and 1" on the nip rolls, place a piece of feeder stock
into the pull rolls with plenty of stock hanging out the front. Close the pull rolls onto the piece of
feeder stock.
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. Pull the film from the upper rear station down to the top of the upper pull roller, separate the
release liner from the film and stick the film to the feeder stock.
4. Route the release liner up and over the film roll to the front upper windup station. Tape the
release liner to the wind up core.
5. Select the reverse direction, set the speed adjust wheel to a low setting.
6. Set shim wheel on pull rolls based your substrate you are using.
7. Place substrate into pull rolls and close pull rolls.
8. Using your process sheets, make all the initial settings for your process. Machine is now ready to
laminate. Follow the procedures in operation to start your prints and set machine in run mode.
9. Place graphic onto board and run through laminator in reverse. (see operation section for mode
sequences)

Operation
4-14
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 e cess 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 pressure.
3. E cessive roll pressure: Reduce upper roll pressure.
4. Wrong spacers being used.