Coating Module: Service Training Mechanik

Service Training Mechanik

15
Coating module
Page
1 Coating module: ........................................................................................3
2 Design of the chambered doctor blade application unit: ........................4
4 Softkey assignment B side .......................................................................5
4 Operating panel at the coating module: ...................................................6
5 Coating module designation:....................................................................7
6 Roller diagram: ..........................................................................................8
7 Two-roller application system:..................................................................9
8 Metering roller adjustment:.....................................................................10
9 Instructions for metering roller adjustment: ..........................................11
10 Sensorics of the auxiliary drive for the metering and coating rollers:..12
11 Construction and mounting of the metering and coating rollers:.........13
12 Metering and coating application roller drive: .......................................14
13 Metering and coating application roller transmission: ..........................15
14 Impression setting diagram: ...................................................................16
15 Chambered doctor blade:........................................................................17
16 The chambered doctor blade/anilox roller coating application method:18
17 Components of the chambered doctor blade:........................................19
18 Chambered doctor blade magnetic switch:............................................20
19 Anilox roller: ............................................................................................21
20 Chambered doctor blade settings: .........................................................22
21 Anilox roller design: ................................................................................23
22 Coating infeed and extraction:................................................................24
23 Setting the forme cylinder to the impression cylinder: .........................25
24 Lateral and circumferential register at the forme cylinder ....................26
25 Interdeck drying with double coating modules:.....................................27
26 Coating module specifications: ..............................................................28
Data Base Documentation 1

© MAN Roland Druckmaschinen AG - Offenbach

15
2 Data Base Documentation


15
1 Coating module:
R7k15_00


15
2 Design of the chambered doctor blade application unit:
1
2
6
3
1 Anilox roller
2 Forme cylinder
3 Impression cylinder
4 Coating drip pan
5 Negative blade
6 Positive blade
R7k15_01
Design of the two-roller application unit:
5
3 4
1
6
1 Forme cylinder
2 Impression cylinder
3 Metering roller
4 Forme roller
5 Coating feed
6 Coating pan
R7k15_02


15
3 Softkey assignment B side
1 2
3 4
5 6
8 9
10 11
12 13
14
15 16
17 18
19 20
R7k15_03


15
4 Operating panel at the coating module:
1. Signal transmitter.
2. Impression OFF, feeder off.
3. Preselect coating application A side; setting the coating metering roller to the coating forme roller A side. Press
key (3), LEDs of keys (5) and (6) blink, the nominal value is shown in percent in the display (14).
4. Preselect coating application B side; setting the coating metering roller to the coating forme roller B side. Press
key (3), LEDs of keys (5) and (6) blink, the nominal value is shown in percent in the display (14).
5. Nominal value minus.
6. Nominal value plus.
7. Chambered doctor blade ON/OFF (shoots the chambered doctor blade into/out of contact to the anilox roller).
8. Coating pump ON/OFF (inflow and outflow pumps).
9. Preselect coating flow rate. Press key (9), LEDs of keys (5) and (6) blink, the nominal value is shown in percent
in the display (14).
10. Coating metering roller ON/OFF (auxiliary drive A side, can only be actuated by preselect:
coat. operation “+”, coat. film “+” and coating pumps ON).
11. Coating forme roller to forme cylinder ON/OFF (in chambered doctor blade mode: anilox roller to forme
cylinder).
12. Positioning backwards (deselect makeready mode).
13. Positioning forwards (select makeready mode); press this key to activate makeready mode, when activated
press key (11) to set the forme cylinder washing cassette ON/OFF; press key (2) for impression ON/OFF.
14. Display.
15. Loudspeaker.
16. Crawl speed.
17. Inch backwards
18. Inch forwards.
19. Emergency stop.
20. Stop (security).


15
5 Coating module designation:
With the “new coating module”, the designation has been changed.
Coating module = L Transfer module = T

Optional extension (914 mm) = V
Standard equipment of the new coating module:
- Roller system (1)

- Transfer module between the coating modules
- 945 mm extension in the delivery (3)
- Blanket washing device (to wash split back offset ink from full-surface blankets)
- Motorized impression setting
- Automatic forme cylinder positioning
- Preparation for IR/hot air end-of-press drying
- Hard-chromed forme cylinder and impression cylinder surfaces
- Cylinder blast device (sheet entry)
- Forme cylinder undercut 2.60 mm
- Multi-purpose plate clamps


15
6 Roller diagram:
5
3 4
1
6
1 Forme cylinder ∅ 300 mm

R7k15_04 2 Impression cylinder ∅ 600 mm
3 Coating metering roller ∅ 182.2 mm (chrome)
4 Coating forme roller ∅ 182.2 mm (+0.0 mm / - 0.4 mm) (rubber)


15
7 Two-roller application system:
- Coating metering roller and coating application roller have the same diameter.
- Depending on the coating and substrate to be run, these rollers can be interchanged. This gives the user a
high degree of flexibility and conversion kits, as used in the past, are no longer necessary.
- Coating is fed from above via an optimized feed pipe.
- The amount of coating applied is adjusted by altering the pressure between the metering and application rollers
and the function is motorized.
- Adjustments to the amount of coating applied is done from the control console for A and B sides separately.
Operation:
- To begin, the press must be in the P/P mode at the control console.
♦ The entry line Coating operation can be seen in the “Preset” menu. This means:
Coating op.+ = after the key WORK POS. (in the “Damp./ink” menu) is pressed, the metering roller moves to
working position and the coating forme roller can be engaged. The coating forme cylinder can be
set to impression ON.
Coating op.- = after the key WORK POS. (in the “Damp./ink” menu) is pressed, the metering roller does not
move to working position and the coating forme roller cannot be engaged. The coating forme
cylinder can be set to impression ON.
♦ The entry line Coating application can be seen in the “Preset” menu. This means:
Coating appl.+ = automatic engagement of the coating forme roller to the forme cylinder with Preset Auto.
Production.
Coating appl. - = the coating forme roller does not engage to the forme cylinder with Preset Auto. Production.
♦ In the “Preset” menu, key “Damp./ink”, an additional line appears: Coating method. (Only when op. Mode
blade/roller has been preset). This line means:
RO = roller operation and

CD = chambered doctor blade operation (can be switched by the +/- keys).
♦ The entry lines coat. rollers ON and coat. rollers OFF can be seen in the “Preset” menu, key “Damp./ink”.
These mean:
Coat roller ON = precoating, i.e. the coating forme roller engages to the forme cylinder 1 to 9 sheets before
the forme and impression cylinders move to impression ON.
Coat roller OFF = decoating, i.e. the coating forme roller disengages from the forme cylinder 0 to 9 sheets
before the forme and impression cylinders move to impression OFF.


15
8 Metering roller adjustment:
The purpose of the adjustment process is to define the working range.
♦ The mask Adjust metering roller can be called up in the menu “General”, “Service”, Adjust”, “Coat”
Adjustment range of the eccentric bearing for the metering roller in mm

R7k15_05
1 Metering roller rest position or overnight position
2 Kiss contact between metering and forme rollers, start of the working
range
3
99 0
Depiction of the working range (regulating distance of the metering roller
R7k15_06 = 0.3 mm), corresponds to the green bar in the “Damp./ink” menu, 99 =
max. coating amount, 0 = min. coating amount.
See menu “Damp./ink”, key “Damp./coat”, selection of the number of the ‘printing unit’s’ coating module, the two
green bars are the nominal values (%) for the amount of coating to be applied.
The start of the working range is determined by the kiss contact (i.e. the contact position between the metering
and application rollers).


15
9 Instructions for metering roller adjustment:
This is necessary because the rubber surface of the roller (forme roller or metering roller) is subject to
wear. The condition of the surfaces should be checked regularly (how often depends on how often they are
used).
1. Checking the parallelism of the coating forme roller (steel roller) to the forme cylinder:
• Remove the ‘blanket’ from the forme cylinder.

• Activate impression ON at the coating module to be checked.
Only in exceptional cases: Check that the coating forme roller is running true (max. true running
tolerance = 0.02 mm).
• Check that the parallel distance between forme cylinder surface and coating forme roller surface is 2.6 mm
(depending on whether the undercut is 1.7 mm or 2.6 mm) and if necessary reset with the dial gauges Take
the dial gauges out of the mountings, set them to zero and put them back in the mountings. Now use the
dial gauges to set the distance (A and B sides) to 0.3 mm (corresponds to 0.6 in the display) and lock the
nuts on the threaded rod.
• Replace the ‘blanket’.
2. Call the menu for adjusting the metering roller (see previous page).
3. Press the Enable key at the control console, both motors start moving for metering roller pressure setting (-
M408 and -M 409) (of the selected coating module) to the position working range = 99%; while the motors are
moving the message “adjustment active” appears and the diagnosis field turns red, the text Enabled in key 10
disappears (motor movement can take up to 4 minutes).
When making this adjustment for the first time, the motors move to a theoretical contact point prescribed by
the control console.
4. Once both motors have reached the position working range = 99%, press the key Preset, Coating appl. A side
or B side (-A007), the keys Makeready minus and Makeready plus are activated.
5. Check the distance between the metering roller and forme roller on both A and B sides with Japan paper
(3/100 mm thick). The paper must come free with a firm pull.
If the distance is not correct:
a) Select key Preset, Coating appl. at the side where the distance is wrong, and
b) correct the distance with the key Makeready minus or Makeready plus.
6. If the new setting is to be stored, it must be acknowledged with the Enter key at the control console (it will be
stored in the EEPROM of the coating module’s process rack).
7. In the position working range = 99%, -S551 (limit switch metering roller is activated) must = “1”.
Connect the hand terminal to the coating module, switch it to active mode, in menu 6 select drives no. 3 and 4,
displayed nominal value: between 6000 and 7800 steps, reduce the nominal value by 300 steps, the acoustic
warning signal must sound and the coating pumps must switch off.
Check: In the position working range = 99%, the coating pumps must be able to be switched on !


15
10 Sensorics of the auxiliary drive for the metering and coating application rollers:
-B133 Proximity switch for clutch overload, ensures that there is coating in order to protect the metering and
forme rollers.
These two rollers turn at different speeds, determined by the auxiliary drive transmission.
In the event of an overload i.e. the coating on both rollers is dry, there is no longer any slip.
The metering roller forces the coating forme roller to turn with it and the overload sensor
-B133 (not active =”1”) is activated by cams (8 cams spread around the circumference).
A548/4: Byte 6, Bit 0
Setting instructions:
1. To exchange sensor -B133, turn oil lubrication OFF, dismount the side cover A side, loosen the Allen screw
and remove the -B133 holding plate.
2. Before loosening the locknut, measure distance X (approx. 36.5 mm) with a caliper.
3. Screw the new -B133 onto the holding plate in the old X position plus 0.1 mm, tighten the locknut and check
dimension X!
8
1
-M410 2 9
1. Auxiliary drive
10
7 -B133 2. Worm drive
3. Drive gear Meetering
roller
R7k15_08 X 4. Wooden wedge
6
5. Overload clutch with
– B 133 sensor
3 6. Forme cylinder
7. Drive gear Forme
roller
5 8. Holding plate
9. Allen screw
4
10. Locknut
R7k15_07
4. Mount the holding plate at the place provided on the overload clutch and fasten the screw.
5. Function check:
- Switch off auxiliary drive -M410. Clamp the metering roller drive gear with a wooden wedge!
- Release the main drive brake (-S010). Turn the press carefully forwards by hand.
- If the metering roller drive gear is firmly clamped by the wooden wedge, the overload clutch
engages. -B133 = “0” i.e. Byte 6, Bit 0 = “1”.
- Turn the press by hand until all 8 cams of -B133 have switched from “1” to “0” (can be seen
at -B133 on the red LED (this goes out when the cam sensor is covered).
- Remove the wooden wedge!
- Switch -M410 on and the 8 cams will be pushed back into the basic position.
- Close the main drive brake (S010).


15
11 Construction and mounting of the metering and coating application rollers:
R7k15_09
1 Metering roller
2 Coating forme roller
3 Forme cylinder


15
12 Metering and coating application roller drive:
R7k15_10
R7Bild117.ai
Front view of the drive for the metering roller and coating forme roller A side with motorized adjustment of the
metering roller, overload clutch and proximity sensor.
The metering and coating forme rollers are driven by a transmission with an overload clutch, alternately by a motor
or by the press.
A proximity switch is mounted on the overload clutch. When the coating forme roller turns at the same speed as the
metering roller (dried coating), the locking bolts are pressed towards the proximity switch which passes an error
message to the control console.
When the rollers run at the same speed, there is no longer any slip between them !


15
13 Metering and coating application roller transmission:
Side view of the transmission

(section) for the metering and
coating forme rollers
1 Proximity switch for the overload

clutch
R7k15_11
R7Bild118.ai


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14 Impression setting diagram:
R7k15_12
r7bild110.ai


15
15 Chambered doctor blade:
R7k15_13


15
16 The chambered doctor blade/anilox roller coating application method:
The chambered doctor blade/anilox roller method of applying coating is a significant new development in
metering technology. A chambered doctor blade takes the place of the metering roller and an anilox roller takes
the place of the coating forme roller. This method enables a defined coating film thickness to be applied over the
entire width of the sheet. Changeover from the two-roller system to the chambered doctor blade system can be
done by the operator The coating film thickness can be varied by using anilox rollers with different
specifications.
The user should place a gantry over the unit to simplify roller changing (this minimizes the risk of injury and
damage).
The chambered doctor blade
The chambered doctor blade consists of an enclosed aluminium chamber with two doctor blades, one of which is
set to the anilox roller in its direction of rotation, the other in the counter direction. The chamber is fixed in a bearing
to ensure the correct position of the system. A pneumatic device maintains a constant pressure between the
chamber and the anilox roller, thus ensuring minimal wear to the doctor blades and gaskets. After a one-time
adjustment to the blades of approx. 0.3 mm, the system automatically regulates the pressing force of the chamber
and equalizes wear to the blades. This ensures tha t the scraping function is always correct and print quality is
consistent. The chamber is effectively sealed at the ends with patented sliding gaskets which keeps the faces of
the anilox roller dry.
The anilox roller
The anilox roller is made of steel and clad with ceramic (99% pure chromium oxide). Characteristics of this surface
are extreme hardness and very low porosity, which prevents corrosion between the steel core and the chromium
oxide layer when working with water-based coatings. The cells are engraved by a computer-controlled laser device
and the chromium oxide layer is applied by a vaporising process. Then the anilox roller is finely polished. A very
precise measuring process then determines the exact carrying capacity of the roller.
The anilox roller supplied as standard has a carrying capacity of 9 cm3/m2 with 200 lines/inch.
The amount of coating on the sheet amounts to approx. 4½ cm3/m2 (halved by splitting on the coating forme
cylinder). This specification has proven to be very practical for most purposes.
A wide variety of anilox roller specifications are available (for thin to very thick coating layers) and the most suitable
specifications for each individual user should be determined in consultation with MRO.


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17 Components of the chambered doctor blade:
The entire chambered doctor blade is manufactured by a sub-supplier.

It consists of the following components:
- A chamber with an integrated setting mechanism for closing and emptying the chamber.
- Two grips to fasten it in the mounting.
- Lateral outlets left and right for excess coating on the blade edge (negative blade).
- Lateral outlets left and right for overflow from the chamber.
- Doctor blades (positive and negative blades).
1
2
4 1 Chamber fastening
2 Chamber outlet lock
3 Positive blade
4 Negative blade
5 Coating outlet
6 Coating overflow chamber
6
R7k15_14


15
18 Chambered doctor blade magnetic switch:
To guard against damage, the chamber is provided with a magnetic switch.

This sends a message to the control console when the chamber is not fitted. All press functions are blocked. When
fitting the chamber into its mountings, care must be taken that it is pushed in in one movement.
Any positional adjustments result in the following error message at the control console:
“Components fitted do not conform”. ?
This error message disappears when the chamber is raised again approx. 15 mm and put back in working position.
Production is not possible without the chamber fitted, even when the coating module is not preselected.
1 Magnetic switch (receiver) on

the chamber
2 Magnetic switch (transmitter) on

the chamber
1 Suspension
2 Chambered doctor blade
3 Anilox roller
2
R7k15_15
r7bild111.ai


15
19 Anilox roller:
The anilox roller surface has a ceramic coating in which little ‘cells’ are engraved with the aid of a laser.
The amount of coating transferred from these ‘cells’ to the substrate is referred to as the carrying capacity.
Every anilox roller is provided with a certificate that indicates its carrying capacity.
Range of anilox rollers available:
• 13 cm3/m2 carrying capacity (Urmi), 80 lines/cm (standard)
• 9 cm3/m2 carrying capacity (Urmi), 80 lines/cm (option)
• 6.5 cm3/m2 carrying capacity, 130 lines/cm, special specification for gold coating (option for the double
coating module )
Important note: The amount of coating transferred to the substrate is always 50% less than the carrying
capacity of the anilox roller!
When changing the anilox roller, take great care to protect the surface. The surface can easily
be damaged and then the roller can no longer be used.
2 3
R7Bild114.ai
R7k15_16


15
20 Chambered doctor blade settings:
Basic setting in the press
1. Setting the chamber to the anilox roller.
Release the compressed air and press the chamber parallel and in light contact to the anilox roller with a strip of
card approx. 0.3 mm thick (visiting card) in between.
Check with a strip of card approx. 0.3 mm thick (visiting card) that the upper blade is in even contact across the
width.
The negative blade should generally be set tighter than the positive blade.
This tighter setting of the lower blade is done by turning the screws of the sliding block. The piston rod must be
altered accordingly.
In the area where the chamber is laterally sealed, the blade edge is arched to the anilox roller!
After the doctor blade is set, check that it can be removed with the chamber set off. The lower blade must not
collide with the anilox roller.
To alter the upper blade: turn to

the right = more pressure
To alter the lower blade: turn to

the right = more pressure
R7Bild113.ai
R7k15_17
2


15
21 Anilox roller design:
The ceramic-clad anilox roller is manufactured to a true-running tolerance of 0.01 mm and a cylindrical form
tolerance of 0.02 mm.
The carrying capacity i.e. depth of the cells and the screen ruling of the roller used depends on the amount of
coating that the user wishes to apply for any particular job. The anilox roller has a diameter of 182.2 mm and this
diameter lies above the effective pitch circle of the drive gear.
This enlarged diameter means that the anilox roller lags 0.5% relative to the forme cylinder.
This lag relative to the forme cylinder is necessary to prevent the gear teeth of the drive gears switching flanks in
the event of a load change caused by the forme cylinder.
Pendulum ball bearings with lifetime lubrication and beveled bores are used as revolving bearings and to
compensate for alignment or operational errors from A to B side.
The tapered seating enables the bearing play to be eliminated with the aid of thrust washers and screw M10.
When doing this, the pendulum ball bearing should be tightened so firmly that the outer ring can be set hard
against the roller body axially but runs easily in the radial direction (revolving direction).
6
2
1
5
7
R7k15_18
1+6 Pendulum ball bearing

2 Transport face
3+7 Thrust washer
4 Ceramic coating
5 Seat of the bearing


15
22 Coating infeed and extraction:
With the two-roller version, the coating is fed to the metering and coating forme roller by a coating pump (double
membrane) via infeed lines and a distributor pipe. There is a scraper blade on both A and B sides that scrapes of
excess coating which is then sucked back into the tank (pump).
With the chambered doctor blade version, the coating is pumped into the middle of the chambered doctor blade
and spreads bubble-free. In the chambered doctor blade, on both A and B sides, there are suction holes through
which the excess coating is sucked back into the tank.
The coating cannot be metered by the chambered doctor blade version.
Attention: The anilox roller is ceramic-clad and can easily be damaged!
R7k15_19


15
23 Setting the forme cylinder to the impression cylinder:
Set the forme cylinder parallel to the impression cylinder with 0.35 mm between the bearers. Set the setting
indicator to zero.
0.0748"
1,9
1
2
1. Blanket
2. Underpacking sheets
3
3. Total thickness 2,6 mm
5 4. Bearer
5. Bearer
6. Bearer
7. Forme cylinder
0,35
8. Impression cylinder
9. Bearer
6
7
11.8110"
11.6063"
Ø294,8
Ø300
0.0138"
0,35
23.6220"
23.5945"
Ø600
599,3
8
Ø
R7k15_20


15
24 Lateral and circumferential register at the forme cylinder (same as with the plate cylinder in the
printing unit)
R7k15_21


15
25 Interdeck drying with double coating modules:
2
1 3
R7k15_22
For process-technical reasons, double coating modules must be equipped with interdeck drying otherwise the
actual benefits of two combined coating applications cannot be realized.
The MAN Roland IR/hot air interdeck dryer is integrated in the transfer module. A height adjustment of max. 170
mm permits the interdeck dryer to be matched to sheet travel. There is a window in the dryer housing through
which sheet travel can be observed. With rigid substrates, whether coating or not coating, the air from the slot jets
of the interdeck dryer is used to guide the sheet.
Dryer equipment:
2 x 2 IR lamps
7 slot jets
Vertical setting distance 170 mm
4
5 6
Impression cylinder
R7k15_23
The drying system includes 7 hot-air jet slots and 2 x 2 short-wave IR lamps that are mounted across sheet travel
direction.


15
26 Coating module specifications:
Sheet
Sheet size max. 740 x 1040 mm

Image area max. 730 x 1020 mm (standard)
Image area max. 730 1040 mm (option*)
Sheet edge to start of print max. 12 mm
min. 10 mm
Blanket (not rimmed)
Blanket size 840 x 1050 mm
Coating plate
Coating plate size 840 x 1045 mm
Underpacking sheets
Size: 770 x 1045 mm

The top underpacking sheet should be 10 mm longer
Forme cylinder
Hard-chromed. Undercut 2.6 mm
Stock thickness adjustment -0.1 to +0.1 mm, motorized
Precoating: Number of sheets before “impression ON” selectable between 1 and 9

Decoating: Number of sheets before “impression OFF” selectable between 1 and 9
Remote register adjustment
Circumferential register max. ± 1 mm, motorized

Lateral register max. ± 2 mm, motorized
Cocking register max. ± 0.2 mm, motorized
*When ordering this option for a coating module with chambered doctor blade equipment, a special anilox
roller (to match the extra width) must also be ordered.


Coating Module: Service Training Mechanik

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Coating Module: Service Training Mechanik

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Service Training Mechanik  

1 Coating module: ........................................................................................3

2 Design of the chambered doctor blade application unit: ........................4

4 Softkey assignment B side .......................................................................5

4 Operating panel at the coating module: ...................................................6

5 Coating module designation:....................................................................7

6 Roller diagram: ..........................................................................................8

7 Two-roller application system:..................................................................9

8 Metering roller adjustment:.....................................................................10

9 Instructions for metering roller adjustment: ..........................................11

11 Construction and mounting of the metering and coating rollers:.........13

12 Metering and coating application roller drive: .......................................14

13 Metering and coating application roller transmission: ..........................15

14 Impression setting diagram: ...................................................................16

15 Chambered doctor blade:........................................................................17

16 The chambered doctor blade/anilox roller coating application method:18

17 Components of the chambered doctor blade:........................................19

18 Chambered doctor blade magnetic switch:............................................20

19 Anilox roller: ............................................................................................21

20 Chambered doctor blade settings: .........................................................22

21 Anilox roller design: ................................................................................23

22 Coating infeed and extraction:................................................................24

23 Setting the forme cylinder to the impression cylinder: .........................25

24 Lateral and circumferential register at the forme cylinder ....................26

25 Interdeck drying with double coating modules:.....................................27

26 Coating module specifications: ..............................................................28

Data Base Documentation 1

2 Data Base Documentation

Data Base Documentation 3

2 Design of the chambered doctor blade application unit:

Design of the two-roller application unit:

4 Data Base Documentation

3 Softkey assignment B side

Data Base Documentation 5

4 Operating panel at the coating module:

2. Impression OFF, feeder off.

5. Nominal value minus.

6. Nominal value plus.

8. Coating pump ON/OFF (inflow and outflow pumps).

12. Positioning backwards (deselect makeready mode).

16. Crawl speed.

17. Inch backwards

18. Inch forwards.

19. Emergency stop.

20. Stop (security).

6 Data Base Documentation

5 Coating module designation:

Coating module = L Transfer module = T

Standard equipment of the new coating module:

- Roller system (1)

Data Base Documentation 7

1 Forme cylinder ∅ 300 mm

8 Data Base Documentation

7 Two-roller application system:

- Coating is fed from above via an optimized feed pipe.

RO = roller operation and

Data Base Documentation 9

8 Metering roller adjustment:

The purpose of the adjustment process is to define the working range.

Adjustment range of the eccentric bearing for the metering roller in mm

1 Metering roller rest position or overnight position

10 Data Base Documentation

9 Instructions for metering roller adjustment:

Service Training Mechanik