UV Flexo - Printing Unit - BG03
UV Flexo - Printing Unit - BG03
UV Flexo - Printing Unit - BG03
Contents
* = When using Easy Change see the operating instructions „Easy Change BG 03“
arsoma
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Contents
* = When using Easy Change see the operating instructions „Easy Change BG 03“
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Description
In the UV printing unit, ink is applied to the All arsoma machines have a uniform drive and
web by means of a flexible printing plate, frame arrangement which enables various
referred to below as the "plate". printing processes to be combined on the
machine. UV flexo printing units can be
The plate is secured to the printing cylinder by inserted at various positions in the machine.
means of double sided foam rubber adhesive Each UV flexo printing unit can be drawn from
foil. The printing cylinder with its stuck-on the machine base towards the operating side,
printing plate is inserted into the printing unit enabling a quick change of printing process
from above and located as near to the and quick access to the UV flexo printing unit
impression cylinder as necessary to ensure for maintenance work. For this purpose,
that during printing, the ink is transferred from insertion erection trolley BG 22 should be
the plate to the web, evenly and without used.
squeezing.
In order to achieve precise inking of the plate, The UV flexo printing unit allows the use of all
an anilox roller is incorporated in the printing common inks encountered in flexo printing
unit. This determines the amount of ink to be (water-soluble ink, UV hardening ink). The
transferred. web path downstream from the UV flexo
The ink is transferred from the ink tray to the printing unit depends on the ink used. UV
anilox roller via an ink roller. In order to inks require a UV drying operation.
ensure that this provides a precisely defined
amount of ink to the plate, a pneumatically
controlled doctor is located in the printing unit
which wipes off superfluous ink from the
anilox roller.
To prevent the ink (water-soluble ink) from
drying on the anilox roller, the anilox roller and
ink roller are separately driven during
stoppages.
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1. Safety
Please observe the general safety instructions
at the beginning of this manual.
Caution:
Risk of explosion!
Water-soluble inks must never be dried by UV Caution:
drying. Risk of injury through the doctor.
The doctor is razor-sharp! Always wear
Caution: protective gloves when carrying out any work,
When changing printing units, only the e.g. cleaning or replacing the doctor.
transport equipment which has been specified
for this purpose may be used. The
instructions for changing the printing unit in
accordance with regulations must be
followed.
Caution:
When changing the printing unit, work
carefully and secure it against dropping down.
Caution:
When carrying out cleaning, there is a danger
of cleaning cloths or hands being drawn into
turning rollers.
Caution:
There is risk of injury when changing the
anilox roller.
Because of the heavy weight of the anilox
roller, fitting or removing it must be done
carefully.
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2. Technical Data
Optional items:
• incorporation of register control BG 27 • double gearing of impression cylinder, (e.g. DIN
• incorporation of nip roller BG 23 (09^ 23 S28) A4 format)
• incorporation of chamber doctor system • incorporation of an ink roller with special coating
• use of negative doctor with manual engagement
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2. Technical Data
The UV flexo printing unit must be supplied The blue hose without plug-in nipple (6 mm
with cleaned and oiled compressed air at 6 dia.) is connected to distribution network e
bar. (continuous air supply) and provides the
pneumatically engaged doctor continouosly
Three compressed air hoses join the with compressed.
connections at the UV flexo printing unit to
the connections at base frame BG 10. After the pneumatic connections have been
made, tumbler switch 79 must be set to the
The black hose with plug-in nipple (6 mm dia.) position "plate cylinder DOWN", by pushing
is connected to distribution network c the tumbler switch down. If this switch is not
(continuous air supply in run mode) and carried out, the pneumatic cylinders will not
provides the pneumatic cylinder with generate any engaging force during running
compressed air for engaging the plate roller. mode or inching mode. This can lead to
In run mode, the function "engage plate roller" possible incorrect operation of the UV flexo
is in operation. printing unit.
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2. Technical Data
2.1.2 Electrical connections
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3. Operation
The ready-to-print plate cylinder consist of the The following parts are delivered with the UV
following parts: flexo printing unit:
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3. Operation
The following parts are not part of the items
supplied with the UV flexo printing unit as these
parts depend on the format length (printing
length).
When ordering parts which depend on the format The calculation for the diameter of the plate
length, the format length must always be given. cylinder is based on the the following
All relevant dimensions can then be calculated assumptions: standard printing plate (printing
from this. plate thickness = 1.7 mm), standard adhesive foil
(adhesive foil thickness = 0.38 mm) and a
compression of 0.05 mm.
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3. Operation
Sample calculation:
outside diameter of plate cylinder da:
format length LF = 12" = 304,8 mm
z x 3.175
da = -2xH=
no. of teeth on gearwheel z = π
z = 96 teeth da = 92.96 mm
normal height:
H=a+s-p=
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3. Operation
3.1.1.1 Determination of printing length
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3. Operation
Table 3
9 228.592 72 68.706
9 1/8 231.767 73 69.716
9¼ 234.942 74 70.727
9 3/8 238.117 75 71.738
9½ 241.292 76 72.748
9 5/8 244.467 77 73.759
9 3/4 247.642 78 74.769
9 7/8 250.817 79 75.780
10 253.991 80 76.791
10 1/8 257.166 81 77.801
10 1/4 260.341 82 78.812
10 3/8 263.516 83 79.823
10 1/2 266.691 84 80.833
10 5/8 269.866 85 81.844
10 3/4 273.041 86 82.855
10 7/8 276.216 87 83.865
11 279.391 88 84.876
11 1/8 282.566 89 85.886
11 1/4 285.740 90 86.897
11 3/8 288.915 91 87.908
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3. Operation
11 ½ 292.090 92 88.918
11 5/8 295.265 93 89.929
11 ¾ 298.440 94 90.940
11 7/8 301.615 95 91.950
12 304.790 96 92.961
12 1/8 307.965 97 93.971
12 ¼ 311.140 98 94.982
12 3/8 314.314 99 95.993
12 ½ 317.489 100 97.003
12 5/8 320.664 101 98.014
12 ¾ 323.839 102 99.025
12 7/8 327.014 103 100.035
13 330.189 104 101.046
13 1/8 333.364 105 102.057
13 ¼ 336.539 106 103.067
13 3/8 339.714 107 104.078
13 ½ 342.889 108 105.088
13 5/8 346.063 109 106.099
13 ¾ 349.238 110 107.110
13 7/8 352.413 111 108.120
14 355.588 112 109.131
14 1/8 358.763 113 110.142
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3. Operation
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3. Operation
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3. Operation
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3. Operation
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3. Operation
3.1.2 Anilox roller
Apart from the plate cylinder and the doctor, The assembled anilox roller in arsoma UV
the anilox roller is one of the most important flexo printing units consists of the following
components of the UV flexo printing unit. parts:
The anilox roller determines the inking of the
web and because of this, the anilox roller 30 coupling hub 094 03 366
must be treated with utmost care. 31 ball bearing LAG-R 025
32 compensating bush
Various parameters must be taken into ATS 094 03 482
account when selecting the anilox roller, some 33 anilox roller 094 03 419
of which are listed below: [EM 410]
093 03 419
• anilox angle (in degrees) [EM 260]
• screen (lines/cm) 092 03 419
• scoop volume (cm³/m²) [EM 510]
• finish of the anilox roller 091 03 419
• screen of plate [EM 340]
34 compensating bush
Because of the large number of parameters, BDS 094 03 483
we cannot make a recommendation for 35 ball bearing LAG-R 025
selection of an anilox roller at this point. We
recommend that you consult your anilox roller When assembling the anilox roller, the
manufacturer about your particular location of the compensating bushes
application. ATS/BDS must be taken into account.
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3. Operation
3. Operation
3.1.3 Ink roller Note:
When fitting the ink roller into the UV flexo
The ink roller transfers ink from the ink tray to printing unit, care must be taken to ensure
the anilox roller. In order to ensure proper ink that the ink roller and anilox roller run in line
transfer from the ink roller to the anilox roller, with one another.
the ink roller should be checked for damage
periodically. Note:
Use of anti-foaming agents (mainly with UV
To prevent damage, the ink roller must not be inks) can lead to swelling up of the ink roller.
in contact with the anilox roller during dry
running (operating without ink).
Note:
Clamping ring 45 and set screw 46 are part of
ball bearing 42.
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3. Operation
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3. Operation
3.1.5 Ink box
The ink box for the UV flexo printing unit
The ink box stores the ink required for consists of the following parts:
printing. The box can be filled in two ways:
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3. Operation
3.1.6 Doctor
The doctor device serves to provide uniform 61 pressure plate 094 30 033
inking from the anilox roller to the plate
cylinder. The doctor blade removes excessive 3.1.7 Printing plate
ink from the anilox roller so that the anilox
cells of the anilox roller are "full to the brim". The printing plate is very important in the
To prevent the doctor from lifting off the flexographic process because on the one hand
anilox roller as a result of the scraped off ink, it must accomodate the height and
the doctor is set at a negative angle. concentricity variations which occur and on
In UV flexo printing units, thin section doctors the other hand it must ensure that the printed
are used. When fitting the doctor, the correct impression is sharply defined.
position of the chamfer must be observed. Printing plates used in UV flexo printing units
The basic equipment of the UV flexo printing should have a plate thickness of 1.7 mm.
unit includes a pneumatically operated doctor Together with the PE foam adhesive foil and
device. The engagement pressure can be under the necessary compression this results
adjusted to suit the requirements. in a standard height of 2.03 mm for the
The doctor for the UV flexo printing unit printing plate and foam adhesive foil. The
consists of the following parts: outside diameter of the plate cylinder is
calculated on the basis of this standard
56 thin section doctor blade (ceramic height.
coating): MEY-D 013 [EM 260] If thin plates with a plate thickness of 1.14
MEY-D 014 [EM 410]
mm or 0.76 mm are used, the difference in
MEY-D 015 [EM 510]
MEY-D 018 [EM 340] height must be accomodated by a thicker PE
59 doctor shaft 094 30 032 [EM 410] foam adhesive foil with a standard plate roller.
093 30 032 [EM 260] When ordering a plate cylinder, the printing
092 30 032 [EM 510] plate thickness and PE adhesive foil thickness
091 30 004 [EM 340] must always be given. This ensures that you
60 doctor clamps 094 30 005 [EM 410] get the correct outside diameter and thus the
093 30 005 [EM 260] desired printing length for your plate cylinder.
092 30 005 [EM 510]
091 30 005 [EM 340]
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3. Operation
The PE foam adhesive foil effects the In UV flexo printing units water-based,
connection between plate cylinder and plate. solvent-based and UV hardening printing inks
In addition, the PE foam adhesive foil must can be used. The decision on the type of ink
take part of the engagement pressure depends on the specific application.
between plate cylinder and impression
cylinder, otherwise the plate would be unduly Caution:
heavily loaded. Water-based inks must not be dried by means
Thus, the function of the PE foam adhesive of a UV drying unit. Risk of explosion!
foil, simply expressed, is as follows:
Caution:
1. Establish connection between plate and UV hardening printing inks must not be dried
plate cylinder by means of hot air or warm air drying units
2. Compensate for concentricity and height BG 14!
variations Risk of contamination.
UV hardening inks require UV radiation in
The thickness of the PE foam adhesive foil order to be hardened.
should be 0.38 mm as standard.
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3. Operation
3.2 Operating elements
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3. Operation
79 tumbler switch "printing cylinder
51 key UP/DOWN"
52 scraper 80 phase shifter gearbox
53 allen screw for securing ink box 81 drive chain
54 ink supply hose 82
55 silicon hose with funnel 83 anilox roller motor
56 doctor blade 84
57 doctor blade clamping screw 85
58 support plate 86 connecting shaft
59 doctor shaft 87 Scotch yoke
60 doctor clamp 88 spigot with thrust washer
61 pressure plate 89 clutch disk
62 mounting angle 90 bevel gear drive
63 spigot 91 register motor
64 cylinder bearer 92 drive chainwheel
65 spring thrust bearing 93 bearer plate
66 plate cylinder 94 clamping lug
67 plate cylinder shaft 95 spring box
68 thrust bearing
69 gearwheel
70 register ring (register control)
71 register ring (register presetting) Note:
(optional item) When using Easy Change BG 03 several of
72 key the following parts will be omitted.
73 plate cylinder mounting plate
74 stop pin
75 transport pin
76 cross piece
77 marking hole
78 switch "anilox roller motor ON/OFF"
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3. Operation
3.3 Setting up
We recommend using our insertion erection • Slide UV flexo printing unit from indertion
trolley BG 22 to install the UV flexo printing erection trolley BG 22 onto base frame BG
unit by sliding it onto the desired base frame 10.
BG 10. • Push insertion trolley BG 22 out of the
When installing the UV flexo printing unit on way.
base frame BG 10, proceed as follows:
Caution:
• Make sure that there is no web present in Risk of damaging UV flexo printing unit and
base frame BG 10. base frame BG 10. Make sure that UV flexo
• Align the guide rails of insertion trolley BG printing unit is seated firmly on the base
22 accurately with the guide rails of base frame and cannot tip over.
frame BG 10 (location and height)
• Push the UV flexo printing unit further onto
Note: the base frame until you notice a marked
To facilitate sliding the UV flexo printing resistance.
unit onto base frame BG 10, the green • Turn the counterpressure cylinder (23)
slides and guide rails 6 should be lighly manually so that the mechanical coupling
greased. will catch correctly.
Caution:
Risk of damaging pneumatic and electrical
connections. Make sure that these are not
nipped.
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3. Operation
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
3.3.2 Fitting and removing anilox roller • Fold anilox roller locks 36 upwards.
• Push the fasteners down and tighten the
3.3.2.1 Fitting the anilox roller
retention screws with an allen key.
Caution:
Risk of injury to hands through their being 3.3.2.2 Removing the anilox roller
drawn in between rollers.
Please refer to item 3.3.2.1, Fitting the anilox
Before lifting the anilox roller into the UV flexo roller. Removing the anilox roller is done in
printing unit you should check whether the the reverse order.
anilox roller is fully prepared for fitting. The
anilox roller must be prepared in the following
way: Caution:
Risk of damaging the anilox roller.
When fitting the anilox roller, please proceed Because of the liability of damage to the
as follows: surface of the anilox roller and its heavy
weight, the removal operation must be carried
• Loosen the two retention screws with an
out with great care.
allen key and push fasteners 37 upwards.
• Fold anilox roller locks 36 down.
• Lift anilox roller 11 into the UV flexo
printing unit.
Note:
Bearings 31/35 must line up with anilox
roller locks 36.
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
Note:
Before removing ink roller 10 you should first
wipe off excess ink from this. Use a soft
cloth and the cleaning solvent specified in
item 4 "Maintenance".
Caution:
Risk of the cleaning material and hands being
drawn in between rollers.
Caution:
Risk of contaminating the UV flexo printing
unit and base frame BG 10.
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
3.3.4.1 Fitting the ink box The ink tray can now be filled with ink.
When inserting ink box 9 in the UV flexo • After filling with ink, scrapers 52 must be
printing unit, please proceed in the following inserted.
order:
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3. Operation
3.3.4.1.1 Mounting of scrapers 3.3.4.2 Removing the ink box
Scrapers (52) are to be mounted on both Removal of the ink box is carried out in the
sides of the tipping and screen rollers to reverse order.
prevent contamination by ink.
Important!
The scrapers may only be mounted when
there is ink in the ink duct because otherwise
they will overheat!
Remove the scrapers as soon as the printing
unit has been switched off.
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3. Operation
3.3.5 Fitting and removing the doctor device
• Secure doctor 12 in its working position
When fitting doctor device 12 or when with fixing screws "doctor".
replacing the doctor blade, attention must be
paid to the position of the chamfer relative to • Set doctor 12 to anilox roller 11 by
the anilox roller. operating tumbler switch 18.
Caution: Caution:
Risk of cutting injury through the doctor. The doctor should only be engaged during
Doctor blade 56 is razor sharp! continuous running of the anilox roller with
During all operations such as cleaning or ink.
changing doctor 12 or doctor blade 56,
protective gloves must be worn. In case of • Adjust the engagement force at pressure
injury, a (medical) doctor should be consulted regulator 26.
immediately.
Note:
3.3.5.1 Fitting the doctor To keep wear on the doctor to a minimum
it should be as lightly set as possible
When fitting doctor device 12, please proceed consistent with a good doctoring result.
in the following order:
Caution:
Risk of cutting injury from the doctor blade.
Doctor blade 56 is razor sharp!
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3. Operation
Caution: Note:
Risk of damging the plate cylinder shaft. Pay attention to the attitude of thrust
Use a vice with soft jaws. bearing 65. The relieved side must point to
the plate cylinder.
• Place a cylinder bearer 64 on preassembled
plate cylinder shaft 67. Note:
The spring thrust bearing must be greased
Note: with bearing grease before fitting.
Pay attention to the location of stop pins
74. These must point to the outside. • Slide the preassembled plate cylinder 66
onto plate cylinder shaft 67.
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3. Operation
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3. Operation
Caution:
• Lay preassembled plate cylinder 22 on the Danger of damaging the gearwheels!
support of lifting device 39. • During lowering of lifting device 39, the
plate cylinder must be lightly turned
Caution: backwards and forwards to enable the
Risk of damaging the gearwheel. gearwheels to mesh properly.
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3. Operation
3.3.7 Fitting and removing mesh guard
If the mesh guard is opened, the printing • Hook mesh guard 38 with the forks on
machine can only be run in inching mode. either side onto the pivot shaft of lifting
This protection device is fitted for your safety device 39.
and must therefore not be removed.
You can now close the mesh guard.
3.3.7.1 Fitting the mesh guard
3.3.7.2 Removing the mesh guard
When fitting mesh guard 38 into the UV flexo
printing unit, please proceed in the following When removing mesh guard 38, please
order: proceed in the following order:
• Turn mesh guard 38 through about 100° • Open mesh guard 38 completely.
as if you were going to open it. • Push mesh guard to the drive side from the
• Push mesh guard 38 from the drive side spigot of the pivot shaft of lifting device
onto the spigots at the pivot shaft of lifting 39.
device 39. • Lift mesh guard 38 from the pivot shaft
and lay it on one side.
Note:
The hole on the drive side of mesh guard Note:
38 must be located on the spigot of the The printing machine can onyl be started in
pivot shaft. run mode when the mesh guard is fitted
and closed.
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3. Operation
3.3.8 Setting the printing axis parallel
In order to achieve the best printing results, When the setting has been carried out, check
the axis of plate cylinder 22 must be parallel it again on the operating side. After this
to the axis of impression cylinder 23 and check has been carried out, the parallel setting
parallel to the axis of anilox roller 11, in both of the axes is complete. A first parallel
the horizontal and vertical planes. setting is carried out at the factory.
A setting bolt 29 is provided which enables
the relative position of the axes to be
established. If this can be entered into the
corresponding setting hole 77 (dia. d = 10
mm) about 40 mm, the "zero position" has
been reached.
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3. Operation
3.4 Inserting web
Caution:
Risk of trapping fingers between ink box 9
and cross piece 76.
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3. Operation
3.5 Starting up
• Remove doctor 12 from the UV flexo • Tighten the fastening screws of doctor
printing unit. mounting angles 62.
• Insert doctor 12 into the UV flexo printing
Caution: unit.
Risk of injury from the doctor. The doctor
is razor-sharp!
Note:
The upper position corresponds to a doctor
angle of approx. 41°.
The lower position corresponds to a doctor
angle of approx. 36°.
The postion of these two angles is
determined by pins.
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3. Operation
3.5.2 Proof printing Note:
The ink roller must not yet be moved up to
When proof printing, please proceed in the anilox roller 11 and the doctor must not be
following order: set against the anilox roller.
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3. Operation
• Fit plate cylinder 22 to UV flexo printing If your printed image is sharp on the operating
unit (see item 3.3.6.2 "Fitting plate side and gets weaker towards the drive side,
cylinder"). a vertical resetting of the printing axis on the
• Now start the printing machine at creep drive side is necessary. This must be done in
speed at the operating panel of drive the following way:
station BG 09 (see operating instruction
"drive station BG 09". • Turn feed screw 2 on the drive side
clockwise until the printed image is sharp
Observe the printing result obtained during on the drive side.
proof printing. If your printed image is sharp
on the drive side and gets weaker towards the Note:
operating side, a vertical resetting of the This adjustment should be done very
printing axis on the operating side is carefully, as often some 1/100 mm is
necessary. This must be done in the enough to achieve the optimum printing
following way: result.
One turn of the feed screw corresponds to
• Turn feed screw 2 on the operating side a feed of 0.1 mm.
clockwise until the printed image is sharp
on the operating side. 3.5.2.1 Setting the ink quantity
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3. Operation
3.5.2.2 Fine adjustment of the print image
The print image should be evenly produced on The following principle applies:
the web with a uniform colour shade. For this
it is necessary that the axis of the plate Feed screw, operating side 2 is used for
cylinder lies parallel to the axis of the settings on the operating side. Turning
impression cylinder. Furthermore there must clockwise reduces the distance between the
be a correct pressing force between plate and axes of the plate cylinder and the impression
web. cylinder. This results in a higher pressing
During proof printing, observe the print image force between plate and web. Turning
over the total web width. If adjustment are anticlockwise enlarges the distance between
made on the operating side, e.g.setting the the axes. This results in a lower pressing
inking, it may be necessary to make an force.
adjusment on the drive side.
Feed screw, drive side 3 is used for settings
Note: on the drive side. Turning clockwise reduces
One turn of the feed screw BDS/ATS (2/3) the distance between the axes of the plate
corresponds to a vertical feed of 0.1 mm. cylinder and the impression cylinder. This
results in a higher pressing force between
plate and web. Turning anticlockwise
enlarges the distance between the axes. This
results in a lower pressing force.
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3. Operation
3.5.2.3 Register setting
This adjustment range can however only be
3.5.2.3.1 Cross register achieved step by step. The maximum step
length is ± 499.95 mm. In this case ± 9999
The cross register is set directly on the UV must be entered on the operating panel of
flexo printing unit. The adjustment is drive unit BG 09 at the appropriate place.
performed on cross register adjusting screw 4. The minimum step length is ± 0.05 mm. In
Turning clockwise causes shifting of the UV this case ± 1 must be entered on the
flexo printing unit towards the drive side and operating panel of drive unit BG 09.
the print image is also shifted towards the The following formula is used to calculate the
drive side. Turning anticlockwise causes value to be entered on the operating panel of
shifting of the UV flexo printing unit towards drive unit BG 09:
the operating side and the print image is also
shifted towards the operating side. X = a x 20
The adjustment range is ± 5 mm. The
adjustment of the cross register can be carried X value to be entered
out both when the machine is stopped and
during running. It is advisable to carry out the a desired longitudinal register
adjustment of the cross register during the adjustment
running operation as the effect on the print
image is then immediately visible. Note:
Note the sign of the value to be entered:
3.5.2.3.2 Longitudinal register
+ longitudinal register adjustment in
The longitudinal register is adjusted from the web run direction
operating panel of drive station BG 09 (see
operating instruction "Drive station BG 09"). - longitudinal register adjustment in
The adjustment range is infinite in both direction opposite to web run direction
directions.
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3. Operation
3.5.3 Production run * Note: When using Easy Change see the
operating instructions
After all necessary adjustments have been „Easy Change BG 03“
made during proof printing and the desired
printing result has been achieved, the machine 3.6 Shutting down
can be run up to the required printing speed.
During a production run the following When the machine stops, plate cylinder 22 is
functions must be monitored by the operator automatically raised. This prevents the plate
of the printing machine: cylinder from getting stuck to the web.
During this lifting operation, the gearwheels of
• Ink level in the ink box, when manual ink plate cylinder 22 and impression cylinder 23
filling is used. remain engaged so that a loss of longitudinal
• Ink level in the ink container in the case of register is avoided.
pump operation.
3.6.1 Shutting down for a short period
Caution:
Risk of damage to ink roller 10. During a short interruption of the printing
Ink roller 10 must never be allowed to run process, no measures need to be taken or
against anilox roller 11 in the dry state. adjustments made to the UV flexo printing
unit.
Caution:
Risk of damage to scraper 52. Examples of short stoppages:
Scraper 52 must never be allowed to run
against ink roller 10 and anilox roller 11 in • splicing on a new web
the dry state. • filling the ink box with ink
• removal of the finished wound roll
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
If water-soluble ink is used for the printing There are no special cleaning operations to be
process, when the stoppage continues for carried out on the UV flexo printing unit
some time this can result in the ink on plate because UV inks harden only under the
cylinder 22 drying off. If this occurs, it is influence of UV radiation. However, you
advisable to remove the dried-on ink from the should take into consideration that UV
plate using a soft rag soaked in solvent. For radiation can be generated by your lamps.
this purpose use a solvent recommended by You should therefore protect all parts which
the ink manufacturer as given in section 4 have been in contact with UV ink, such as ink
"Care and maintenance". box 9, ink roller 10, anilox roller 11, plate
Cleaning dried-on ink off the plate within the cylinder 22 and the printed web which has
UV flexo printing unit may only be carried out not yet been dryed by UV drying unit BG 38
in the inching mode. from the influence of such radiation. If the
UV flexo printing unit is exposed to this
Caution! radiation without protection, the UV ink can
Risk of injury to hands through their being harden and lead to costly cleaning work.
drawn in between rollers. If these measures for protecting the reverse
side printing unit from UV radiation have been
carried out, then at the beginning of a new
3.6.2 Shutting down at end of shift shift and after a short running-in period, the
run operation can be continued.
The steps to be performed at the end of a
shift depend on the ink used.
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
3.6.2.2 Shutting down with water-
based inks Caution
Risk of cutting injury !
If the end of the shift can be anticipated and The doctor blade is razor sharp. Wear
you are printing with a water-based ink, the protective gloves during fitting and cleaning
ink level in ink box 9 should be not be work on the doctor.
increased but reduced as far as possible.
Remember that water-based inks dry out after • Remove ink box 9 from the UV flexo
a short time. For this reason, certain printing unit and clean it with a suitable
maintenance and cleaning work is necessary cleaning fluid or solvent (see item 3.3.4
at the end of a shift so as to avoid damage. "Fitting and removing the ink box" and item
The following work must be carried out: 4.2 "Care".)
• Remove ink roller 10 from the UV flexo
• Switch off the printing machine (see printing unit and clean this with a suitable
operating instruction "Drive station BG cleaning fluid or solvent (see item 3.3.3
09"). "Fitting and removing ink roller" and item
• Dismantle mesh guard 38 (see item 3.3.7 4.2 "Care").
"Fitting and removing mesh guard").
• Remove plate cylinder 22 from the UV • Remove anilox roller 11 from the UV flexo
flexo printing unit and clean it with a printing unit and clean this with a suitable
suitable cleaning fluid ( see item 3.3.6 cleaning fluid or solvent (see item 3.3.2
"Fitting and removing plate cylinder" and "Fitting and removing anilox roller" and
item 4.2 "Care".) item 4.2 "Care").
• Remove doctor 12 from the UV flexo
printing unit and clean it with a suitable After anilox roller 11 has been removed and
cleaning fluid or solvent (see item 3.3.5 cleaned, get rid of any ink contamination
"Fitting and removing doctor" and item 4.2 within the UV flexo printing unit, paying
"Care"). particular attention to impression roller 23.
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3. Operation
Dried out remains of ink which are not If you wish to store ink roller 10 separately,
eliminated can cause damage. When cleaning this must be stored on its spigots. Avoid
the UV flexo printing unit, use suitable storing on the rubber surface because this can
solvents and cleaning fluids (see item 4.2 lead to damage.
"Care").
3.6.4 Shutting down the printing unit
If the same job is to be printed in the next
shift you can prepare the UV flexo printing It is possible to shut down the UV flexo
unit for this straight away. printing unit so that plate roller 22 remains in
the raised position during the run operation.
Please remember that in the dry condition, ink
roller 10 must not be engaged with anilox Shutting down is carried out as follows:
roller 1. Note that the ink box must not yet
be filled with ink as this could dry out before • Operate tumbler switch 79 "printing
beginning of the next shift. cylinder UP/DOWN"
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3. Operation
3.7 Malfunctioning
Fault Cause Remedy
• anilox roller and ink roller • anilox roller motor not • switch on anilox roller at push
do not continue to run switched on switch 78 of base frame BG
when machine stops 10
• free running-device defective • replace free-running device
• motor protection device
defective or incorrectly set
• 4-pin plug not plugged into • plug 4-pin plug into socket
socket
• couplings have been decoupled • engage couplings by turning
lever 17 in direction of drive
side
• ink not cleanly doctored • doctor pressure too low • set doctor pressure higher at
pressure regulator 26
• doctor damaged • replace doctor blade
• no further cross register • end of adjustment range has • carry out a completely new
adjustment available been reached setting of cross register
• no further longitudinal • 9-pin plug not screwed into • screw 9-pin plug X3.6 into
register adjustment socket X3.6 socket
available
• register motor defective • replace register motor
• print image has squashed • pressing force between plate • reduce pressing force by
edges and web too high turning feed screws 2 and 3
anticlockwise
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3. Operation
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Cleaning and maintenance work may only be When cleaning the anilox roller, please
performed by staff who are familiar with the proceed as follows:
machine (see "General safety instructions",
item 1.1.5 "Responsibility of staff" at the • Remove anilox roller 11 from UV flexo
beginning of this manual). printing unit (see item 3.3.2 "Fitting and
removing anilox roller") and lay this down
4.2 Care on a soft surface.
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Caution:
Risk of damaging the anilox roller. Only the
cleaning fluid recommended by ink and anilox
roller manufacturers may be used. Never use
sharp or pointed objects to remove ink
remains.
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• Remove ink roller 10 from UV flexo printing After ink roller 41 has been cleaned it can be
unit (see item 3.3.3 "Fitting and removing prepared for a further application. This is
ink roller"). carried out in the reverse order.
• Remove coupling hub 43 by undoing
clamping screw of the ink roller 10.
Pull self-clamping bearings 40 and 42 off ink
roller 10 and remove the shaft circlip from the
ink roller on the drive side. Clean any
adherent ink remains off the self-clamping
bearings.
Caution:
Risk of damaging the self-clamping bearings.
The lifetime lubricant of the self-clamping
bearings must not be washed out. If
necessary fit new self-clamping bearings.
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Cleaning the ink box should be carried out in If the supply of ink to the ink box is via ink
the following order: pump BG 33, proceed as follows:
• Lift ink box cover 48 from ink box 9 and • Close the overflow openings in ink tray
clean it thoroughly. Use a soft rag soaked stopper 49 with sealing sleeve 50.
in solvent using a solvent or cleaning fluid • Remove ink supply hose 54 and silicon
recommended by the ink manufacturer. hose with funnel 55.
Caution: Caution:
Risk of damaging the ink box cover. Risk of contamination of UV flexo printing unit
Never use sharp or pointed objects for and base frame BG 10.
cleaning the ink box cover. Use a rag to catch the ink drops.
• Remove scraper 52 from UV flexo printing The subsequent steps are identical for the two
unit (see item 3.3.4.2.1 "Removing methods of ink supply to ink box 9.
scraper") and clean off adherent ink
remains.
Caution:
Risk of contaminating the UV flexo printing
unit and base frame BG 10.
Use a rag to catch ink drops.
Caution:
Risk of damaging the scraper!
Never use sharp or pointed objects for
cleaning scraper 52.
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• Remove ink tray 47 from the UV flexo Clean adherent ink remains off doctor 12.
printing unit and clean this of ink. Use Use the cleaning fluid or solvent
cleaning fluid or solvent recommended by recommended by the ink manufacturer.
the ink manufacturer.
Caution:
Caution: Risk of damaging the doctor blade!
Risk of damaging the ink tray, sealing Use a soft rag soaked in solvent for
sleeve and ink tray stopper. cleaning. Never use sharp or pointed
Never use sharp or pointed objects to clean objects for cleaning.
these parts.
Caution:
Risk of injury to the hands!
The doctor is razor sharp. For your own
safety wear safety gloves during fitting and
cleaning.
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4. Instandhaltung
• 4.2.8 Cleaning materials
• Remove ink remains from UV flexo printing
unit. A cleaning fluid or solvent Ink roller 10 must never be cleaned with sharp
recommended by the ink manufacturer or pointed objects. Only a soft rag soaked in
should be used for this. solvent should be used. Only use the
following solvents:
Caution:
Risk of damage. • Cleaning fluids containing ester
Only use a soft cloth soaked in solvent for
cleaning the UV flexo printing unit. • Cleaning fluids containing ketone
It must never be cleaned with sharp or
pointed objects. The following cleaning fluids must not be
used as these damage ink roller 10:
After the UV flexo printing unit has been
cleaned it can be prepared for a further • solvents containing mineral oil
application (see item 3.3 "Setting").
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4.3 Maintenance
• Loosen the four allen fixing screws of
For your own safety, only carry out anilox roller motor 83.
maintenance work when the printing machine
has been switched off. Attach a warning Note:
notice "Attention! Maintenance work" to The fixing screws are situated on the
secure it additionally against unauthorised gearwheel side of the plate.
starting up.
• Push anilox roller motor 83 towards the
inlet side of UV flexo printing unit until
4.3.1 Anilox roller continued running drive chain 81 is adequately tensioned.
• Tighten the two allen fixing screws of
To ensure proper functioning of the continued chain tensioner 82.
running function of the anilox roller, the • Tighten the four allen fixing screws of
following maintenance work must be carried anilox roller motor 83.
out regularly:
Note:
4.3.1.1 Drive chain The anilox roller motor must lie parallel to
the edge of the plate.
Drive chain 81 must be sprayed with adhesive
oil (Hotemp 2000, Klüber company). during • Secure the cover of the anilox roller drive
this maintenance work, the tension of drive with the seven allen fixing screws.
chain 81 should be checked. If the tension is
too low, proceed as follows to restore the After drive chain 81 has been tensioned it
correct tension: should be sprayed with adhesive oil (Hotemp
2000, Klüber company).
• Remove the cover of the anilox roller drive
on the inlet side by loosening the seven
allen fixing screws.
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4. Instandhaltung
4.3.1.2 Driving gearwheels • Remove the cover of the anilox roller drive
(anilox roller continued running) on the inlet side of the UV flexo printing
unit by loosening the seven allen fixing
The gearwheels of the continued running screws.
function must be checked for suffient • Uncouple the anilox roller drive by turning
lubrication every 40 operating hours. Please lever 17 towards the operating side (BDS)
proceed as follows: of the UV flexo printing unit.
• Loosen the clamping screws of spigot 88
• Remove the cover of the anilox roller drive which holds Scotch yoke 87 in clutch disk
on the inlet side of the drive cover by 89.
loosening the seven allen fixing screws. • Remove spigot 88 and Scotch yoke 87
• Lubricate the gearwheels with adhesive oil from clutch plate 89.
(Hotemp 2000, Klüber company) and refit
the cover. Note:
There are two compression springs within
4.3.1.3 Coupling hub the coupling which center the Scotch yoke.
The coupling hub of ink roller 10 and anilox Fitting the Scotch yoke is carried out in the
roller 11 and Scotch yoke 87 of the anilox reverse order.
roller drive must be checked for damage every
40 operating hours. During this check, the
coupling must be greased to avoid excessive
wear.
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The drive gears of the UV flexo printing unit The four centering elements 20 center the
must be cleaned after each job change and plate cylinder within the UV flexo printing unit
sprayed with adhesive oil (Hotemp 2000, with the help of the cylinder bearers and
Klüber company). If the UV flexo printing unit bearer plates. To ensure proper functioning of
is positioned on the printing machine but used centering elements 20, these must be greased
only as a deflection unit and not as a printing at regular intervals. Centering elements 20
unit, the drive gears must be sprayed with must be cleaned after each job change.
adhesive oil (Hotemp 2000, Klüber company)
every 100 operating hours. Centering elements 20 must be greased after
every 100 operating hours. Locking screw 1
To enable the drive gears to be oiled, the should be greased at the same time.
following steps must be carried out:
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