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Marquess Plus

Operators and Engineers Manual


Issue 00 – Jan 2006 Title Page


Marquess Plus

Operators and
Engineers Manual

Crabtree of Gateshead
Kingsway
Team Valley Trading Estate
Gateshead
Tyne & Wear
NE11 0SU
England
Telephone (0) 191 487 5071
Telefax (0) 191 487 3997
E-mail sales@crabpress.co.uk
Title Page Issue 00 – Jan 2006

This manual has been produced in order to provide operators and engineers with
recommended procedures and instructions for the installation, operation, maintaining and
servicing on the MARQUESS PLUS METAL DECORATING PRESS.
Information contained within this manual is sufficient for normal operation, maintenance
and servicing and is correct at the date of publication. It must be appreciated, however,
that it has not been possible to include every setting and adjustment necessary for the
varied classes of stock used within the printing trade. Assistance and advice on any
problem arising from the operation of the Press can always be obtained from Crabtree of
Gateshead Service Department.
The policy of Crabtree of Gateshead is one of continued improvement to their products.
Instructions in this manual as well as machine design and construction may be subject to
changes in keeping with this policy. Crabtree of Gateshead therefore reserve the right to
make any changes without prior notice.

Amendments issued since last publication

Amendment No. Date Text affected

Crabtree of Gateshead 2006

NO COPYING IN ANY FORM WITHOUT WRITTEN PERMISSION FROM CRABTREE OF GATESHEAD


Issue 00 – Jan 2006 Contents

1 Purpose and Planning


Warranty
Health and Safety
Scope Of Use
Capabilities And Performance Data
Physical Dimensions And Weight
Required Utilities
Power Consumption

2 Handling, Installation, Storage and Transit


Responsibilities
Preparation Of Site And Services
Reception And Handling
Installation
Removal Of Preservative Coating
Storage Of Equipment Not To Be Used Immediately

3 Technical Description
Introduction
Press Unit Infeed
Press Unit General
Inking System
Main Drive
Unit 2 Infeed
Unit Synchronisation
Delivery

4 Setting
Make-Ready Procedure
Cylinder Settings
Inking
Feeder Synchronisation
Interdeck Synchronisation

Page 0-1
Contents Issue 00 - Jan 2006

5 Operating Information
Modes Of Operation
Pre-Start Checks
Pre-Start Warning
Start-Up Procedures
Instructions For Normal Running
Emergency Procedures
Shut-Down Procedures
Alarms
Fault Diagnosis And Correction
NOTE General and Register fault diagnosis and correction.
For DAMPER see Section 7.
For PRINT see Section 8.

6 Maintenance
Maintenance Schedule
Cleaning And Inspection Schedule
Recommended Lubricants
Recommended Cleaning Solutions
Maintenance Instructions
Cleaning Instructions

7 Damping System
Technical Description
Setting
Operation
Maintenance, Cleaning And Inspection

8 Guide to printing
Roller System
Ink Transfer And Fount Solution Considerations
Troubleshooting Guide

9 Disposal
Hazardous Waste

Page 0-2
Issue 00 – Jan 2006 Purpose and Planning

Purpose and planning


Warranty 1-2
Health and safety 1-3
General 1-4
Moving Parts 1-4
Hazardous Substances 1-4
Sharp Edges 1-4
UV Radiation 1-5
High Pressure Fluids 1-5
Electrical Shock 1-5
Lifting Equipment 1-5
Scope of use 1-6
Electromagnetic Compatibility 1-6
Electrical Supply 1-6
Ambient Air Temperature 1-7
Humidity 1-7
Altitude 1-7
Capabilities and performance data 1-8
Physical dimensions and weight 1-8
Required utilities 1-8
Power consumption 1-8

Page 1-1
Purpose and Planning Issue 00 – Jan 2006

Warranty
We undertake to repair or replace at our option, parts of our manufacture which, during
the period hereinafter defined, shall be found to be defective due either to faulty
workmanship or use of defective materials. This warranty shall be valid for a period of
12 calendar months from date of arrival of the goods at the Purchaser's premises or 14
calendar months from the date of notified availability for despatch, whichever of these
periods shall be the shorter.
This warranty is strictly subject to the following conditions:
(a) Unless otherwise agreed, installation and demonstration of the goods must have
been carried out by us, or under our supervision.
(b) The goods must have been correctly operated and adequately maintained.
(c) If we consider necessary, we may supply at our labour cost but excluding travel and
living expenses the services of one skilled engineer to assist in or supervise the
alleged defective part or parts but the Purchaser shall provide at his cost all the
necessary equipment and assistance including, but not limited to, labour for
dismantling and re-erection.
(d) Purchaser's materials provided for test purposes are at Purchaser's risk and expense.
(e) We shall accept no liability for damage from corrosive materials, incorrect solvents,
fluids or lubricants, incorrect or faulty power supply, or arising from the ingress of
foreign bodies or materials.
(f) Warranty claims must be made to us in writing within 14 days of the alleged defect
becoming apparent to the Purchaser. A full report on the defect shall be made and,
if required by us, the alleged defective part or parts shall be returned to our works at
the Purchaser's expense.
(g) In the case of goods not of our manufacture we shall pass on the manufacturer's
warranty, and any other indemnities given and shall not be liable for any greater
sum than we can recover under same.
(h) In the event of faulty workmanship on items or materials of Purchaser's supply
(other than for test purposes) our sole liability shall be to rectify same.
(i) Our warranty does not extend to either second hand goods or unless otherwise
agreed, goods manufactured to the purchaser's own drawings or specifications, or to
any equipment provided and fitted by the purchaser.
(j) Our warranty shall not be valid where repairs, modifications or alterations have been
carried out without our written agreement.
Save as mentioned in this clause all warranties conditions and representations where
express or implied by statute trade customer or otherwise and relating to the quality or
nature of the goods their condition or their life or wear or suitability for any particular
purpose of use under any specific conditions are hereby excluded notwithstanding that
the purchaser may have indicated that the goods are being bought for a particular
purpose.
We shall in no circumstances be liable to the Purchaser in contract tort or otherwise for
any direct or consequential damages loss or expense howsoever caused whether to the
Purchaser or to any other person or thing and whether arising directly or indirectly from
the defect and for the avoidance of doubt we shall not be liable for loss of profit, wastage
of goods, loss of press time or production, wastage of labour or any other loss or damage
whether or not of similar nature to the foregoing.

Page 1-2
Issue 00 – Jan 2006 Purpose and Planning

Health and Safety


Before operating this equipment, read the Operators and Engineers Manual and become
familiar with it and the machine. Safe and efficient operation can only be achieved if the
machine is properly operated and maintained. Many accidents are caused by failure to
follow fundamental rules and precautions.
Common causes of accidents include:
 running the machine without the guards in place
 making adjustments while the machine is running
 reaching into the machine to clean, lubricate or adjust without first shutting off
power
 wearing clothes that can become entangled in the moving parts of the machine
 not concentrating when operating the machine
 allowing people to crowd around the machine when operating or maintaining
 poor communication between operators during make-ready
 cleaning moving parts while the machine is running
 wearing rings or watches when operating the machine
 allowing grease and oil to remain on platforms or on the floor around the machine
 failing to read and follow warnings and labels
The following words, found throughout this manual, alert you to potential dangerous
conditions to the operator, service personnel, or the equipment.

DANGER
This word warns of immediate hazards that will
result in severe personal injury or death.

WARNING
This word refers to a hazard or unsafe practice
that could result in severe personal injury or
death.

CAUTION
This word refers to a hazard or unsafe practice
that could result in minor personal injury or
product or property damage.

Page 1-3
Purpose and Planning Issue 00 – Jan 2006

GENERAL
All operations, including transport, installation, commissioning and periodic maintenance
must be carried out by skilled responsible technical personnel. Improper handling can
cause serious personal injury and damage to property.
The specific national, local and installation-specific regulations and requirements shall be
taken into account.
Warning signs affixed to the machine must, on all accounts, be observed and must never
be defaced or removed. Replacements can be obtained by contacting the Service
Department at Crabtree of Gateshead.

MOVING PARTS CAN CAUSE SEVERING, CRUSHING AND ENTANGLEMENT


Do not allow unauthorised or untrained personnel access to the machine.
Do not defeat or circumvent guards and protection devices.
When operating machinery do not wear jewellery, ties, belts or loose clothing. Long hair
must be kept under a hat or hair net.
Regularly check that safety devices and guards are in place and are working correctly.
Check that guards are replaced and secured if they have to be removed for maintenance.
When carrying out make-ready or maintenance ensure that a barrier is provided to
prevent access to exposed hazardous parts of the machine by unauthorised persons. Do
not allow people to ‘crowd’ around the machine and watch.
Communication is vital during make-ready. Ensure that operators can communicate
clearly and effectively when working together.
Test the functional operation of the emergency stop pushbuttons at the start of every
shift.

HAZARDOUS SUBSTANCES CAN CAUSE SKIN AND RESPIRATORY


IRRITATION
Ensure ventilation equipment is working correctly. Periodically check performance
against the design specification.
Containers for inks, varnishes and lacquers should be kept closed when not in use.
Store cleaning solvents in suitable closed containers. The containers should be labelled to
indicate that skin contact should be avoided.
Provide suitable lidded containers for the disposal of contaminated cleaning rags. The
containers should be labelled to indicate that skin contact should be avoided.
Wear impervious gloves and eye protection during operations where there is a risk of
contact with inks and solvents. Contaminated personal protective equipment should be
discarded and disposed after use.
Keep the machine clean and deal with spillages immediately.
Do not wash hands using abrasives or solvents.

SHARP EDGES CAN CAUSE SEVERING AND CUTTING


Wear cut-resistant gloves when handling metal stock.
Do not manually remove sheets moving on the conveyor sections of the machine. Use
the sheet eject/reject stations.

Page 1-4
Issue 00 – Jan 2006 Purpose and Planning

U.V. RADIATION CAN CAUSE DAMAGE TO THE SKIN AND EYES


Regularly check that interlocked and fixed screens are in place and are working correctly.
Ensure that damaged screens and broken filter glasses are replaced.
Do not inspect printed sheets under U.V. lamps.
Wear goggles suitable for protection against U.V. light if the lamps have to be run
without screening during maintenance.

HIGH PRESSURE FLUIDS CAN CAUSE DAMAGE SEVERE PERSONAL


INJURY
Do not tamper with pressure or flow control devices.
Isolate and dissipate pneumatic energy before carrying out servicing or maintenance.
Test the functional operation of the emergency stop dump valve.
Wear impervious gloves and eye protection during operations where there is a risk of
contact with lubricating oils. Contaminated personal protective equipment should be
discarded and disposed after use.

ELECTRICAL SHOCK CAN CAUSE BURNS OR DEATH


Work on electrical equipment must only be carried out by qualified electricians.
Isolate and dissipate electrical energy before carrying out servicing or maintenance. Lock
the isolator to prevent re-energising.
After servicing or maintenance ensure that all connections are permanent and safe and
remove all dirt and moisture from terminal boxes.

LIFTING EQUIPMENT CAN TRAP AND CRUSH


Do not exceed the safe working load.
Do not use stock outside the specified parameters.
Periodically examine all load-bearing parts for signs of wear and fracture.
NOTE
Lifting chains may be subject to differing national legislation regarding periodic
examination.

Page 1-5
Purpose and Planning Issue 00 – Jan 2006

Scope of use

ELECTROMAGNETIC COMPATIBILITY
This machine is intended for use inside a factory in a heavy industrial environment. The
machine, when installed, is not connected to the public mains network but is connected
to an industrial distribution network with a dedicated distribution transformer. Typical
examples of heavy industrial environments where this machine is installed are industrial
printing factories, industrial manufacturing factories and industrial canning and packaging
factories.
The electromagnetic disturbances generated by this machine do not exceed a level that
could prevent other machinery from operating as intended. This machine shall continue
to operate as intended when exposed to electromagnetic disturbances at levels expected
at industrial locations. There may be a temporary loss of function to certain digital
readouts when they are exposed to an electrostatic air discharge of  8kV e.g. Sheet
Counter, Sheets Per Hour Indicator, Damper Indicator and Stock Thickness Indicator.
These components will not be damaged and will return to normal operation by removing
and re-applying the machine power via the main control panel isolator.

ELECTRICAL SUPPLY
The electrical equipment of the machine complies with EN 60204 Safety of machinery –
Electrical equipment of machines. It is designed to operate correctly under full load as
well as no load under the conditions of nominal supply specified below:

Voltage 90 … 110% nominal steady state voltage


Frequency 99 … 101% of nominal frequency continuously
98% … 102% short-time
Harmonics Harmonic distortion not to exceed 10% of the total r.m.s.
nd
voltage between the live conductors for the sum of the 2
through 5th harmonic. An additional 2% max of the total
r.m.s. voltage between the live conductors for the sum of the
6th through 30th harmonic is permissible.
Voltage unbalance Neither the voltage of the negative sequence component nor
the voltage of the zero sequence component shall exceed
2% of the positive sequence component.
Voltage impulses Not to exceed 1.5ms in duration with a rise/fall time between
500ns and 500s and a peak value not more than 200% of
the rated r.m.s. supply voltage.
Voltage interruption Supply interrupted or at zero voltage for not more than 3ms
at any random time in the supply cycle. There shall be more
than 1s between successive interruptions.
Voltage dips Voltage dips shall not exceed 20% of the peak voltage of the
supply for more than one cycle. There shall be more than 1s
between successive dips.

NOTE
Any doubts concerning the specification of the electrical supply should be relayed to the
Service Department at Crabtree of Gateshead.

Page 1-6
Issue 00 – Jan 2006 Purpose and Planning

AMBIENT AIR TEMPERATURE


The machine is capable of operating correctly in an ambient air temperature between
+5 C and +40C. The average ambient air temperature over a period of 24 hours must
not exceed +35C.

HUMIDITY
The machine is capable of operating correctly within a relative humidity range of 30% to
95% (non-condensing).

ALTITUDE
The machine is capable of operating correctly at altitudes up to 1000m above mean sea
level.

Page 1-7
Purpose and Planning Issue 00 – Jan 2006

Capabilities and performance data


Sheet size Max 1143965 mm
Min 711 406 mm
Sheet thickness Max 0.40 mm
Min 0.14 mm
Printing area Max 1137 959 mm
Printing plate W L 1143 1067 mm
Thickness 0.30, 0.40 mm
Underpacking 0.20, 0.10 mm
Front of plate to start of print
Printing blanket W L 1156 1194 mm
Thickness 1.95 mm
Underpacking 0.15 mm
Gripper margin Min 5 mm
Mechanical speed Max 6000 sheets per hour

Physical dimensions and weight


Weight - single 11680 kg
Weight - tandem 22350 kg
Overall length - single 6900 mm
Overall length - tandem 10800 mm
Overall width 3710 mm
Overall height 2280 mm

Required utilities
Compressed air 6 bar
Three phase earth and neutral 230/380 or
400/440 V
For other voltages consult Crabtree of Gateshead.

Power consumption
Compressed air – per unit 30 l/min
Electrical – single with feeder 30 kW
Electrical – tandem with feeder 45 kW
Electrical – tandem with feeder and 56 kW
coater
kW power details are given for guidance only, and will vary with different voltages. In
specific cases consult Crabtree of Gateshead.

Page 1-8
Issue 00 – Jan 2006 Handling, Installation, Storage and Transit

Handling, installation, storage and


transit
Responsibilities 2-2
Customer 2-2
Crabtree Of Gateshead 2-2
Preparation and site services 2-3
Foundation 2-3
Building Alterations 2-3
Services 2-3
Reception and handling 2-4
Installation 2-5
Unpacking 2-5
Removal of preservative coating 2-6
Storage of equipment not to be used immediately 2-7

Page 2-1
Handling, Installation, Storage and Transit Issue 00 – Jan 2006

Responsibilities

CUSTOMER
The customer is responsible for the following:
1 Providing details of their health and safety rules and regulations one calendar month
before the start of the installation
2 Local authority/state approval for the installation.
3 Environmental permits and testing.
4 Insurance for Crabtree of Gateshead Service Engineers during installation and
commissioning.
5 Office facilities for Crabtree of Gateshead Service Engineers, including a telephone
and fax.
6 Access to first aid facilities or medical assistance.
7 Lifting equipment with qualified operators.
8 The collection and disposal of installation rubbish and debris.
9 A dry storage area for the packing cases.
10 Materials required for testing and commissioning.
Crabtree of Gateshead are not responsible for any delays connected with the failure of
the customer to provide the above.

CRABTREE OF GATESHEAD
Crabtree of Gateshead are responsible for:
1 Supplying after sales service and spare parts for the installed equipment for a
minimum period of 10 years. This is from the date of purchase and at the prices
ruling at the time the service or parts are ordered.
2 Providing a detailed list of equipment that is required for the installation.
3 Carrying out the installation in accordance with the customer’s health and safety
rules and regulations, if included in the contract price.
4 Keeping the installation area clean and tidy.

Page 2-2
Issue 00 – Jan 2006 Handling, Installation, Storage and Transit

Preparation of site and services

FOUNDATION
The customer is responsible for the design and design calculations of the foundation.
Necessary information with regard to stresses, forces etc. can be obtained from the
machine installation floor plan or from Crabtree of Gateshead Service Department. The
following considerations should be evaluated in the design stage:
1 There is sufficient stability to withstand possible shock forces due to machine
malfunctions.
2 The foundation should be designed so that vibrations are isolated and prevented
from reaching other parts of the building.
3 Adequate space is provided for inspection, maintenance, pipework, electrical cables
and trunking.
The mounting area of the machine must be level and free from vibrations. For these
reasons a concrete foundation is recommended.
Before the installation can commence the site must be clear, all services must be
available and there must be adequate heating, lighting and ventilation.

BUILDING ALTERATIONS
The customer is responsible for all stackwork and ductwork and any associated
alterations and penetrations to the roof.

SERVICES
The customer is responsible for providing the services at the locations indicated on the
machine installation floor plan.

Page 2-3
Handling, Installation, Storage and Transit Issue 00 – Jan 2006

Reception and handling


At despatch all machines are protected against corrosion and wrapped with a layer of
polythene. A layer of wax paper is placed over the machine to prevent the bubble and
barrier foil from sticking to the metal and painted surfaces. A layer of bubble wrap is
placed over the machine to prevent the foil barrier from busting during transit due to
contact with the sharp edges of the machine.
The machine is placed on a barrier foil groundsheet and bolted to the base of the packing
case. A barrier foil bag is placed over the machine and sealed and evacuated. The sides
of the case are built up around the machine, fastened with nails. Internal packing is
placed inside the case to provide additional stability and to prevent movement during
transit.
The packing cases are marked with the following information:
1 case number
2 net weight
3 gross weight
4 case dimensions
5 international handling symbols
‘keep dry’ ‘fragile’ centre of gravity ‘slinging’

On receipt carefully move the packing cases into the storage area. Use the slinging and
fork truck markings to prevent damage to the packing cases. Cases can be overstored
with care.

CAUTION
Do not store packing cases more than two high.
Always store heavy cases at the bottom.

Page 2-4
Issue 00 – Jan 2006 Handling, Installation, Storage and Transit

Installation
The following checks are recommended before installation:
1 The foundation corresponds to the certified foundation drawing.
2 The erection site is clean.
3 The erection site is prepared for installation, e.g. channels have been provided for
services where necessary.
4 Access has been provided for inspection and maintenance.
Mark the centre line and any datum lines. Working from the packing case identification
list, position the packing cases close to the location where they will be erected.

UNPACKING
Before unpacking, check all numbered packing cases against the consignment list. If
packing cases show signs of external damage open immediately and check the contents.
Report damage immediately to Crabtree of Gateshead Service Department.
The packing cases are nailed together and can be unpacking using a ‘jemmy’ or a nail
remover.

Packing case side Internal packing

Nail remover Foil bag

Prise open the lid with the ‘jemmy’. Remove the lid with care and avoid contact with the
exposed nails. Remove all internal packing. Remove the packing case sides and ends.
Remove or make-safe protruding nails and store the packing cases in a suitable location.
Cut and remove the foil bag. At this stage do not remove the bubble wrap and wax
paper as these provide protection against dust. Unbolt the unit from the packing case
base.
Attach the correct lifting tackle (i.e. lifting blocks, eye bolts) and move the unit to its
installation position. Remove or make-safe protruding nails and store the packing case
base in a suitable location.

Page 2-5
Handling, Installation, Storage and Transit Issue 00 – Jan 2006

Removal of preservative coating

WARNING
Marine pollutant. Disposal of used/contaminated
product must be in accordance with local and
national legislation. Do not empty into drains,
sewers or water courses.

All machines leave the factory of Crabtree of Gateshead with a preservative coating of
Rustilo DWX 33 applied to all exposed metal and ‘blackodised’ surfaces.

Rustillo DWX 33

Rustilo DWX 33 is a high quality soft film solvent deposited preservative that, on
evaporation of the solvent, leaves a powerful preservative film. This soft, greasy
preservative film prevents rust and provides good water displacement for a minimum of
12 months.
Rustilo DWX 33 should be removed using a petroleum solvent such as white spirit (CAS
No 64742-88-7). Metal surfaces coated with the preservative should be rubbed with a
cleaning rag impregnated with white spirit.

Page 2-6
Issue 00 – Jan 2006 Handling, Installation, Storage and Transit

Storage of equipment not to be used immediately

CAUTION
Exposed metal surfaces will rust. Check the
condition of the preservative coating. Wrap
polythene or wax paper around exposed metal
surfaces.

Special attention must be given to machines, assemblies and spare parts that are to be
stored for a long period of time before commissioning or use. In such cases the
machine, assembly or spare part should be stored indoors, in a dry room or building
where the temperature varies as little as possible.

Page 2-7
Handling, Installation, Storage and Transit Issue 00 – Jan 2006

THIS PAGE LEFT BLANK

Page 2-8
Issue 00 – Jan 2006 Technical Description

Technical description
Introduction 3-2

Marquess Plus Metal Decorating Press 3-2
Press Unit Infeed 3-3
Operation 3-3
Sidelay Mounting 3-4
Sprung Sidelay 3-4
Fixed Sidelay 3-5
Infeed Setting 3-6
Press Unit General 3-7
Damping System 3-7
Inking System 3-7
Plate Cylinder 3-7
Blanket Cylinder 3-8
Impression Cylinder 3-8
Gripper assembly 3-9
Stock Thickness Adjustment Mechanism 3-9
Inking System 3-11
Inking System 3-11
Ink Duct 3-12
Inker Wash Up 3-12
Damping System 3-13
See Section 7 For Damper Details
Main drive 3-13
Unit 2 Infeed 3-14
Unit Synchronisation 3-15
Delivery 3-17
Sheet Stripping 3-18
Mechanical sheet strippers 3-18
Gripper release segment 3-19
Air knives 3-20

Page 3-1
Technical Description Issue 00 - Jan 2006

Introduction

MARQUESS PLUS METAL DECORATING PRESS



The Marquess Plus Metal Decorating Press is a sheet fed offset lithographic machine for
printing on tinplate or aluminium. Each printing unit is self contained and modular, and
may be integrated into a printing line consisting of multiple units according to customer
specification.

For the purposes of convenience the manual shall describe a typical tandem machine (2
colour), as this shall encompass all aspects of any printing line.
The terms feedside (FS) and driveside (DS) are used in the text and refer to the
respective sides of the press. The feedside is the side fitted with most of the operating
controls, and is the side from which the printer usually works the press. It is on the left
hand side looking in the direction of sheet travel. The driveside is the side on which the
driver motor and gearboxes are fitted, and is on the right hand side looking in the
direction of sheet travel.
There are a number of non-Crabtree, or proprietary options that may be fitted to the

Marquess Plus press as original equipment. For example, it is possible to have the
standard Crabtree ink duct or a proprietary automatic duct controlled by a remote
computer.
The damping system may be either a Crabtree Delta® [registered trademark] system or
an alternative supplier’s system.
All electrical control functions on the press are executed and monitored by a
Programmable Logic Controller (PLC). As with the above this may be standard Crabtree
or the product of another company.
In situations where non-Crabtree parts are fitted as original equipment, this manual
should be read in conjunction with the supplier manuals for those parts.

Page 3-2
Issue 00 – Jan 2006 Technical Description

Press Unit Infeed


OPERATION
Sheets are fed into the press by an automatic sheet feeder, with the surface to be
printed uppermost.
Unit 1 infeed is designed to receive automatically fed sheets, control their speed and to
position the sheets in preparation for Unit 1 printing. The sheet feeder is mechanically
coupled permanently to Unit 1 main drive, with synchronisation adjustment provided
Unit 2 (and subsequent) infeed is of similar design but is modified to accept sheets fed
from a preceding unit. Sheets will not feed however unless both Unit 1 and Unit 2 are
synchronised, and damping, drying and sheet stacking systems are ready.
Sheets of tinplate or other material are fed to the press conveyor from the feeder. As
they leave the feeder, the sheets are carried on belts, which run a little slower than press
speed. The belts advance each sheet until dogs, travelling a little faster than belt speed,
come into contact with the trailing edge of the sheet, taking over the transport of the
sheet.

Dogs
Pushers

Pusher scale

After the sheet has settled in contact with the dogs, a pair of sprung pushers rises up
behind the sheet. The pusher’s travel faster than the dogs, and the sheet is carried
forward by the pushers so that the trailing edge moves clear of the dogs.
Sidelaying commences shortly after the leading edge passes between the sidelays, and is
complete, with sidelays fully in, just as the pushers begin to build up back pressure (also
called back push), after the leading edge of the sheet contacts the front lays.

Page 3-3
Technical Description Issue 00 - Jan 2006

SIDELAY MOUNTING
The sidelays are mounted on slides that move outwards and inwards to control the
movement of sheets entering the lay area. The drive for this motion is taken from the
unit gear train and controlled and timed by cam action to ensure precise alignment of the
sheets before printing.

The press may be equipped with either single point ‘bobbin’ type sidelays or,
alternatively, the extended sidelays. The extended sidelays must be used for scroll sheet,
but are also suitable for rectangular sheets.

SPRUNG SIDELAY

Bobbin

Spring

The sprung sidelay is fitted with a spring that applies the side laying force to the runner
that touches the sheet. Different springs are supplied so the force applied to the sheet
can be varied. This is required for different sheet thicknesses and for aluminium. Optional
on the Marquess Plus are pneumatic sprung sidelays. The force applied to the sheet is
via an air cylinder and this force can be adjusted on the run.

The positions of the sprung and fixed sidelays are interchangeable. The reference lay is
the fixed lay and the spring lay guides the sheet against it. When printing both sides of a
sheet it will be necessary to change the sidelays over to ensure the reference is always
on the same edge of the sheet.

Page 3-4
Issue 00 – Jan 2006 Technical Description

FIXED SIDELAY

Bobbin

The fixed sidelay is secured to its operating bar by a clamp bolts.



Sidelay adjustment can now been done on the run with the Marquess Plus as can be
seen in the photo below. The main door guard has been removed for clarity.

Position indicator

Adjusting knob

Page 3-5
Technical Description Issue 00 - Jan 2006

INFEED SETTING
The Pushers are adjusted for sheet size by moving to the appropriate place on the
pusher scale – this is shown in photo above. The dogs also need to be adjusted for sheet
size. This is done by adjusting the dog clutch that is situated behind the main guard and
is shown in the photo below.

Dog clutch

Dog adjustment

Sideguides are positioned using handwheels on each side of the infeed frames.

Operator side sideguide


adjustment

Page 3-6
Issue 00 – Jan 2006 Technical Description

Press Unit - General


The Marquess Plus  Metal Decorating Press unit is designed to print a single colour image
on to tinplate with precision at high speed. The unit consists of the following principal
sub-assemblies:

DAMPING SYSTEM
Designed to provide a thin film of low alcohol fountain solution on the printing plate. The
damping system supplies the minimum amount of fountain solution to keep the non-
image areas free of ink. See section 7 of this manual for a more detailed description.

INKING SYSTEM
Designed to provide a controlled flow of ink via a set of rollers from the ink duct to the
printing plate. The control of ink is facilitated by setting keys on the Crabtree Manual ink
duct or the remote inking system and by adjusting the dwell on the oscillating duct roller.

PLATE CYLINDER

Plate cylinder

Clamp bar

Designed to support the printing plate that passes ink to the blanket cylinder. A printing
plate is fitted to this cylinder and tensioned. The plate cylinder is provided with quick
release clamps as an additional option. Circumferential adjustment is provided for image
fit.

Page 3-7
Technical Description Issue 00 - Jan 2006

BLANKET CYLINDER

Tensioning shaft

Adjuster

Blanket cylinder

Designed to transfer the ink pattern on to the surface of the sheet being printed.
Ensures the ink pattern is transferred on to the sheet without indenting the surface being
printed upon. The blanket cylinder trips to the plate cylinder during printing. The plate
and blanket cylinders run on bearers in contact during printing.
The blanket on the blanket cylinder accepts the ink pattern from the printing plate and
transfers it to the sheet. During printing the sheet is compressed between the blanket
cylinder and the impression cylinder to ensure accurate image transfer.
It is not necessary to punch the blankets before fitting to the blanket bars. As an option,
blanket bars may be provided to suit customer’s own quick-release blankets.

IMPRESSION CYLINDER
Designed to hold a sheet in registration and to apply pressure during printing. The
precise and controllable nip to the printed sheet ensures optimum print transfer.
Gripper and front lay mechanisms are fitted to the impression cylinder so that the front
lays are in position above the sheet path ready for the leading edge of the sheet. The
pushers urge the sheet into contact with the front lays until the sheet is gripped just
before top dead centre on the impression cylinder.
The pushers are mechanically sprung and pusher force may be changed by changing the
type of spring.
When the sheet has been accepted and is held by the grippers, the pushers automatically
move away from the trailing edge of the sheet. This then makes clearance for them to
drop down behind the sheet and return to continue the feeding cycle. The sidelays also
move away from the sheet after grip and the dogs drop down behind the sheet and
return to continue the feeding cycle.

Page 3-8
Issue 00 – Jan 2006 Technical Description

Gripper Assembly

Gripper
Front lay

Gripper shaft

The sheet to be printed is held to the impression cylinder with a set of six sprung
grippers. The gripper shaft is operated by a runner lever with cam follower and cam on
the feed side. The pressure of the grip exerted by the grippers is pre-set by using the
tension adjusting screw. Note that the grippers are cam closed spring opened.
To obtain accurate register there are two front lays fitted to the gripper shaft.
The front lays can be adjusted to provide image fit by skewing the sheet relative to the
printing plate.

A positive cam close action is designed to operate the gripper shaft. The grippers are
opened by two compression springs fitted at each end of the cylinder. Each gripper
assembly is keyed and clamped to the gripper shaft.
The grip to the sheet is carefully controlled by a factory set adjustment screw.
Adjustment of this should be done during maintenance tasks as instructed later.

STOCK THICKNESS ADJUSTMENT MECHANISM


The impression cylinder is mounted in an eccentric bush in each side frame. Rotation of
this bushes serves to trip the impression cylinder away from the blanket cylinder and also
to adjust for stock thickness.
Adjustment of the stock thickness is done via a push button on the operator side of the
press unit.
A digital indicator provides a guide for the thickness of sheet being printed.

Page 3-9
Technical Description Issue 00 - Jan 2006

View showing the stock thickness adjustment assembly fitted to the eccentric bush in the
main frame.

Page 3-10
Issue 00 – Jan 2006 Technical Description

Inking System

INKING SYSTEM
The inking system comprises 17 rollers and a drum in total, including duct roller, palette
roller and feed roller. Of these, ten are rubber covered, six are copper covered, the main
drum is copper covered and the duct roller is in a hardened cast iron. As an option, the
duct roller may be ceramic covered if so requested by customer. They are itemised as
follows:

The bridging roller (item 19) is mounted on the damping system and can be moved to
link the inking rollers to the plate damping roller for washing up, or to run ‘integrated’
during printing.
The ink fountain roller (item 1) is run intermittently while the press is in motion. If
required the roller can be made stationary by raising the handle, which rotates the ink
cut off disc to stop the pawl operating the ratchet wheel.
The ink knife adjusting screws are adjusted to allow varying quantities of ink to be fed
along the length of the fountain blade to suit the type of work on the plate.
Four of the copper covered rollers and the coppered ink drum reciprocate to aid the
sideways distribution of ink. One side to side movement of the rollers occurs for each
revolution of the press and the return movement occurs during next press revolution.
Plate inking rollers are individually adjustable to the printing plate and to the two lower
reciprocating rollers on the run. Adjustment of the rollers ensures correct alignment with
the plate and inking rollers.
The change in direction of reciprocating movement occurs in a fixed position relative to
the plate cylinder and the reciprocation is synchronised to the plate cylinder. The
reciprocation movement varies between rollers for best effect in distributing the ink flow.
Page 3-11
Technical Description Issue 00 - Jan 2006

The drive is taken from a gear on the feed side of the plate cylinder and fed through the
frame. All gears on the outside of the frame are efficiently guarded but accessible
The reciprocating mechanism is connected to the ink rollers on the inside of the drive
side frame.
To stop the inking plate rollers falling into the plate cylinder gap, they are preset in house
against dead stops. This prevents any damage being caused to the rollers.

THE INK DUCT


An intermittently rotating duct roller works with a flexible blade, having 35 adjusting
levers, to give the desired ink flow. The ink duct roller is made to specification to resist
scratching. It is driven from the press and any speed overrun controlled with a spring
drag clamp acting against a retaining post.
The overall ink feed rate is controlled by an adjusting lever on the feed side. Overall ink
flow adjustment is achieved by altering the dwell time of the feed roller.
The design of the ink flow control screws allows full ink flow to be set up at one screw
zone while no ink is being fed at the screw zones on each side of it. The 38 adjustment
zones along the length of the ink duct are adjusted to suit the ink distribution required by
a specific sheet print pattern.
The ink control is similar when using the remote inking system equipment except that all
adjustments are remote, accomplished via servomotors on a dedicated PC, operators
interface and screen.

INKER WASH UP
The wash up device is operated by turning the adjusting knobs on each side of the wash
up trough in a clockwise direction to urge the blade unit against the main ink drum.
The trough may be quickly removed for cleaning purposes but removing the split pins at
each end and withdrawing the trough clear of the unit.
When the blade requires attention for renewal, the blade assembly can be removed by

Page 3-12
Issue 00 – Jan 2006 Technical Description

turning the adjusting knobs anti-clockwise until they reach their limiting stop. The
adjusting knobs can then be swung out of the locating block on the blade assembly,
leaving the blade free to be withdrawn.


Optional on the Marquess Plus is a semi-automatic wash up (not shown). The press unit
is supplied with a pneumatically operated wash up blade and spray bar assembly. The
wash up sequence can be pre-set using the plc.

Page 3-13
Technical Description Issue 00 - Jan 2006

Damping System
The Delta damper system is covered in detail in section 7 of this manual.

Main Drive
Each unit of a tandem press is driven by its own AC motor. Synchronisation of the units
is electronic. Where additional equipment forms part of the line, further electronically
synchronised motors may drive each item.

Emergency brake

Main motor

The drive motor is situated below the driveside platform and drives a 4-way gearbox
mounted on the side frame of the press. One of the output shafts is used to drive the
press unit. One of the output shafts is fitted an emergency brake. The remaining shaft
from the gearbox is used to drive the feeder and/or oven. The oven drive rotates 4
revolutions per press impression either ‘top towards frame’ or ‘top away from frame’,
depending on the direction of the oven drive.
Under all normal operating conditions, motor regenerative braking is sufficient to stop the
press within a single revolution from its maximum mechanical design speed of 6,000 sph.
If for any reason the press is not brought to a standstill within this time, the emergency
brake fitted to the drive gearbox is brought into action automatically to assist. In the
event of loss of pneumatic air pressure or complete failure of the electrical supply, the
emergency brake is automatically applied and can stop the press within one revolution
from 6,000 sph independently.
To turn the press for setting, or in an emergency, a hand wheel is fitted to the brake on
the output shaft of the drive gearbox. Access to this handwheel is only possible after the
platform has been removed. The platform is interlocked ensuring that the main drive is
disabled when the platform is removed.
Press units are powered by AC motors. A toothed belt drives from the motor to the drive
gearbox and then this gearbox drives reduction gears inside the main frame. The main
cylinders are driven by this gear train. Inking and damping rollers are driven from the

Page 3-14
Issue 00 – Jan 2006 Technical Description

plate cylinder

Unit 2 Infeed
Unit 2 Infeed is similar to the design of Unit 1 infeed. The major difference is the
addition of a drop down section of conveyor, which is hinged about a shaft. This
movable section of conveyor allows operator access to the back of Unit 1 cylinders.

Drop down

Pneumatic ram

The drop down section of the unit 2 press is pnuematically operated.

Page 3-15
Technical Description Issue 00 - Jan 2006

Unit Synchronisation
With two units in tandem a speed control system is necessary to synchronise the speed
and relative position of both independently driven units.

Encoder

An encoder monitors the position of each unit and a controller in the electrical panel
synchronises both in a constant relative position.
Interdeck synchronisation is adjusted using an advance and retard switch mounted on
the infeed.

Advance/retard switch

Page 3-16
Issue 00 – Jan 2006 Technical Description

Delivery
The delivery is designed to transfer the printed sheet to the next stage in the line. The
delivery has a rack back conveyor section between press units to allow access. It is
driven from the impression cylinder of the proceeding unit.

Sheet strippers

Lubrication unit

Drive gear

Page 3-17
Technical Description Issue 00 - Jan 2006

SHEET STRIPPING

There are two standard features and one optional feature of the Marquess Plus press
that ensure effective sheet stripping from the blanket during printing.

Mechanical sheet strippers

The machine is equipped with a series of mechanical strippers to force the sheet from the
blanket. The stripping wheels can be aligned with margins or other non-image areas.

CAUTION
Care should be taken to ensure the stripper
position does not foul any mechanics associated
with the impression cylinder. Crawl the machine
one full revolution to make sure no clashes occur.

Page 3-18
Issue 00 – Jan 2006 Technical Description

Gripper release

Gripper release
adjusting segment

The gripper cam on the Marquess Plus has an adjusting segment for gripper release –
this can be altered if required to delay the release of the sheet from the impression
cylinder.

Page 3-19
Technical Description Issue 00 - Jan 2006

Air knives (optional)

Air inlet

Nozzle

Air knives, when fitted, improve sheet stripping by directing a downward high volume
blast of air to the sheet as it exits the blanket cylinder nip. This is particularly useful for
aluminium sheet, large solids or UV inks. The air knives are switched ON or OFF at the
main console.

Page 3-20
Issue 00 – Jan 2006 Setting

Setting
Make-ready 4-3
MAKE-READY PROCEDURE 4-4
Sidelay And Pushers 4-4
Timing The Press 4-4
Sideguides 4-6

CYLINDER SETTINGS 4-7


Pressure Settings 4-8
Setting The Blanket Cylinder To Plate Cylinder 4-9
Setting The Blanket Cylinder To Impression Cylinder 4-10
Setting The Impression Cylinder Grippers 4-10
Front Lays 4-11

INKING 4-12
Setting The Plate Inking Rollers 4-12
Distribution Rollers 4-13
Ink Feed Roller 4-14
Checking The Settings Of The Rollers 4-14
Ink Fountain 4-15
Setting The Ink Knife Blade 4-15
Cleaning The Ink Knife Blade 4-15
Wash Up Device 4-16
Inking Rollers Trip 4-17
Palette Roller 4-17
Reciprocating Motion For Drums And Rider Rollers 4-17

FEEDER SYNCHRONISATION 4-18

INTERDECK SYNCHRONISATION 4-19

Page 4-1
Setting Issue 00 – Jan 2006

Make-ready
No tools are necessary to set the infeed for sheet size.
Sheet support slats can be removed quickly for smaller sheet sizes and easily restored for
larger sheet sizes.
Side guides are easily adjusted by a handwheel at each side of the infeed.
Sidelays are adjusted by slackening a lever clamp and sliding them into position and
tightening.

Page 4-2
Issue 00 – Jan 2006 Setting

MAKE-READY PROCEDURE
Sidelay and pushers.
The sidelay spools may be placed in two different positions by exchanging the bolt in
the carrying member. This is only required for small sheet sizes. The sidelay
adjustment is made through the bronze clamping pieces just outside the press
frames, indicating the width of the sheet. Note that there are two sets of numbers,
one for each position of the sidelay roller holding pieces. The top set of numbers
apply for smaller sheet, when the sidelay spools are fastened to the sidelay bar in
the inner position.
The numbers on the side apply for the larger sheets, when the sidelay spools are
fastened to the sidelay bar in the outer position. To make sure that the setting is
correct, measure the distance between the sidelay spool ball bearings. The spring on
the variable sidelay should be selected to suit the sheet size and thickness, springs of
varying capacity are supplied for this purpose.
In the same way the pusher heads must be adjusted to suit the length of the sheet.
The bars that carry these pushers have tapped holes for adjustment purposes, while
the pusher assemblies have slots so the different lengths of metal sheets within
certain limits can be used. Here too, different springs are supplied, select the one
best suited for the sheet thickness.
Springs for sidelays and pushers should be selected strong enough to firmly feed and
register the sheet, but weak enough to prevent distorting the sheet.

Timing the Press

1. Mark lines on a 0.010” (0.25mm) thick sheet 11.3/8” (289mm) and 11.5/8”
(295mm) from its leading edge, and also down the centre line as shown in the
diagram above. Place the sheet on the infeed supports so that the centre line of
the marked sheet is ¼” (6.35mm) off centre towards the fixed sidelay guide and
set the sheet opposite guides to touch the sheet.
This applies to all units.
2. With the cylinders in the printing position, set the test sheet so that the 11.3/8”
(289mm) mark is level with the front edge of the sidelay beam. At this point the
Page 4-3
Setting Issue 00 – Jan 2006

grippers should be just closed on the sheet.


Note the cam runner on the impression cylinder which controls the grippers, will be
just free of the cam. If not then this should be adjusted to suit. Also at this position
the pushers should touch the back edge of the sheet. Prior to this setting both the
impression cylinder front lays should have been adjusted 0.010” (0.3mm) away
from the cylinder body.

3. Turn the press by hand until the pushers are at their highest point and are level
with the correct sheet size on the brass scale. Move the dogs on the conveyor
chain until they are 1/8” (3.125mm) in front of the pushers. Now lock up conveyor
chain clutch.
4. Replace the sheet on the supports and turn the press until the edge of the sheet is
½” (12.7mm) from the trip operating finger.
Check and set runner on the high point of the cam and 0.031” (0.8mm) between
the operating arm and trip finger. The adjustment is made when the 4, 5/8”
locking bolts are removed from the main drive gear and the movement of the
camshaft. Recheck the ½” dimension after tightening up.
5. Turn the press by hand until the 11.5/8” (295mm) line is level with the front edge
of the sidelay beam.
Check the position of the brass sidelay blocks – they should be up to the side
frames on both feedside and offside.
6. Adjust sidelay toggle until 0.012” (0.3mm) feeler enters between the sidelay
runners and the low part of the sidelay cam at the feedside and offside – then lock
up the toggles.
7. Turn the cam until the brass blocks are 0.003” (0.08mm) clear of the side frames,
and then lock up cams at feedside and offside.

Page 4-4
Issue 00 – Jan 2006 Setting

Sideguides

Fixed Sprung
sidelay sidelay

Sheet
2.5 to 2.5 to
3mm 3mm

Pushers
Sideguide Sideguide

1 Ensure the sheet is at the set position, held on the sidelays and frontlays.
2 Turn the adjustment handwheel clockwise to move the sideguides inwards until
there is 2 to 3mm clearance on the fixed and sprung sides.
3 Ensure that the sideguides are behind the sidelay bobbins at the sidelay end of the
side guides when the leading edge of the sheet passes the sidelay bobbin.
4 Where necessary, adjust the sideguide position to prevent the possibility of the
leading corner of the sheet catching the sidelay bobbin.

CAUTION
Damage to the leading edge of the sheet
will cause misregister.
Ensure the sideguides are correctly set.

Page 4-5
Setting Issue 00 – Jan 2006

IMPRESSION
The plate and blanket cylinders run in bearer contact with one another. The bearer
contact pressure is kiss plus 1 flat pre-load of the blanket trip warwicks. Hence the
blanket plate gap is set and underpacking is used to define printing pressure between
blanket and plate.
The required pressure between plate and blanket for effective transfer depends upon the
type of ink and the type of blanket. Crabtree standard cylinder undercuts usually provide
0.1mm under the plate and blanket. This would provide a 0.025 to 0.075mm squeeze,
relating to 7.5-9mm stripe - acceptable for conventional blankets.
For UV inks, and or fully compressible blankets additional squeeze is required to provide
good transfer. This is to compensate for the blanket’s softer action and the additional
compression set on the compressible carcass. The additional packing should be placed
under the blanket to maintain print length. An additional 0.05 (9 to 10mm stripe) or
0.1mm (10-11mm stripe) should be sufficient.
A check should be made on the dot transfer to ensure that the additional pressure has
not unduly increased dot gain, as this can happen with inks characterised by high yield
and short ratios.
The impression cylinder gap should be adjusted for the appropriate stock thickness or
gauge of plate. The stock thickness indicator is calibrated at the factory and re-
calibrated during the commissioning/demonstration stages of the press. The impression
squeeze stripe is calibrated such that whatever stripe is obtained from the plate/blanket
nip is reflected on the sheet under impression.
When changing stock thickness on the substrate, the operator should adjust the stock
thickness setting on the machine using the pushbuttons provided. Both sides need to be
altered evenly.

Page 4-6
Issue 00 – Jan 2006 Setting

Pressure settings
In order to avoid misunderstanding concerning the special meaning of the terms
‘pressure’ and ‘impression’, in the following instructions their definitions are given below.
‘Pressure’ is that which is varied by mechanical setting of the cylinder centre.
‘Impression’ is that which is varied by the packing of the cylinder dressings/under packing
The press is designed for operation with firm bearer contact between plate and blanket
cylinders and adjustable setting between blanket cylinder and impression cylinders to suit
the thickness of stock being used.
Pressure setting is the first operation with a new machine or on resetting an old one. The
first step is to remove all plates and blankets. Before setting pressure make sure the
bearers are perfectly clean.
Adjustments are then carried making sure the blanket and impression cylinders are in the
printing position.
Slacken the lock nuts on the upper pressure rod (warwick) for regulating the pressure
between the plate and blanket cylinder and rotate the adjusting screw in an anti-
clockwise direction. Next slacken the lock nuts in the lower pressure rods (warwick) for
regulating the pressure between the impression and blanket cylinders and rotate the
adjusting screw in an anti-clockwise direction.
Each flat of the adjusting screw represents an increase or decrease of approximately
0.002” (0.05mm) and a complete turn in either directions equals an increase or decrease
of 0.011” (0.28mm).

Upper pressure rod (warwick)

Page 4-7
Setting Issue 00 – Jan 2006

Lower pressure rod (warwick)

Setting the blanket cylinder to plate cylinder


Remove the plate and blanket from the cylinders.
Measure the distance between the plate and blanket cylinder bodies using gauges at both
the feed and off sides.
This measurement should be:
Printing plate thickness + blanket thickness – 0.002” (0.05mm) or alternatively
The diameter stamped on the plate cylinder plus the diameter stamped on the blanket
cylinder subtracted from 32” (812.8mm) then divided by 2.
This is to say, that when a press is supplied for operation with a 0.025” (0.64mm) thick
plate and a 0.075” (1.9mm) thick blanket, the diameter stamped on the plate cylinder will
be 15.954” (405.23mm) and on the blanket cylinder 15.850” (402.59mm).
Then the distance between the plate and blanket cylinder main diameter will be:
0.025” (0.64mm) + 0.075” (1.9mm) – 0.002” (0.05mm) = 0.098” (2.49mm)
Or alternatively
32” – (15.954” + 15.850”)/2 = 32” – 31.804”/2 = 0.196”/2 = 0.098”

812.8 – (405.23 + 402.59)/2 = 812.8 – 807.82/2 =4.98/2 =2.49mm

This gives 0.002” (0.05mm) pressure between plate and blanket and brings bearers just
in contact.
After this setting has been completed make sure to securely re-tighten the lock nuts.

Page 4-8
Issue 00 – Jan 2006 Setting

Setting the blanket cylinder to impression cylinder


The next step is to check the body diameters of the blanket to the impression cylinder.
The basic setting is always on a standard test sheet 0.010” (0.25mm) thick.
Measure the distance between the blanket and impression cylinder bodies on both the
offside and feedside.
This distance should be:
0.075” (1.9mm) + 0.006” (0.15mm) = 0.081” (2.06mm)
When the blanket cylinder is clothed with one blanket the distance between the blanket
and impression cylinders will be 0.006” (0.15mm). This gives a pressure of 0.004”
(0.1mm) on a 0.010” (0.25mm) thick sheet.
Adjust the pressure between the two cylinders by means of the adjusting screws on the
lower pressure rods until feelers can be withdrawn with a firm even pull.
When correct contact has been achieved, the lock nuts must be securely locked down,
ensuring NOT to disturb the original settings.
Now return all cylinders to the tripped position.
Next check the stock thickness readings are set at 0.010” (0.25mm).
The next operation is to fit printing plates and blankets to the cylinders.
Firstly place the printing plate with the required under packing on the plate cylinder to
suit the recess, the plate locked in position should be 0.002” (0.05mm) above the
bearers.
The blanket cylinder should also be fitted with a blanket and the required under packing
to suit the recess. This should bring the blanket level with the bearers.
The impression cylinder carries no underpacking.
NOTE: The actual diameter of each cylinder body (undressed) is stamped on the
machined surface of the cylinder gap.
To test for correct impression, ink up with a plate solid and after putting the blanket
cylinder into printing position with the plate cylinder see that the impression appears on
the blanket. The impression should be light and even.
If the impression is found to be too light then pack up the blanket to suit.
Run a few sheets through the press and gauge the effect, after which the pressure
between the blanket and impression cylinders may be increased or decreased to suit the
work being printed on.

IMPORTANT NOTE
Although the full setting procedure has been described above, it must be emphasised
that when the pressure has been set up in our works the following conditions pertain.
1. The adjusting rods (i.e. the upper pair) are set to give bearer contact
between the blanket and plate cylinders.
2. The adjusting rods (i.e. the lower pair) are set to give 0.004” (0.1mm)
squeeze between blanket surface and impression cylinder body when the
pressure setting on the stock thickness reading is 0.010” (0.25mm).
There should be no necessity for any further adjustment of the blanket cylinder
eccentrics except after several years of use to compensate for possible wear of the
bearers.

Page 4-9
Setting Issue 00 – Jan 2006

Setting the impression cylinder grippers


This cylinder is fitted with individually sprung grippers, one of the essentials of high
speed register. The grippers are positively closed by the gripper spring acting on a cam
via a cam roller lever.
The setting of the gripers is a very simple matter but care must be taken before
commencing this operation to ensure that the cam runner is on the low portion of the
cam and the grippers are closed.
First loosen the ¼” BSF lock nuts and rotate the adjusting screw until a 0.006” (0.15mm)
feeler gauge can be placed between the gripper blade and the gripper rest bar. This
should be adjusted for a light pull on the feeler gauge on all grippers.
Tighten the locknut making sure not to upset the setting of the adjusting screw.
This initial gripper setting permits the handling of a wide range of stock thickness without
the need of any further adjustment.

Lock nut

Adjusting screw

The photograph shows two of the individually sprung grippers

Page 4-10
Issue 00 – Jan 2006 Setting

Front lays
In between the grippers, two adjustable front edge stops are located; these are front lays
having a similar function to the front lays on a paper printing press.
The sheet is driven by the pushers at its rear edge to locate correctly against the front
lays on the cylinder, thus achieving perfect register.
They require little adjustment except to see that both line up evenly against the sheet
and the grippers hold on the sheet is 3/16” (5mm) – this is known as the gripper margin.
If any adjustment is necessary firstly release the clamp screw, i.e. the 5/116” BSW Allen
screw, then rotate the lock nut in the direction to move the front lay to the correct
position.
After setting tighten up the clamp screw.

Front lay

Clamp screw

Adjusting screw

Page 4-11
Setting Issue 00 – Jan 2006

INKING
1. Setting the plate inking rollers
Before commencing to set the plate inking rollers first ensure that:
a) The plate is 0.002” (0.05mm) above the bearers.
b) The ink roller sockets are in the printing position.

First release the caps and lift out the geared inker riders (12 and 16).
The two inner plate inking rollers (14 and 17) are now placed in position, also the
two inker rider rollers.
Lock up all four rollers in position.
The method of setting each roller is as follows:
The first step is to release the bolt clamping each inker fork socket. Next
insert strips of paper (film) 0.003” (0.08mm) thick at each end, between
the plate and plate inking roller. By means of the top adjusting screw set
the roller to the plate until the test strips of paper can be withdrawn with
an even pull at each end.

Page 4-12
Issue 00 – Jan 2006 Setting

Now set the roller to the inker rider by means of the two side adjusting
screws using the test strips of paper as before.
Lock up the end bolt to secure the inker fork sockets. A final check
should be made to ensure the settings have not been disturbed.
Now remove the inker riders in order that the smaller diameter roller is
adjacent to the damping unit. This makes easier access to the plate
damping rollers. Replace the inner riders and to each plate inker, first to
the plate and then to it’s respective rider as previously described.

2. Distribution rollers
The distribution rollers (numbers 4, 7, 9, 11 and 15) are placed in the press after the
plate inking rollers and must be inserted in a certain definite order.
All rollers can be set by adjusting the position of the roller forks. Before the fork and
socket can be adjusted the clamp bolt and nut securing them must be loosened. The
roller can now be adjusted into its required setting by rotating the nut and the side
adjusting screw.

All slides, securing the rollers, must be removed to allow the rollers to be assembled.
First place into position the distribution roller number 15 lying immediately above the
geared inker rider roller and lock in position. Set the rollers to the large ink drum (10)
and inker rider (16) by inserting a 0.003” (0.08mm) paper strip, at each end,
between the ink drum and roller and between the inker rider roller. Set the roller
until the test strips can be withdrawn with an even pull at each end. Lock up the
clamp bolts and nut. A final check should be made to ensure that the settings have
Page 4-13
Setting Issue 00 – Jan 2006

not been disturbed.


Now repeat for the other distributor roller (11). The next distribution roller (7) to be
placed in position is the one that lies underneath the second small ink drum (6).
Adjust the setting between the large ink drum (10) and the second small ink drum as
previously described.
Now place in position the second distributor roller (9) in the group and also the outer
ink rider roller (8) and set as previously mentioned. The last distribution roller to be
placed into position is the very top one (4), which lies between the first and second
small ink drums (3 and 6). No setting is required for this roller as its own weight lies
equally in the two small in drums.
Then finally place the palette roller (5) in position. This roller must be set to be clear
of the roller (4) underneath it, when its lifting handle lie in a near horizontal position.

3. Ink feed roller


Before placing the ink feed roller (2) in position it will be necessary to loosen the
latch on both levers. Place the roller in its own ink fork levers and lock in position.

Inch the press until the roller contacts the first ink drum (3). This is when the runner
is riding on the lower part of the cam and the roller is under spring pressure. Next
loosen the lock nut and the two lock nuts on the adjusting bolt.
The ink feed roller is now set to the first small ink drum by adjusting the bolt in the
roller lever until the test strips of paper 0.003” (0.08mm) thick can be withdrawn
with an even pull at each end.
When correctly set, lock up the lock nuts and screw. A final check should be made to
ensure that the settings have not been disturbed.
The setting of the ink feed roller in relation to the fountain roller (1) is automatically
controlled by the cam.

4. Checking the settings of the rollers


After all the rollers have been placed in the press and set, a final check is necessary
with the ink on the rollers.
Set the press running with the plate inking rollers (13, 14, 17 and 18) lifted. Apply
some ink to the palette roller and run until the ink is evenly distributed on all the
rollers. Stop the press with the plate surface under the four plate inking rollers and
trip the rollers to contact the plate, and then trip out again. Inch the press around so
that the contact lines made by the rollers can be inspected and if all four rollers are
similarly set, as they should be, all four lines should be 5/16” (8mm) wide. As the
rollers sag slightly the lines may be a little wider in the centre, but all four should be
approximately 5/16” (8mm) wide at each end.

Page 4-14
Issue 00 – Jan 2006 Setting

Now run the press with the rollers down on the plate.
If correctly set, the plate inking rollers should give no perceptible ‘kick’ on running on
to the leading edge of the plate.

5. Ink fountain
The ink fountain (1) is run intermittently while the press is in motion. If required the
roller can be made stationary by raising the handle, which rotates the ink cut off disc
to stop the pawl operating the ratchet wheel.
The ink knife adjusting screws are adjusted to allow varying quantities of ink to be
fed along the length of the fountain blade to suit the work on the plate.
NOTE: All duct settings should start from the centre of the blade to avoid springing
the blade, and to make setting quicker.

Ink duct

Adjusting screws

To temporarily increase the supply of ink, or when washing up the fountain roller
when the press is stationary, the roller can be rotated manually by the handle.
Before putting ink in the fountain make sure that both the front edge of the blade
and the fountain roller are perfectly clean as any hard substance, such as grit or
dried ink can damage the blade and roller, as well as altering the blade setting.

6. Setting the ink knife blade


The ink knife blade should be set to the fountain roller by means of the adjusting
screws. Any wear of the ink knife blade may be compensated for by re-positioning
the adjustable screw stops and allowing the blade to move nearer to the fountain
roller, the required gap being 1/16” (1.58mm).
During this adjustment all adjusting screws should be set clear of the blade.

7. Cleaning the ink knife blade


To clean the ink knife blade it is first necessary to lower the ink duct to a horizontal
position. The duct is lowered by a handle, lying on the offside of the machine, after
releasing the support catch.
The duct while in its low position allows the blade to be easily cleaned.

Page 4-15
Setting Issue 00 – Jan 2006

Ink duct in lower position

When the duct is raised to its normal position, no resetting of the blade is required.
The ink duct blade assembly can be removed from the duct rail by releasing the
securing screws lying on the underside, and withdrawing the blade assembly to the
rear.

8. Wash up device
The wash up device is operated by turning the adjusting knobs on each side of the
device in a clockwise direction to urge the blade unit against the main ink drum.

Adjusting knob

The trough may be quickly removed for cleaning purposes by removing the split pins
at each end and withdrawing the trough clear of the unit.
When the blade requires renewal, the blade assembly can be removed by turning the
adjusting knobs anti-clockwise until they reach their limiting stops. The adjusting
knobs can then be swung out of the locating block on the blade assembly, leaving
the blade free to be withdrawn.

Page 4-16
Issue 00 – Jan 2006 Setting

9. Inking rollers trip


When the press trips, the plate ink rollers are raised from the plate, the duct roller is
silenced, and the movement of the ink feed roller is arrested.

10. Palette roller


When quick inking of the roller is required the palette roller (5) is used. It is brought
into use by raising its operating handle to a vertical position.
NOTE: The palette roller should not be used when setting up the ink duct for
production running, as it will give a false impression of the amount of ink being fed
to the plate.

Palette roller

11. Reciprocating motion for drums and rider rollers


An oscillating motion is imparted to the geared rider rollers and the ink drum by
means of a lever operated by a rotating cam, at the ends of their respective shafts.
The oscillation of the rollers is fixed.

Operating lever for


oscillation

Page 4-17
Setting Issue 00 – Jan 2006

FEEDER synchronisation
Some adjustments of feeder timing relative to the press may be required when the sheet
length has changed.
Under normal running the Tin Feeder should place sheets on the infeed belts of the press
unit so that the trailing edges are roughly 25 mm ahead of the dogs when they dogs rise
through the sheet path. This distance may vary a little as running speed is changed.
1 Observe the position of the sheet on the infeed when the dogs rise through the
sheet path.
2 Use the Feeder Timing selector switch to advance or retard the position of the sheet
as necessary.
NOTE
To prevent sheet mishandling, damage or misregister, the trailing edges must be in
contact with the dogs well before the pushers come into position behind the sheet.

Page 4-18
Issue 00 – Jan 2006 Setting

INTERDECK SYNCHRONISATION
Under normal running the delivery of the previous printing unit should place sheets on
the infeed belts of the press unit so that the trailing edges are roughly 25 mm ahead of
the dogs when they dogs rise through the sheet path. This distance may vary a little as
running speed is changed.
1 Observe the position of the sheet on the infeed when the dogs rise through the
sheet path.
2 Use the Synchronisation selector switch to advance or retard the position of the
sheet as necessary.

NOTE
To prevent sheet mishandling, damage or misregister, the trailing edges must be in
contact with the dogs well before the pushers come into position behind the sheet.

Page 4-19
Setting Issue 00 – Jan 2006

THIS PAGE LEFT BLANK

Page 4-20
Issue 00 – Jan 2006 Operating Information

Operating information
Modes of operation 5-2
Pre-start checks 5-2
Pre-start warning 5-3
Full Line Starting 5-3
Re-Start After A Crash 5-3
Crawl 5-3
Sequential Line Starting 5-3
Location Of Pre-Start Warning Devices 5-4
Timing Charts 5-4
Start-up procedures 5-5
Instructions for normal running 5-6
Feeder 5-6
Ink Duct 5-6
Fountain Solution 5-6
Changing A Plate 5-7
Changing Blankets 5-9
Emergency procedures 5-12
Shut-down procedures 5-12
Alarms 5-12
Fault diagnosis and correction 5-13
General Faults 5-13
Key For Register Diagrams 5-14
Front/Back Misregister Over Whole Sheet 5-15
Distortion At Back Of Sheet 5-16
Sidelay Misregister Over Whole Sheet 5-17
Sidelay Distortion 5-18
Skew 5-19

Page 5-1
Operating Information Issue 00 – Jan 2006

Modes of operation
The Marquess Plus has four modes of operation:
1 Run LITHO.
2 Run DRY.
3 Non Print.
4 Wash Up.
During printing the press line (feeder, press units, coater, oven, stacker) operates
automatically with minimum assistance from the operator. Access to all printing controls
is possible without opening guards or entering danger zones.

Pre-start checks
1 Ensure there is an air supply to the press unit.
2 Ensure the main electrical panel is switched ‘ON’
3 Ensure the refrigeration circulation unit is switched ‘ON’.
4 Ensure there is power to the press units (and feeder).
5 Ensure all other printing line equipment is operational.

Page 5-2
Issue 00 – Jan 2006 Operating Information

Pre-start warning
There are 4 situations when the metal decorating press line can be started.
1 Full line starting (full run)
2 Re-start following a crash
3 Independent crawl
4 Sequential line starting
Each of these situations requires an identifiable pre-start warning. For factories with
multiple lines this could lead to the sensorial saturation of the operator. To reduce the
likelihood of this occurring the pre-start warning is designed as follows.

Full line starting (full run)


After pressing the LINE START push-button, the siren will sound for 3 seconds and the
beacons located along the line will begin to flash. After 3 seconds the siren will stop
indicating that the line can be started by further activation of the LINE START push-
button. The beacons will continue to flash until the line starts or until the end of the
release time (12 seconds after the siren stops).

Re-start after a crash


After pressing the LINE START push-button, the siren will sound for 3 seconds and the
beacons on the press units that had stopped as a result of the crash will begin to flash.
After 3 seconds the siren will stop indicating that the press units that have stopped can
be started by further activation of the LINE START push-button. The beacons will
continue to flash until the stopped press units’ start or until the end of the release time
(12 seconds after the siren stops).

Crawl
After pressing a CRAWL push-button the siren will sound for 3 seconds and the beacon
located on the unit to be crawled will begin to flash. After 3 seconds the siren will stop
indicating that that unit can be crawled by further activation of the CRAWL push-button.
The beacon on the unit will continue to flash as long as the unit does not stop crawling
for periods longer than the release time (12 seconds) or a safety device is tripped.

Sequential line starting


It is possible to start the line by sequentially starting each unit in the line, starting with
the unit furthest downstream (in most cases this will be the Unloader).
After pressing the START push-button of the unit furthest downstream, the siren will
sound for 3 seconds and the beacon located on that unit will begin to flash. After 3
seconds the siren will stop indicating that that unit can be started by further activation of
its START push-button. The beacon will continue to flash until that unit starts or until the
end of the release time (12 seconds after the siren stops).
Once that unit has started the unit directly upstream from it can be started by pressing
its START push-button. After pressing its START push-button the pre-start warning
repeats as indicated above. This process is repeated back along the line until all the
units are running.

NOTE
To prevent the coater rolls from drying-up during periods when the line is not running the
Coater can be started in isolation.

Location of pre-start warning devices


The pre-start warning comprises of a siren and a number of beacons.
Each line has one siren that is typically located on one of the press units. The type of
sound (e.g. alternate two-tone, continuous tone, interrupted tone, whoop etc.) is
Page 5-3
Operating Information Issue 00 – Jan 2006

selected on site so that it does not conflict with existing sirens and warnings. The
volume is adjusted so that it is at least 10dB(A) above the ambient background noise
level.
Every unit that can be either crawled or started remotely is fitted with a beacon (e.g.
press, coater, flow out/UV conveyor, unloader etc.).

Timing charts
Starting the line/unit after a standstill or after a crash.
waiting release

Siren

Beacon NOTE 1

Line

Time 0 3 6 9 12 15 18 21
(sec)
NOTE 1
The beacons on the press units will continue to flash after the line has and will only stop
when synchronisation is achieved.
Starting a unit after hold-to-run crawl motion
release

Beacon

Line

Time 0 3 6 9 12 15 18
(sec)
Key

Siren sounding Pre-start warning required

Beacon flashing Unit/line cannot be started

Unit crawling Line can be started / unit can be crawled

Page 5-4
Issue 00 – Jan 2006 Operating Information

Start-up procedures
All three modes of operation (run litho, run dry, non print and wash up) are started using
this procedure. Ensure that all the printing line units have been made-ready and are
operational.
1 Switch on the main power supply.
2 Press the ‘Power on’ pushbutton on the press console.
3 Open the air supply shut-off valve. Check the reading on the air supply pressure
gauge.
4 Check the stacking beacons.

COLOUR STATUS ACTION


ALL RED E-stop activated Reset E-stop(s)
RED Guard circuit open Close guard(s)
FLASHING YELLOW CRAWL selected front and rear Select RUN
YELLOW CRAWL selected Select RUN

5 Select the mode of operation for each press unit using the mode selection
pushbuttons on the press console.
6 Check the feeder stack is loaded and is in the run position.
7 Check the ink duct. Replenish if necessary.
8 Ensure the fountain solution is adequate.
9 To start the press units press the START and SPEED UP pushbuttons together. The
press units will start and speed up to 2000 sph. The START FEEDER lamp will flash
when the line is ready to feed sheets.
10 Select run with oven at the press console.
11 Press START FEEDER at the press console. The START FEEDER lamp will remain lit
during sheet feeding.

Page 5-5
Operating Information Issue 00 – Jan 2006

Instructions for normal running

FEEDER
1 Visually check the stack level
2 Replenish as required.

INK DUCT
1 Visually check the ink level in the ink duct.
2 Periodically stir the ink with a palette knife.

FOUNTAIN SOLUTION
1 Visually check the fountain solution level.
2 Check that there is a supply of isopropanol (or suitable substitute) in the automatic
alcohol control reservoir.
3 Check the level of refrigerated fountain solution in the tank.

Page 5-6
Issue 00 – Jan 2006 Operating Information

Plate cylinder
Cylinder Dressing
This cylinder is recessed to take both a plate and under packing to suit the customer’s
requirements, with the plate being 0.002” (0.05mm) above the bearers.
The Marquess plus can be fitted with two different types of clamp bars. The standard
supplied with the press has no pin register facility. More commonly fitted is the optional
quick release type clamp bars and these do have the facility for pin register. The pin
register dimensions are to suit the customer’s requirements.
Standard clamp bars
If a pre-register table is available then the printing plate can be pre-registered in the
leading edge clamp bars. Clip the pre-registered plate with its clamping bars into position
in the clamp holder on the cylinder and tighten the two locking screws.
If the printing late is not pre-registered then the clamp bars will already be located into
the clamp holder and the printing plate will be inserted into these bars while they are in
situ. The clamping screws will then have to be tightened.
It is important that the blanket cylinder is now in the printing position. Inch the press
round until the back edge comes into position and insert the tail edge of the printing
plate into the open jaw of the spring loaded trailing edge clamp bar. This is done with the
blanket dressed and in pressure to ensure the printing plate does not slip when clamping
the rear edge.
Secure the printing plate by means of the clamping screws and ensure that there is no
distortion or bulging of the plate.
After the initial setting of the front plate clamp in conjunction with the pre-register table
will, in theory, require no further adjustment.
Longitudinal adjustment may be obtained by first screwing back one of the regulating
screws, and pushing the plate across the cylinder by means of the regulating screw at
the opposite end.
To move the plate around the cylinder, ensure that the side adjustment screws are
loosened off first, the plate tensioning screws in one set of clamps bars can then be
slackened whilst the screws in the other clamp tightened. When the desired position of
the printing plate is obtained the screws should be tightened.
A record of the required adjustment from zero position may be obtained by referring to
the indicator scales attached to the front clamp holder.
Before proceeding with further late plate changing, it is essential that the clamp holder
be returned to zero setting in both directions.
To enable the position of the work to be moved a little in relation to the front edge of the
sheet, provision has been made whereby the plate cylinder may be given a limited rotary
movement relative to the blanket cylinder. To obtain this movement release the screws
clamping the gears to the plate cylinder bearer and turn the hexagonal headed pinion
mounted in the recess of the gear. Re-tighten all screws after making the adjustment and
before running the machine.
When it is necessary to adjust the position of the plate cylinder, the four securing bolts in
the flange of the gear must, of course, be eased to permit the gear to move relative to
the cylinder. A pinion and segment on the cylinder end assist in this adjustment. When
re-tightening the bolts the press must be turned to render each bolt accessible in
succession. In these circumstances the press must be turned by the bar and not by the
crawl button.
Quick release pin register clamp bars (optional)
The leading edge of the printing plate, with punched register holes, is inserted into the

Page 5-7
Operating Information Issue 00 – Jan 2006

leading edge clamp bar and over the pins fitted to the bar. The clamp bar is then closed
via the toggle supplied with the press. This is a single action lever mechanism that is also
provided on the tailing edge clamp bars.
The clamps do not crimp the printing plate therefore reducing the damage and increasing
the life of the plate.
Once the leading edge clamp bar has been closed the press is inched around until the
trailing edge of the printing plate can be inserted into the trailing edge clamp bar. Again
once this has been done the clamp bar can be closed using the toggle provided.
Tension is applied mainly via the trailing edge clamp bar, which has a rapid tensioning
mechanism, using a standard wrench. The final tension is applied by the leading edge
clamp bar, which has limited travel.
The above features result in a reduction in the plate changing times.

Leading edge clamp


bar
Pin register

Toggle clamp for clamping


the printing plat Trailing edge clamp
bar

Disconnecting the inker


Before disconnecting the inker always ensure that the inking rollers are tripped out and
away from the plate cylinder – there has been a safety device added to the Marquess
plus to ensure that this cannot happen.
To disconnect the drive to the inker a special key is provided to operate a clutch which
permits the inker to be disengaged and silenced at will.
By inserting the key, into a square hole, on the block between the inking gear and the
plate cylinder bearer plate and turn ‘OUT’, disconnects the inking gear from the cylinder
which allows the inking unit to remain stationary if the press is being used to convey
sheets without printing.
To lock the gear to the cylinder again the pointer must be brought into line wit the line
on the block by means of the barring lever provided. The key can then be inserted and
turned towards ‘IN’.

Page 5-8
Issue 00 – Jan 2006 Operating Information

To disconnect/connect
the inker turn the square
key to either ‘IN’ or ‘OUT

Inker disconnect/connect

Pointer to be in line with


mark so gear can be locked
in place

Inker gear locking position

Page 5-9
Operating Information Issue 00 – Jan 2006

Blanket cylinder
1. Cylinder Dressing
This cylinder is normally recessed to take one blanket, 0.075” (1.9mm) thick with and
under packing if necessary. The blanket is level with the bearers when locked in position.
Further reference to this can be found in ‘Pressure settings’ above.
Before a blanket is placed on the cylinder, ensure that all edges are both straight and
square, also when using a new blanket remove the protective dressing with which it is
treated.
After the rear and leading edges of the blanket are punched, clamp it between the two
bars by means of the socket head screws.
To dress the cylinder, remove the gap guard and add the adhesive backed under packing
as supplied with the press. Place the blanket clamp bar assembly on the tightening shaft
of the leading edge and secure in position by means of the two socket headed screws.
Rotate the tightening shaft approximately half a turn. Inch the press round until the rear
tightening shaft comes into position and place the clamp bar assembly attached to the
tail edge of the printing blanket in position on the tightening shaft. Secure it in position
by means of the two socket head screws.
Now tighten the blanket by rotating the shaft. To ensure uniform tension across the full
blanket width it is advisable to obtain the final tightness using a torque wrench and using
both front and rear tightening shafts.

NOTE
The torque setting depends upon the type of blanket and the construction of the carcass.
Information on blanket recommendations is readily available for all commercial blankets.
Advice should be sought from blanket suppliers on this matter.
We find different manufacturers with different carcass designs differ significantly with
their tension specification.
By way of example, and for guidance only, the calculation for torque setting is illustrated.
Two commercially available compressible blankets have been selected with different
tensioning specification. In both cases a 1156mm wide blanket is used.
The torque wrench setting can be shown by:
Manufacturer 1 Manufacturer 2
Tension specification 1% stretch at 10N per mm 1.4% stretch at 20N per
of width mm of width
Blanket width 1156mm 1156mm
Force calculation 10 1156 20 1156
Total force 11560N 24240N
Torque calculation 5 + (11560 0.032) / 25 5 + (24240 0.032) / 25
Torque 20Nm 35Nm
Torque setting 20 to 25Nm 35 to 40Nm

NOTE
The values 5 , 0.032 and 25 , used to calculate the torque, are constants for the
machine.

Page 5-10
Issue 00 – Jan 2006 Operating Information

For guidance only the following table correlates the tension required in Newton per mm
of blanket width to torque requirements.
Blanket 1212mm wide.
Blanket Tension Calculated Torque Torque Wrench Setting Nm
N/mm Nm
10 20 20-25
15 27 25-30
20 35 35-40
25 42 45-50
30 49 50-55

Blanket tensioning

2. Removal of the blanket from the press


a) Remove the gap guard.
b) Inch the press until the rear tightening shaft is accessible. Using the
special square spanner, release the tension on the blanket.
c) Unscrew the two Allen screws which free the blanket from the cylinder.
d) Inch the press in the reverse direction at the same time pulling the
blanket free.
e) Remove the leading edge blanket bar in the same way as above.

Page 5-11
Operating Information Issue 00 – Jan 2006

Emergency procedures
1 Press the nearest emergency stop pushbutton.
2 Isolate the main power at the electrical panel.

NOTE
Ensure that all electrical supplies to the line are disconnected e.g. UV drying equipment,
automatic ink duct systems, anti-flecking devices, non-Crabtree coater, etc.
3 Shut off the compressed air supply at the shut off valve.
4 Inform site supervision.

Shut-down procedures
All three modes of operation (run litho, run dry and run silenced) can be shut-down using
this procedure.
1 Press the STOP FEEDER pushbutton at the press console or the delivery.
2 Press the SLOW DOWN pushbutton at the press console until the press speed is at
idle.
3 Press the STOP LINE pushbutton at the press console.
4 Wash-up the inking and damping system. See the routing cleaning procedures.
5 Isolate the main power at the electrical panel.
6 Shut off the compressed air supply at the shut off valve.

Alarms
An audible alarm bell is fitted to the Feeder. The bell rings for 5 seconds after the feeder
has fed the last sheet. When the bell stops ringing the pile platform automatically lowers
to the lower position (approximately 120mm above the operator platform). The following
actions should be taken:
1 Lower the pile platform to the floor using the hold-to-run LOWER pushbutton.
2 Remove the empty pallet from the pile platform.
3 Load a full pallet onto the pile platform.
4 Raise the pile platform to the feed position using the hold-to-run RAISE pushbutton.
The feeder is now ready to feed sheets.

Page 5-12
Issue 00 – Jan 2006 Operating Information

Fault diagnosis and correction

GENERAL FAULTS
FAULT POSSIBLE CAUSE REMEDY
Machine will not Stop pushbutton engaged. Release pushbuttons.
start.
Guard open. Check indicator panel and close
offending guard(s).
Guard sensor/switch defective. Check indicator panel. Replace
faulty switch.
Low air supply/no air supply. Check air pressure gauge and
ensure air valve is open.
Fuse blown. Check fuses.
Overload tripped. Check overloads.
Guard override switch active. Turn guard override switch to
normal position and remove key.
Line stopped Stock piled too high on feeder. Remove excess stock.
during printing.
Unstripped sheet. Remove sheet.
Jam at unit infeed. Clear sheets. Check feeder
timing is correct to place trailing
edge of sheet 25 mm in front of
dogs.
Crash. Remove sheet or obstruction.
Damper float level. Check the level and the
operation of the switch.
Press units not synchronised. Ensure the press green
‘synchronised’ lights are lit.
Consult an electrician.

Page 5-13
Operating Information Issue 00 – Jan 2006

KEY FOR REGISTER DIAGRAMS

FRONTLAYS

SPRUNG FIXED
SIDELAY SIDELAY

REGISTER
MARK
SHEET TRAVEL

PUSHERS

Page 5-14
Issue 00 – Jan 2006 Operating Information

FRONT/BACK MISREGISTER OVER WHOLE SHEET


FAULT POSSIBLE CAUSE REMEDY
Misregister Gripper nip and rest bars. Check gripper nip and rest bars.
Gross front/back Gripper adjustment. Check circumferential
misregister, adjustment.
sheets over the
Inadequate drag on sheet. Switch on infeed vacuum.
grippers
(check for Backpush pressure. Check backpush setting.
gripper marks)
Pusher timing. Check pusher timing.
Gripper throat. Check gripper throat.
Cylinder trips. Check cylinder trips.
Early start of Backpush pressure. Check backpush setting.
print
Pusher timing and backpush. Check pusher timing and setting
Ride up fingers. Check ride up finger setting.
Pusher assembly damage/wear. Check pusher assembly for
excessive leakage from pivot or
kinks in air line
Unlevel top plates. Check infeed top plates and lays
for level.
Too much drag on sheet. Switch off vacuum infeed. Clean
the infeed with mild metal polish
and blanket wash.
Ride up finger damage. Replace ride up finger

Page 5-15
Operating Information Issue 00 – Jan 2006

DISTORTION AT BACK OF SHEET


FAULT POSSIBLE CAUSE REMEDY
Distortion Backpush pressure. Check backpush setting.
Check pusher action and clean
piston.
Check operation of high/low air
pressure circuit on pushers.
Sideguide clearance. Check sideguide clearance.
Impression nip. Check impression nip.
Unlevel top plates. Check top plates for flatness.

Page 5-16
Issue 00 – Jan 2006 Operating Information

SIDELAY MISREGISTRATION OVER WHOLE SHEET


FAULT POSSIBLE CAUSE REMEDY
Sidelay Late frontlay contact. See EARLY START OF PRINT.
misregister
Sidelay/backpush pressure. Increase pressure.
Sidelay clearance. Check sheet size settings for
sidelay and sideguide clearance.
Sidelay timings. Check sidelay timings
Sprung sidelay action. Check sprung sidelay action for
notches. Clean piston and
replace slide if necessary.
Excessive sheet drag. Reset vacuum infeed.
Insufficient sheet drag. Reset vacuum infeed.
Sheet fouling. Ensure side of sheet does not
foul machine parts e.g. ride up
finger cut-outs, top plate edges,
side faces etc.
Check front lays and gripper
blades for notches, rags and
sharp side edges.
Insecure fixed sidelay Check positive security of fixed
sidelay.
Check clamp (non-CNC)
Check sidelay stretcher clearance
Check back support plate for
wear

Page 5-17
Operating Information Issue 00 – Jan 2006

SIDELAY DISTORTION
FAULT POSSIBLE CAUSE REMEDY
Sidelay distortion Excessive sidelay pressure. Decrease sidelay pressure.
Sheet buckling. Increase height of sheet support.
May require an increase in
sidelay pressure.
Sprung sidelay action. Check sprung sidelay action for
notches. Clean piston and
replace slide if necessary.

Page 5-18
Issue 00 – Jan 2006 Operating Information

SKEW
FAULT POSSIBLE CAUSE REMEDY
Skew Poor quality sheets. Check sheets for flatness.
Check sheets for knocked
corners.
Infeed Check front/back settings
Check infeed for flatness.
Can be caused by any of the Refer to FRONT/BACK
faults that cause front/back MISREGISTER.
misregister.

Page 5-19
Operating Information Issue 00 – Jan 2006

THIS PAGE LEFT BLANK

Page 5-20
Issue 00 – Jan 2006 Maintenance

Maintenance
Maintenance Schedule 6-2
Air Filter Units 6-2
General Lubrication 6-3
Cleaning And Inspection Schedule 6-6
Routing Cleaning And Inspection 6-6
Recommended Lubricants 6-7
Recommended Cleaning Solutions 6-7
Maintenance Instructions 6-8
Infeed And Delivery 6-8
Lubrication Of Infeed Gearbox Drive 6-8
Removal And Replacement Of Unit 1 Infeed Conveyor Belts 6-9
Removal And Replacement Of Unit 2 Belts 6-10
Pushers And Dogs 6-11
Cylinders 6-12
Plate And Blanket Cylinder Bearers 6-12
Plate Cylinder 6-13
Cylinder Drive Gears 6-14
Gripper Shaft 6-15
Gripper And Frontlay Levers 6-15
Inker 6-16
Removal And Replacement Of Duct Roller Drive Belt 6-16
Inker Washup Chain Drive 6-16
Removal Of Ink Rollers 6-18
Replacement Of Ink Rollers 6-21
Stripe Settings 6-23
Inker Trip Stop 6-24
Checking The Inker Trip Stop Setting 6-25
Checking The Spring Pack 6-27
Impression Cylinder Setting 6-28
Plate To Blanket Setting 6-29
Impression To Blanket Setting 6-31
Cleaning Instructions 6-33
Crabtree Ink Duct 6-33

Page 6-1
Maintenance Issue 00 – Jan 2006

MAINTENANCE SCHEDULE
NOTE
DAILY activities should be carried out after 24 hours operation, WEEKLY activities should
be carried out after 168 hours and MONTHLY activities should be carried out at the start
of each calendar month.

AIR FILTER UNITS


LOCATION MAINTENANCE FREQUENCY GENERAL
TASK TO BE COMMENTS
PERFORMED

12 MONTHLY
3 MONTHLY
6 MONTHLY
(See Maintenance

MONTHLY
instructions for further

WEEKLY
details)

DAILY
Air pressure Check * Ensure the air
gauges supply is 6 bar
Unions and Ensure unions and *
pipe pipe connections are
connections secure and free from
leaks

Page 6-2
Issue 00 – Jan 2006 Maintenance

GENERAL LUBRICATION
LOCATION MAINTENANCE TASK FREQUENCY GENERAL
TO BE PERFORMED COMMENTS
(See Maintenance

12 MONTHLY
instructions for further

3 MONTHLY

6 MONTHLY
MONTHLY
details)

WEEKLY
DAILY
Auto-lube Top up * Centralised
reservoir lubrication
system
Plate and Replenish oil on felt * Pads are
blanket pads mounted on
cylinder cylinder nip
bearers guards
Impression Grease the three *
cylinder grease points
gripper shaft
Gripper cam Grease the surface *
Cylinder drive Grease *
gears
Inker drive Grease *
gears
Drive gears Examine and grease if *
and other necessary
gears between
frames

Page 6-3
Maintenance Issue 00 – Jan 2006

GENERAL LUBRICATION (CONTINUED)


LOCATION MAINTENANCE TASK FREQUENCY GENERAL
TO BE PERFORMED COMMENTS
(See Maintenance

12 MONTHLY
instructions for further

3 MONTHLY
6 MONTHLY
MONTHLY
details)

WEEKLY
DAILY
Damper roller Examine and smear * Refer to the
gears grease sparingly if Damper section
necessary
Inker wheel Grease *
mounted on
plate cylinder
Gripper cam Apply oil sparingly *
runner
Ink duct Apply oil sparingly *
retract lever
pins
Pusher head Apply oil sparingly *
Pusher chains Brush on oil sparingly * Crawl the press
Dog chains Brush on oil sparingly * Crawl the press

Page 6-4
Issue 00 – Jan 2006 Maintenance

GENERAL LUBRICATION (CONTINUED)


LOCATION MAINTENANCE TASK FREQUENCY GENERAL
TO BE PERFORMED COMMENTS
(See Maintenance

12 MONTHLY
instructions for further

3 MONTHLY

6 MONTHLY
MONTHLY
details)

WEEKLY
DAILY
Cylinder Remove main guards *
bearings and grease
Pneumatic Remove main guards *
cylinders pivot and oil
points and
linkages
Roller Grease *
adjustment
worm wheel
mechanisms
Roller Oil *
adjustment
shafts

Page 6-5
Maintenance Issue 00 – Jan 2006

Cleaning & Inspection Schedule

ROUTINE CLEANING AND INSPECTION


LOCATION CLEANING TASK TO FREQUENCY GENERAL
BE PERFORMED COMMENTS
(See Cleaning

12 MONTHLY
instructions for further

3 MONTHLY
6 MONTHLY
MONTHLY
details)

WEEKLY
DAILY
Working Remove debris *
platforms
Clean up ink or solvent *
spills
Infeed belts Inspect and remove * Use a brush
loose contamination
Infeed and Inspect and remove * Use a brush
delivery loose contamination and vacuum
conveyors and a build up of dust cleaner
and debris
Ink duct Clean * Refer to
suppliers
manual
Inker rollers Check the setting of *
the plate rollers
Inspect for build up of * Use a roller
ink solids and clean conditioner to
thoroughly remove glazing
Check the roller *
settings
Damping Check roller settings * Refer to the
rollers Damper section
Inspect for build up of *
contamination and
clean thoroughly
Pushers Inspect and clean *
Sidelays Inspect and clean *
Refrigerated Drain the system, * Refer to
circulation unit flush and clean suppliers
manual
Clean the Alcosystem *
sensor
Impression Check settings *
cylinder

Page 6-6
Issue 00 – Jan 2006 Maintenance

Recommended lubricants

LUBRICANT PLAIN & NEEDLE BALL & ROLLER GEARS & CAM GENERAL OIL
ROLLER BEARINGS PROFILES LUBRICATION
BEARINGS
CASTROL Spheerol L H.S.C. N.N. Perfect
ESSO Beacon 3 Beacon 3 Teresso 52
MOBIL Gargoyle grease Gargoyle grease Mobil-plex Gargoyle Vactra
AA No. 2 RB No. 1 Special Heavy Medium
SHELL Livone grease Livone grease Alvania 2 Vitrea Oil 100
3 RB RB
DUCKHAMS Admax L3 Keenol X Garnet 6
REGENT Caltex Royal Caltex Royal Caltrex Stazon
TEXACO Starfak No. 2 Starfak No. 2 B.P.
ROCOL BG151 BG151 ROCOL ASP

The use of oil or grease of differing composition may result in premature damage to
bearings and lubricated surfaces. Consult your lubricant supplier before using products
bearing different brand names.

Recommended cleaning solutions

CAUTION
Petroleum and aromatic hydrocarbon based
cleaning solutions will cause damage to EPDM
rollers.

Activity Ink Cleaning solution Manufacturer


Cleaning rollers & Conv. Conventional roller PRISCO/VARN/BOTTCHER
blankets wash
UV FEBOCLEAN BOTTCHER
De-glazing rollers Conv. JELLY REVITOL VARN

Page 6-7
Maintenance Issue 00 – Jan 2006

Maintenance instructions
Many items on the press are part of the auto-lubrication system and as such are oiled
automatically. Other items as per below need to be manually oiled or greased.

INFEED
Pusher blocks

Grease blocks

There are 2 sets of grease blocks on the infeed of the press as shown in the photograph
above. These blocks should be greased monthly.

Tape Wheel shaft

Grease point

The above point should be greased weekly.

Page 6-8
Issue 00 – Jan 2006 Maintenance

Infeed Drive

Grease block

Grease the two grease blocks shown above and below weekly.

Grease block

Page 6-9
Maintenance Issue 00 – Jan 2006

Conveyor clutch

Grease point

Grease the conveyor clutch point every four months

Pushers

Oil holes

Place a drop of oil in the two holes highlighted above every week.

Page 6-10
Issue 00 – Jan 2006 Maintenance

Main shaft bearings

Main shaft bearings –


lubrication points

Grease the two lubrication points shown above every week – these are located beside the infeed
step on the Feedside of the press.

Infeed belts
Photos of infeed belts needed here

1 Cut damaged or worn belts. Take care not to damage the sheets guides or belt
running surfaces.
2 Remove the damaged or worn belts from the infeed.
3 Fit a new belt to the infeed. Belts are supplied cut to length to ensure correct
tension when fitted.
4 Use a continuous heated belt jointer to form a smooth join in the new belt.

Page 6-11
Maintenance Issue 00 – Jan 2006

Slowdown and Delivery

Grease point

Slow down pivot lubrication point – one either end – grease every four months

Roller and bearing


grease points

Grease all rollers and bearing points on the delivery monthly.


Slowdown and delivery belts
Removal and replacement of the belts on the slowdown and delivery should be carried out in the
same way as the ones described earlier on the infeed.

Page 6-12
Issue 00 – Jan 2006 Maintenance

CYLINDERS

NEW PHOTO REQUIRED HERE

Plate and blanket cylinder bearers


1 Remove dried ink deposits on the bearers with a suitable solvent.
2 Replenish the oil on the felt pads.
3 Replace the felt pads when they become contaminated.

Page 6-13
Maintenance Issue 00 – Jan 2006

Plate cylinder

Grease point

Apply grease using a grease gun to the grease nipple every four months. This point is for
the plate cylinder bearings.

Blanket cylinder

Grease point for


bearings

Grease points
for housing trip

Apply grease using a grease gun to the grease nipples shown above every four months.
The points above are for the cylinder bearings and for the blanket cylinder trip.

Page 6-14
Issue 00 – Jan 2006 Maintenance

Cylinder drive gears

Cylinder
gears

1 Remove the cylinder gear guards.

WARNING
Rotating parts. Can draw-in and crush the hands.
Do not apply grease when the cylinders are
rotating.

2 Sparingly apply grease to the cylinder drive gears.


3 Crawl the press and repeat the above until all parts of the cylinder gears have been
greased.

Page 6-15
Maintenance Issue 00 – Jan 2006

Gripper shaft

Grease point

Gripper
cam

1 Crawl the press until the gripper shaft is accessible from the rear (as shown
above).
2 Apply grease using a grease gun to the grease nipples. There are 3 grease
points along the gripper shaft assembly. There is one at either end and one in
the centre.
3 Smear grease sparingly onto the surface of the gripper cam.
4 Brush oil sparingly onto the cam runner.

Impression cylinder
trip grease points

Bearing grease point


Stock thickness
adjustment grease
point

Apply grease using a grease gun to the grease nipples shown above every four months.
The points above are for the cylinder bearings, the impression cylinder trip and the stock
thickness adjustment pivot.

Page 6-16
Issue 00 – Jan 2006 Maintenance

INKER
Inker drive gear
The inker drive gear is fitted to the plate cylinder and the grease point is shown in the
photograph below. This should be greased every four months.

Grease point

Inker trip lever

Trip lever pivot


point

Grease the above point every 4 months. There is a grease point on both sides of the
press.

Page 6-17
Maintenance Issue 00 – Jan 2006

Inker drive gears

Inker drive gears


grease point

The above gears should be greased weekly.

Ink duct

Inker lift motion


oil points

Ink duct
lowering shaft
grease point

The inker lift motion points above should be oiled every week and the lowering shaft
grease point should be done every month.

Page 6-18
Issue 00 – Jan 2006 Maintenance

Cleaning instructions

CRABTREE INK DUCT


1 Remove unused ink from the ink duct using a palette knife.
2 Drop the duct to its low position (away from the ink roller) using the handle at the
side of the duct.
3 Clean the duct and the duct roller. Do not allow ink to accumulate on the adjusting
levers.
4 Raise the duct back into its working position.

GMI INK DUCT


1 Please refer to the Maintenance sections of the GMI Manual.

Page 6-19
Maintenance Issue 00 – Jan 2006

THIS PAGE LEFT BLANK

Page 6-20
Issue 00 – Jan 2006 Damper

DELTA® Damper
TECHNICAL DESCRIPTION
General 7-2
Drive 7-3
Roller Tripping 7-3

SETTING
Preparation 7-5
Pre-Setting Checks 7-5
Meter Roller to Forme Roller 7-6
Forme Roller To Plate Cylinder 7-6
Forme Roller To Bridge Roller 7-7
Bridge Roller To 1st Inking Roller 7-7

OPERATION
Pre-Operation Checks 7-9
‘Run Litho’ 7-9
Run Integrated 7-11
Delta ® 7-11

MAINTENANCE
Schedule 7-12
Notes 7-12

Page 7-1
Damper Issue 00 – Jan 2006

Figures
1 Trip conditions of the Delta® damper 7-4
2 Damper adjusters 7-5

Photographs
1 The Marquess Delta® Damper 7-2
2 Metering roller trips 7-6
3 Forme roller trip stop and spring rest. 7-7
4 Bridge roller adjustments. 7-8
5 Fountain and skew adjustments. 7-10
6 Bridge roller recip. controls. 7-11

General
The damping system is a four-roller continuous alcohol type with a fountain roller, meter
roller, damp forme roller, an oscillating ink receptive bridge roller and a drive
arrangement facilitating the selection of Baldwin’s ‘Delta®’ feature. See Photograph 1.

Bridge roller

Forme roller

Metering roller

Fountain roller

Photograph 1 The Marquess Delta® Damper.

Page 7-2
Issue 00 – Jan 2006 Damper
®
The Delta feature describes the process where the damp forme roller rotates with a
circumferential speed different to that of the plate cylinder.

NOTE:
With the Crabtree of Gateshead Delta® Damper
this feature can be switched in or out during the
print run with no disturbance to the printing
process.

®
The benefits of Delta damping are the removal of print defects called Plate Hickey’s,
caused by particle contamination of the plate, improved print fidelity, contrast and
improved screen characteristics.
The reciprocating bridge roller can be used to connect the damper to the inking train
during the print run to ‘Run Integrated’, and during wash up to clean the forme roller.
Control of the damp is achieved using three controls, fountain roller nip adjustment,
fountain roller skew adjustment and meter roller speed adjustment.

Drive.
Drive for the damper is taken from the plate cylinder. The drive is arranged so that the
damp forme roller can rotate at plate surface speed or can rotate below plate surface
speed (Delta®), and that the speed selection can be made during a print run. This is
accomplished using a combination of roller and tooth clutches. The fountain and meter
rollers are driven independently using an AC motor and drive. The motor gearing gives a
nominal operating window around 40 to 60 % where water feed speeds approximate to
100ft/min.
The speed is controlled independently from the damper control panels.

Roller tripping.
Trip ON sequence is meter, forme, and bridge, if required. Trip OFF is the opposite. The
only exception is during wash up. The five trip conditions of the damping unit are as
follows (see Figure 1):

Trip Cylinders
Forme Meter Bridge
PRINT WITH BRIDGE (Integrated) Extend Extend Extend
PRINT NO BRIDGE Extend Extend Retract
PRINT READY Retract Extend Retract
FULLY TRIPPED OUT Retract Retract Retract
WASH UP Retract Retract Extend

Page 7-3
Damper Issue 00 – Jan 2006

®
Figure 1 Trip conditions of the Delta damper.

Page 7-4
Issue 00 – Jan 2006 Damper

NOTE:
This setting should be done during commissioning, after a roller change or as a
check during fault finding. Regular checks at 8-week intervals are
recommended as part of the routine maintenance programme.

Preparation
The following tools and equipment are required:
2 5/16” BSW Spanners
1 13 mm A/F Spanner
2 0.1 mm Pull Tapes
French Chalk

Pre-setting checks
Ensure all damp rollers are clean and dry.
Ensure a suitably underpacked plate is fitted and an even film of ink is applied to the
plate by tripping in the inkers.
Ensure the plate is positioned to prevent a false stripe being made in a start or end of
print area.
Have the printing unit set up in ‘Run litho’ with the upper damper guard open.

Figure 2 Damper adjusters.

Page 7-5
Damper Issue 00 – Jan 2006

CAUTION
Do not, under any circumstances, stripe heavier
than 9.5mm.

Meter to forme roller


Apply small amounts of chalk to the rollers near their ends to use 0.004” (0.01mm) pull
tapes. Place the tapes in the nip between meter and forme rollers. Trip the meter roller
in. Adjust the screw identified in Figure 2 as the ‘meter roller adjuster’ until a light
resistance to pull is achieved evenly across the nip. Trip the rollers out. The stripe test
should be parallel with a width of 4-5mm. See Photograph 2.

Metering roller trip


stop
Metering roller trip
cylinder and link

Photograph 2 Metering roller trips.

Forme roller to plate cylinder


Use the damper push button station to trip in the meter roller and then the damp forme
roller. After a couple of seconds trip out both rollers and crawl the damper until the
stripe is visible on the forme roller. The stripe should be parallel with a width of 7 to
9mm. Adjust the screws identified in Figure 2 as the ‘forme trip adjusters’ and repeat
this step until the correct stripe is obtained. See Photograph 3.

NOTE:
With this adjuster rotate clockwise to reduce
stripe width.

Page 7-6
Issue 00 – Jan 2006 Damper

Trip stop

Spring rest

Photograph 3 Forme roller trip stop and spring rest.

Forme to bridge roller


Place the 0.004” (0.01mm) pull tapes in the nip between the forme and bridge roller.
Adjust the screw identified in Figure 2 as the ‘bridge roller adjuster’ until a light pull is
achieved evenly across the nip. The stripe test should be parallel with a width of 3mm.
See Photograph 4.

Bridge to 1st inker roller


st
Place the 0.004” (0.01mm) pull tapes between the bridge roller and 1 Inker. Trip the
bridge roller only in for adjustment of the wash up nip. Adjust the rod end adjuster
identified in Figure 2 as the ‘wash up adjuster’ until a light pull is achieved evenly across
the nip. Trip the bridge roller out.

Page 7-7
Damper Issue 00 – Jan 2006

Bridge roller adjusting


screw and locknut

Bridge roller trip


cylinder

Photograph 4 Bridge roller adjustments.

Page 7-8
Issue 00 – Jan 2006 Damper

Operation
Pre-operation checks
Ensure that a suitable chilled filtered fountain solution is available. This should consist of:
1. clean water (hardness around 8-10°);
2. a buffered fount additive to provide a pH of approximately 5.5;
3. and alcohol not exceeding 8% or alternatively some form of alcohol substitute.
Ensure that the rollers have been set up, correct tripping operation has been checked
and the press has been finally commissioned and is ready for litho printing with ink
applied to the inking rollers.

‘Run litho’
Plug the drainpipe into the fountain pan, and open the fountain gate valve carefully until
the level has reached the top of the drain plug.
Ensure the following:
1. the flow in and out of the trough is matched and the level remains constant;
2. ensure the fountain roller is separated from the meter roller by backing off the fine
pitch fountain adjusters;
3. ensure all guards are closed.
Engage ‘Run litho’.
Select a damper speed of around 30%.
Select a press speed over 3000 sheets per hour (SPH) so that the fountain roller is in
contact with the meter roller and increase the nip pressure on both ends until the roller
no longer looks wetted, and has the appearance of a light sweat on it’s surface. To get a
'better feel' of this setting, back off the adjustment and re-apply.
Advance the adjusters around one full turn.
See Photograph 5.

NOTE:
The lock rings should be used to secure the
fountain roller setting. The coarse thread adjust
can be used as a night stop once the setting has
been secured.

Page 7-9
Damper Issue 00 – Jan 2006

Photograph 5 Fountain and skew adjustments.


Return the damper speed to around 5-10%.
Select a press speed over 3000 sheets per hour (SPH). The plate is now being wetted with
fountain solution.
Set the run speed of the damper to around 30 - 45% and trip in the unit’s inker. Drop the
water feed until the scumming pattern is obtained. Adjust FS / DS fountain pressures or
the Skew setting to get an even scum across the plate, this will level the damp feed across
the plate.
Adjust the three settings so that an even scumming pattern is established. Adjustment of
the skew away from the zero setting increases the nip force at the centre segment of the
fountain/meter rollers. This ensures a fine water film and maximises the sensitivity of the
meter roller speed adjustment.
Reset the water feed to the correct level.
Select a damper speed that provides the minimum water required for sharp clear screens
and solid edges. Adjust to suit varying conditions, i.e. temperature, humidity, press
conditions and plate artwork.
Reciprocation of the bridge roller is controlled by air-flow regulators that are located inside
the feedside main guard. Turn the adjustment screws clockwise until the regulator is
closed. Slowly turn the adjustment screws anti-clockwise until the bridge roller reciprocates
smoothly every 1-2 seconds.

See Photograph 6.

Page 7-10
Issue 00 – Jan 2006 Damper

Photograph 6 Bridge roller recip. Controls

Aside from conventional operation there are two alternative configurations of the damper:
1. Run Integrated,
®
2. Delta .
They can be selected before starting or during run.

RUN INTEGRATED
This connects the damper to the inker through the bridge roller, which maintains its
reciprocation. Additional water feed is required if run integrated is selected for the
print run. Run integrated should only be used if there is a specific benefit with
particular types of artwork. It is recommended that if this is the case the unit is set
before the print run.
As the damper is used as plate feed device in run integrated, extra care should be taken
with water balance, particularly with the more soluble UV inks.

DELTA®
Selection of Delta ® ensures the removal of plate hickeys. Due to it’s scrubbing action it
increases the strength and fidelity of solid colours producing finer tighter screens.
There is a fixed offset to slightly adjust water levels when this selection is made
®
which is set at 3% i.e. the damper motor speed is increased by 3% when Delta is
selected.
There may be an impact on screen reproduction and colour formulation with the use of
®
Delta Damping.

Page 7-11
Damper Issue 00 – Jan 2006

Maintenance
Schedule

LOCATION MAINTENANCE TASK TO BE FREQUENCY RESOURCES


PERFORMED REQUIRED

2 Monthly
Monthly
Grease manifold Apply grease to the grease  Grease gun
point nipples
Gears Lightly brush anti-scuffing Anti-scuffing paste
paste onto the gears
 Brush
General Check the settings of the  See Page 7-5
rollers

NOTE:
All oil fed bearings are auto lube.

Grease
manifold

Grease manifold – shown on the Feedside – there is also a manifold on the Offside.

Page 7-12
Issue 00 – Jan 2006 Guide to printing

Guide to printing
Roller system 8-2
Summary 8-2
Ink transfer and fount solution considerations 8-4
Print Characteristic 8-4
UV Inks 8-4
Figure 1 Relationship of density to ink film thickness 8-5
Ink Solubility 8-5
Fount Solution 8-6
Summary 8-7
Troubleshooting guide 8-8
Poor Washup Of Machine 8-8
Ghosting 8-9
Incorrect Tone Transfer For Image Reproduction 8-11
Poor Solid Transfer 8-13
Image Blinding 8-15
Scumming 8-16
Tinting And Misting 8-17
Poor Film Weight Control 8-18
Colour Variation Up And Down Sheet 8-20

Page 8-1
Guide to printing Issue 00 - Jan 2006

Roller System
The Marquess Plus is fitted with roller coverings regarded as the most advanced
available at the time of specification. Because of their progressive R&D programme and
the excellent world wide support network Crabtree normally specify Bottcher as their
preferred supplier for roller coverings.
Nevertheless there are issues with rollers that require attention in housekeeping,
maintenance and selection of consumables.
The composition of the roller compound is usually the result of compromises between
roller life, printing performance, dimensional stability and chemical compatibility.
Conventional inks result in the selection of NBR/Nitrile materials. UV inks usually result
in the selection of EPDM compounds. In dual ink medium environments there is much
difficulty in roller selection, and little choice at the moment. The choice is from
NBR/Nitrile derived universal compounds. This is because of the total inability of EPDM
compounds to handle oil based substances.
It is very important that chemical compatibility testing is performed on the full range of
pressroom chemicals and inks used if they deviate in whatever shape of form from
Crabtree recommendations. If in doubt – get it tested. Chemicals readily available on
the press line should be limited to those known to be compatible.

CAUTION
Any contamination of EPDM compounds with
aromatic hydrocarbons or mineral oil based
substances will immediately render the rollers
useless. This is particularly the case for wash
chemicals, where conventional washes used with
EPDM shall cause instant and permanent damage
to rollers, and potentially damage the inker itself.

All roller coverings are susceptible to poor dimensional stability in their early life. The
extent of this depends on the compound and the chemicals. NBR/Nitrile materials shall
swell and get softer, and EPDM materials shall shrink and get harder.
This means attention to detail, regular roller setting checks and adjustments are
necessary.
All new rubbers in the first week of life absorb a lot of wash-up solvents and ink. If the
solvents are not very compatible as in the case of UV solvent and conventional
NBR/Nitrile rubber this can significantly shorten the life of the rubber. In these initial
conditions solvents penetrate deep into the rubber causing them to swell initially more
than 10%. This will be demonstrated by not being able to achieve stable roller settings.
After a further 2 or 3 weeks the rollers relax somewhat reducing to a more stable size.
Providing the rollers do not dry out they will run near these settings until they fail. How
long they last depends largely on the compatibility of these initial solvents.
It is strongly recommended to condition conventional rubber rollers in a dual purpose
(UV/conventional) environment with conventional inks and solvents in the first weeks of
life in order to prevent the penetration of subsequent aggressive UV solvents and
chemicals.

Page 8-2
Issue 00 – Jan 2006 Guide to printing

SUMMARY
 Roller Selection is a compromise between life, stability, performance and chemical
compatibility.
 If in doubt ALWAYS seek advise on chemical issues for pressroom chemicals before
usage. This service would be available from Bottcher if requested.
 Be prepared for frequent roller setting in the first month or two of new rubber roller
usage.
 NEVER use aromatics or oil based chemicals on EPDM.

Page 8-3
Guide to printing Issue 00 - Jan 2006

Ink transfer and fount solution considerations


Sometimes the specification of the machine continues a company policy to use UV
mediums in the print operation. In this case the foundations for material selection are
already built and the following sections shall serve as general interest.
Sometimes the specification of a UV machine reflects a change in policy, in effect to
restructure the print operation to encompass UV. The following sections should be
carefully considered in preparation for receiving the machine to prevent unwanted
difficulties occurring.
Many people who have had experience of UV and conventional inks on Metal would agree
that there is greater difficulty in printing UV, despite the considerable advances made
since it’s launch, particularly in Metal Decorating. The following sections serve to give a
rudimentary understanding of why it is more difficult, and what to do to ensure as
smooth a transition as possible. There are many sources of reference/research should a
fuller understanding be required.

PRINT CHARACTERISTIC
We have found that different ink mediums can print differently.
UV inks can print good open screens, quite accurately, whereas some dot gain is usually
a feature of conventional inks. To obtain matched process sets on UV to copies printed
conventional some dot gain compensation in the film production sometimes is required.
It is the good screen characteristics and wet on dry trapping that have encouraged the
use of UV on multi-colour press lines.
For solids we often find that these can be printed on conventional inks with more gloss
and chroma or intensity than UV inks which generally print very flat, and rely totally on
Varnish coats to provide gloss.
These considerations should reflect the attention to detail that shall be required on repro
work. Housekeeping and materials selection for inks and blankets must also be carefully
considered and maintained. Proofing methods should take into consideration different
gloss and chroma of the mediums. More importantly once the standards for film weight,
colour formulation, ink manufacturer, blanket type and underpacking are set they should
be maintained to ensure press repeatability.

UV INKS
Many print related problems for UV relate to two characteristics of UV:
1 The medium does not readily transfer. This is a particular problem in metal
decorating as the substrate is not permeable. It is not such a problem in paper
packaging where permeable substrates are used. This is because water transfer into
the substrate helps transfer of the ink/water emulsion. Obviously Blanket selection
for UV inks then becomes very critical.
2 The ink is more soluble than conventional inks. Printing UV inks usually results in
high amounts of background tinting, (especially with alcohol damping). This is
normally a problem that can be controlled with the better inks. If the ink is very bad
then the ink/water balance shall be more critical and printing defects caused by
emulsification can result if the ink/water balance is not set up well and maintained
during the run. Excessive emulsification can also affect transfer adversely as it tends
to make the interfacial tension of the ink in fount solution even more polar (non
dispersion or cohesive) in nature and this can encourage ink piling on the forme
roller.
Both of the above characteristics imply that film weights and colour matching should be
done carefully. A UV ink can print up to a certain film weight without problems and
‘Forcing colour’ using heavy film weights is not recommended. However it is not simply a
case of making the colour formulation as strong as possible, there are three reasons for
Page 8-4
Issue 00 – Jan 2006 Guide to printing

this. The reology, and hence transfer of the ink can be affected by excess pigmentation.
A strong ink printed with a thin film is working in the steep portion of its reflectance
curve, hence any slight film weight variation caused by mechanical ghosts etc. shall
result in obvious and unacceptable colour variation. In addition considerations such as
opacity on mixed colours need to be taken into consideration in film weight selection.

3
B

2.5
C
M
2 Y
Density

1.5

1
Normal ink film
for lithography
0.5

0
0 1 2 3 4
Ink film (microns)

Figure 1 Relationship of density to ink film thickness

We have found the transfer and solubility properties of ICI Edward Marsden’s inks are
such that we feel comfortable recommending them as an industry standard.
They can provide guidance on acceptable film weights for colour matching – ranging
from about 0.4 (Solids) to 0.2 (screens) milligrams on their Duncan Lynch Roll Out
Machine.

INK SOLUBILITY
The solubility of the ink provides the operating window for damp tolerance. There has
been a lot of general research into this – to try and provide good empirical predictive
data on ink performance.
A good ink manufacture can take this aspect on board whilst he is formulating the ink for
the press.
During early research into press performance Surland (Finland Graphic Art Research Est.)
and Bassemir (Sun Chemical) used emulsion phase equilibria and water absorption tests.
A lot of people now will use yield and short ratios to define reological changes that occur
with water mixing.
ICI Edward Marsden measure tack changes as water is tested to a roller machine – they
have developed over the years a characteristic of the tack results that they know should

Page 8-5
Guide to printing Issue 00 - Jan 2006

print well – and their method seems to work.


Certainly there have been experiences with bad inks from manufacturers that have
looked to improve colour saturation and drying without considering litho performance and
have rendered the ink unprintable by the addition hydrophilic catalysts and amene
synergistists.
The ideal water absorption characteristic with the ink is to take on a percentage of water
then stabilise. Too much or no stabilisation then scumming problems – too little then not
attaining density or in extreme cases causing blinding.
Bob Bassemir’s work was quite clever in that he just looked at phase equilibria after
mixing the ink and fount solution, completely separate ink and water gave
stripping/blinding. A single emulsified mixture gave emulsification, piling etc. The ideal
is two separate phases, the first fount solution in ink the second fount solution on it’s
own. Good conventional ink/water chemistry would fit into this bracket. Another
condition he found was two phases, again the first phase was fount solution in ink, but
the second phase was ink in fount solution. This often resulted in poorer colour control
and tinting, it is more typical of soluble inks such as UV.
As inks have developed his test is now considered a little course, as the mixing methods
were crude. It still gives some insight on behaviour however. Surland also discovered
that the same ink can display different water take up graphs dependant upon pH, and
conductivity.

NOTE
With the sensitivity of UV inks to emulsification it is not recommended to use excessive
amounts of tack reducer in the ink. It is better to improve the release via blanket
selection.

FOUNT SOLUTION.
The fount solution must work the plate but not be too aggressive on the ink. Kaeble &
Dynes (Rockwell Int) have done a lot of research on surface energetics – particularly for
plates.
They have produced charts for wettability envelopes, which show the sensitivity of acid
levels to correct operation on aluminium plates. The charts cover conventional ink – UV
is worse due to its polar nature. The charts show that the preferential wetting window is
much smaller for aluminium plates than for copper/chrome plates. Hence the chemistry
of the water is more critical.
For UV we should use good quality positive plates and a carefully selected buffered fount
additive to soft water. Du Pont Howson 605 at 1-2% gives us 4.7 to 5.2pH
approximately and this has given good general results. Baking the positive plates allows
etch chemicals to be used to de-sensitise any marginal scumming problems.
Also with fount solution remember conductivity. After our experiences we find that base
Carbonate Hardness plays an important part – for two reasons emulsification and roller
glazing.
The best practice advice for areas with hard water is to use distilled water. RO water is
in this case not acceptable for two reasons. First they require a lot of maintenance in
hard water areas to be affective at all. Secondly, they use the ion exchange process to
reduce conductivity and to reduce the Total hardness – the actual carbonate hardness
remains largely unaffected.
Water harder than 4 deg d (Carbonate) is unacceptable. Better than 2 deg is the
objective.
Any carbonate salts left in the water shall react with the fount solution acids (usually
Citric) to form an insoluble precipitate for example calcium citrate, this can glaze and
blind rollers.

Page 8-6
Issue 00 – Jan 2006 Guide to printing

Because most fount additives are now buffered with acid salts conductivity should be
used to measure condition of the fount solution. Once the baseline conductivity is
established with clean water and fresh chemicals the conductivity should be periodically
checked to evaluate water condition. Rises in conductivity mean that the water needs to
be changed.
Our best practise consumables are therefore:
Distilled Water.
1 to 2 % Howson 605 FountSol
ICI Edward Marsden Inks
Baked Positive Plates
Kinyo Compressible Blankets
Bottcher Approved Roller Wash Solutions.
As far as blankets go the best transfer we have obtained through the blanket is with the
Kinyo UV blanket. We find solids and screens are good and ink release and embossing is
not such a problem. We find that often an additional layer of underpacking is required
with compressible blankets – up to 0.1mm. Many dual purpose blankets we have found
unsuitable for a UV environment due to tack related print length problems and
embossing.
All these measures are aimed at maximising transfer – to get the most out of the film
weight carried at the plate, and to minimise solubility. A poor blanket does not just give
transfer problems - because of the transfer problems you have to carry more ink – more
water is required to keep things open and you are then into a vicious ink/water balance
circle. Much the same applies to everything else. The main factors of the process
control can affect the result – but they all interact with one another, and this can make
things even worse.

SUMMARY
 UV Inks have a different print Characteristic to Conventional.
 UV inks do not transfer as well – blanket selection is critical.
 Care is required in colour strength formulation.
 Water Chemistry is important.

Page 8-7
Guide to printing Issue 00 - Jan 2006

Troubleshooting guide

1 POOR WASHUP OF MACHINE


Press does not wash very well. Ink residue is left on rollers.

Problem Possible Cause Corrective Action


An overall Ink residue The air pressure for the Increase or decrease as
is left on rollers wash up blade is incorrect – necessary
this is an option on the

Marquess Plus
Incorrect solvent is selected Check solvent compatibility
for the roller wash to the ink
Too much solvent is applied Reduce solvent on time on
to the rollers and making the wash up parameter
them skid. Once the solvent control.
dries the rollers drive and
back transfer ink up the
inker train. Try increasing blade on
time.
Insufficient solvent is added Adjust wash settings to
to inker during wash increase solvent on time.
Also try reducing blade on
time to help soften ink.
An ink residue is left The scraper blade, back Clean the front (bevelled)
on the rollers in bands edge is fouled with ink. edge of the blade.
done specific areas of
OR Remove the trough and
the inker
clean the back of the
There is ink piling on the
scraper blade.
scraper blade.
Renew the scraper blade.
OR
The scraper blade is worn.
A Spray bar nozzle is Remove and clean the
blocked. Preventing an offending nozzle.
even application of solvent –
this is an option on the
Marquess Plus
The roller settings prevent Check and adjust roller
transfer of solvent laden ink settings as appropriate.
due to swell or shrinkage of
rollers, or just a bad setting.

Page 8-8
Issue 00 – Jan 2006 Guide to printing

2 GHOSTING
The printed result is unacceptable because of mechanical starvation ghosts or water
repeat marks. Ghosting is usually seen as variations in density or opacity across the
sheet in solid areas around reverse patterns. Often lines are seen in the direction of
sheet travel through the solid areas following the edges of the reverse pattern. Water
repeat marks are seen as repeat patterns of the reverse. The repeat patterns of the
reverse are visible due to their lower density/opacity. They usually follow the actual
reverse in the direction of sheet travel. The problem solving for both these phenomena
is similar – except the first step for water repeat is ink/water balance.
It should be noted that for certain artwork and film weights, ghosting is unavoidable.

Problem Possible Cause Corrective Action


Sheet shows Ghosting Ink/water balance has been Wash the roller train, and
or water repeats. lost. Ink has started to restore the correct ink/water
emulsify and pile. The balance.
transfer properties of the ink
Check the water chemistry
are thus spoilt.
and replace if necessary as
Note if the loss of ink/water per Crabtree
balance was caused by recommendations.
forcing the film weight to
Check ink to ensure its
get colour.
formulation is correct.
Increase the colour strength
if necessary.
Ensure no tack reducer is
used in the ink.
Desensitise the Chrome
Meter roller with acid Etch.
The film weight of the ink is Reduce the colour strength
low. Slight film weight of the ink with an
variation then causes appropriate medium. Run
exaggerated differences in the job with more film
reflectance. weight and feedback
findings to future colour
formulation recipes.
Artwork is inappropriate. Reorganise plate imaging
The patterns could be and reproduction.
avoided altogether by
rotating plate artwork.
The damping system can be Ensure no emulsification has
configured as a plate feed resulted, clean rollers if
device, or a combination necessary.
device (Integrated). For this
Modify the damper
job the configuration of the
configuration.
dampening system is
Select/Deselect Run
inappropriate.
Integrated.
Select/Deselect Run Delta.

Page 8-9
Guide to printing Issue 00 - Jan 2006

Problem Possible Cause Corrective Action


Sheet shows Ghosting Roller settings are not Reset inker rollers.
or water repeats correct; this can affect both
Reset damper rollers.
(continued) inker and damper. Poor
Ensure the bridge to forme
inker settings can reduce
setting is light.
the rolling power of the
inker, increasing the chance
of mechanical ghosts.
Forme/Plate and
Forme/Bridge settings on
the damper can also be
critical.
The Plate inkers or more Replace the affected roller.
importantly the Damper
Fully check compatibility of
Forme roller has been
pressroom chemicals with
attacked with incompatible
the roller compound.
chemicals. The resulting
surface chemistry is
unsuitable for printing. This
can often be detected by
variation in setting and a
stickiness or tackiness of the
roller surface.

Page 8-10
Issue 00 – Jan 2006 Guide to printing

3 INCORRECT TONE TRANSFER FOR IMAGE REPRODUCTION


Half tone colour reproduction gives an unacceptable match to the copy. The artwork has
a combination of solid areas to trade marks etc and halftones for product rendition – the
printed result cannot match both the screens and solid image areas.

Problem Cause Corrective Action


The machine is The print characteristic is Fingerprint press.
printing in a different.
Use the print characteristic
satisfactory manner
The colour formulation for of the machine to modify
with good accurate
the inks may need to be Dot compensation in plate
screen transfer to the
changed. If it is necessary reproduction. Modify the
plates used. But the
to force colour to get solid colour formulation of the ink
colour standard was
density – thus spoiling the to suit.
produced on another
screens then often
machine, or on a On future jobs with no
increasing the strength of
different ink medium colour standard or copy
the colour to print a lower
and cannot be previously printed on the
film helps. Another thing to
reproduced with machine obtain proofs of
try in this case is to print
sufficient accuracy. plate artwork with
with the damper in Delta as
fingerprint results included.
This can often be this can improve contrast.
seen with solids and
The dot sizes on the plate
screens printed
screen work may need
together.
modifying.
The machine prints Solvent residue on rollers Increase the dry time on the
with what is regarded has softened ink. wash programme set up
as excessive dot gain. Reasonable impression screen.
settings squash the dot.
Change solvent and improve
evaporation rate.
The Ink is to long and prints Improve the reology of the
very soft by the time it gets ink. Improve the short ratio
to the plate. of the ink.
The ink becomes tacky and If tack is produced because
transfer is poor. of water examine water pick
up, and water chemistry.
Look at the inker
temperature and modify it if
necessary by adjustment of
water cooling temperature.
(If inker chiller is specified)
Too much damp is used on Reduce damp feed, and
the plate and this has balance the feed across the
resulted in Dot spread. sheet.
Check water Chemistry and
ink formulation.
Desensitise the plate and
the damper meter roller.

Page 8-11
Guide to printing Issue 00 - Jan 2006

Problem Cause Corrective Action


The machine prints The ink on the plate looks Improve transfer properties
with what is regarded okay, but the blanket image of the Blanket. Change
as excessive dot gain is poor by comparison. Ink blanket for a new one.
(continued) is piled on the blanket. Change the type of blanket.
Sheet stripping is difficult.
Note: With UV poor blanket
Ink release and Blanket
transfer can be a feature
transfer is therefore poor.
until the production run has
completed a few hundred
sheets. Again changing the
blanket type can help with
this.
On checking the blanket to Revise impression settings.
plate stripes, and blanket to
Have you changed the
sheet stripes it is found that
blanket type?
the stripe width is excessive.
(For non-compressible Re pack the blanket and
blankets over 9mm, for good check/adjust impression
compressible blankets over settings as instructed in the
11mm) manual.
The dot is squashed by
excessive impression.
The ink feed is excessive for Strengthen the colour
the percentage image formulation and reduce the
coverage. The film weight is ink feed.
therefore very heavy. The
dots are squashed because
of the film weight.
There is doubling of the Go through the register
dots. The machine is not checklist.
registering correctly.
The press prints the plates Screen reproduction needs
accurately but the dots are to be modified.
large and are affecting
colour.

Page 8-12
Issue 00 – Jan 2006 Guide to printing

4 POOR SOLID TRANSFER


The printed sheet is characterised by poor solids. A large amount of ink is carried on the
roller train and plate compared to what is expected for the percentage image area. The
solids are pin holed and grainy. The ink has picked and stands up on itself so that a
heavy film of ink results in a low density.

Problem Causes Corrective Action


The ink has picked Ink tack results in poor Reduce ink tack.
badly and large film transfer. Blanket release is
Improve ink release from
weights result in low poor. The ink is not stripped
the blanket by changing
densities. correctly.
blanket selection.
Reticulation patterns The surface tension of the
Usually a combination of
can be seen in the sheet coating prevents good
Hardness and texture of the
cured ink under a whetting of the ink, which
blanket surface define these
glass. usually has quite polar
characteristics.
surface tension bonds.
If the sheet is not
Check the surface energetics
cured and left to
of the sheet coating.
stand the effects can
Consult ink and coating
get worse.
supplier.
Smoothing the ink
after printing
drastically increases
density
General Solid Impression is low. The ink Check impression settings.
reproduction is poor. has not been properly Increase underpacking and
smashed. stock thickness pressure if
possible.
Solvent residue has been left Modify solvent on time, or
on rollers. Spoiling ink drying time on the roller
reology and transfer. wash control screen.
Improve evaporation rate of
solvent.
Ink/water balance is Reduce water feed.
incorrect. Colour is washed
out by excess water.
Plate Inker roller settings Reset or replace plate inkers
are poor. as necessary.
Plate inker roller condition is
very poor with roller surface
badly pitted or perished.

Page 8-13
Guide to printing Issue 00 - Jan 2006

Problem Causes Corrective Action


General Solid Density is low. On Change the plate. Ensure
reproduction is poor examining the plate there is good baked positive plates
(continued) little ink in the image areas. are processed correctly.
Plate is blinded by wear of
Modify water chemistry in
the sensitised image area, or
line with plate
solvent attack. (If not
manufacturer’s
baked). OR the plate is
recommendations.
blinded by excess acidity of
the fount solution
Ink does not transfer very Modify ink formulation.
well due to its very high
polar component of surface
tension.
Ink is taking too much water Check water chemistry.
and washing out or blinding
on rollers.

Page 8-14
Issue 00 – Jan 2006 Guide to printing

5 IMAGE BLINDING
Certain areas of the image are missing from the sheet, or solid densities are low, with
light film weights of ink transferred only.

Problem Cause Corrective Action


Discrete areas of Removal of sensitised image Change the plate. Ensure
image are missing area from plate through good baked positive plates
from printed sheet. wear or solvent attack. are processed correctly.
Local collapse in blanket Change blanket.
prevents image transfer.
General loss of Ink is totally insoluble, and Modify ink formulation.
density in solid areas. will not take up water. Plate
inker rollers are therefore
blinded by water on the
plate.
Excess water feed washes Reduce water feed.
the image out.
Bad compression set in Change blanket.
blanket reduces impression
to such an extent that
transfer is affected.
The acid content of fount Change water chemistry to
solution is high enough to lower acidity that the plate
preferentially whet the can work well with.
image areas of the plate.
The use of Hard water has Use distilled water for fount
resulted in the precipitation solution.
of calcium citrate salts onto
Use a roller conditioner, de-
rollers that cause blinding.
glazing compound or
suitable acid to remove
precipitate.

Page 8-15
Guide to printing Issue 00 - Jan 2006

6 SCUMMING
Permanent catch up seen on the plate, cannot be removed with water. Usually needs to
be rubbed or washed in solvent to remove.

Problem Cause Appropriate Action


Scumming on printing The plate has sensitised and Try etching and gumming
plate. Shows up on allowed ink attractive sites the plate.
sheet as a visible tint to be created. Sometimes
Change plate.
in non-image areas. caused through plate wear –
erosion of the baking gum
or the oxide layer.
Insufficient pH of the fount Modify the water chemistry.
solution means it does not Make the water more acidic
break into the non-image – within the limits set by the
area whettability envelope plate manufacturer.
for the plate.
The ink is very soluble and Modify ink formulation.
heavily tinted areas look like
Try modifying alcohol
scum, but changing the
content in fount solution.
plate does not help.
(Increase OR decrease)
If conductivity of fount
solution is high – replace
fount solution using clean
water. Use distilled water to
maintain a low overall
conductivity.
The scum appears at the Clean and etch the lead
lead edge of the sheet. The edge – followed by an
gum or the oxide layer of application of gum. Replace
the lead edge of the plate plate.
has worn.
Check inker trip stop, plate
inker roller settings and
belleville spring pack
settings.
Check damper forme roller
settings.

Page 8-16
Issue 00 – Jan 2006 Guide to printing

7 TINTING AND MISTING


Tinting is seen as ink feedback into to non-image areas that is normally acceptable if it is
very slight and can only be seen with a glass. Misting is visible to the eye and appears as
catch up that does not clear – even when damp is increased to the point that the image
areas are washed out.

Problem Cause Corrective Action


Tinting on sheet is not Ink is dissolving into water, Modify ink to reduce its
acceptable. and is fed back to the plate solubility in fount solution.
in fine dispersed droplets. Possibly a modification to
the medium, or selection of
alternative non bleeding
pigments is required.
Modify water chemistry –
mainly alcohol levels and
conductivity.
Reduce ink feed levels and
water feed levels.
Ink is misting onto The damping solution on the Check the water
sheet. plate is not stable. temperature. Water
Evaporation or lack of temperature at the trough
whetting is the cause. should be 10 deg Celsius.
High water temperature
results in loss of alcohol and
increased evaporation rates.
If water temperature is too
high check operation of
water chilling units.
Check alcohol dosing units –
increase alcohol if
necessary.
Solvent residue left on ink Modify roller wash
rollers or plate is affecting parameters. Change solvent
surface energetics at the to one with quicker
plate. evaporation characteristics.

Page 8-17
Guide to printing Issue 00 - Jan 2006

8 POOR FILM WEIGHT CONTROL


Characterised by colour variation sheet to sheet – requiring frequent adjustments to
press settings during the run.

Problem Cause Corrective Action.


Poor general Roller settings on inker or Reset Rollers as necessary.
performance, frequent damper are not correct.
press adjustments
required to maintain
colour. OR the film
weight required
cannot be established
in printed results.
The Plate inkers or more Replace the affected roller.
importantly the Damper
Fully check compatibility of
Forme roller has been
pressroom chemicals with
attacked with incompatible
the roller compound.
chemicals. The resulting
surface chemistry is
unsuitable for printing. This
can often be detected by
variation in setting and a
stickiness or tackiness of the
roller surface.
Poor transfer across blanket Improve blanket transfer.
means ink film carried on
blanket is very heavy.
Transfer becomes variable
and stripping is a problem.
Ink duct requires re- Calibrate ink duct and
calibrating. Repeat job sweeps.
settings have needed
Ensure frequent mechanical
adjustment. The duct
zero checks are done on
profile does not match the
duct and sweep motors – if
image requirements.
fitted.
SEE REQUIRED MANUAL.
Water control is poor. Balance water across sheet.
Causing washout of colour Reduce the water feed.
or catch – up.

Page 8-18
Issue 00 – Jan 2006 Guide to printing

Problem Cause Corrective Action.


Poor general Emulsification Problems are Reduce ink and water feeds
performance, frequent causing poor transfer and to obtain a balance.
press adjustments poor repeatability of inker.
Examine colour formulation
required to maintain
as a means of reducing film
colour. OR the film
weight requirements.
weight required
cannot be established Check ink solubility.
in printed results
Check fount solution
(continued)
conductivity.
Check damper forme roller
surface chemistry for
chemical attack. (See start
of this table)
Sudden Change of Impression settings on Check stock thickness
colour during the run. impression cylinder have setting. Check impression
moved. settings.
Impression to the sheet is Check that the trip lever
lost. stops are set hard in the
tripped in position.
Check for loose warwick
adjusters or loose damaged
shaft keys.
Check trip timing for missed
sheets.
Consult Crabtree.
The ink duct is not properly Ensure that the duct is
secured causing excess ink correctly secured.
to be fed into ink train.
The ink ductor roller silence Correct position of silence
handle has moved – handle.
resulting in a loss of ink
Check condition of latch
feed.
pins.
Check roller setting for the
ductor.

Page 8-19
Guide to printing Issue 00 - Jan 2006

9 COLOUR VARIATION UP AND DOWN SHEET


The front to back colour of the sheet is not within tolerance.

Problem Cause Corrective Action.


Front to back colour Colour variation is caused by Change blanket.
variation impression quality being
Check tensioning practices.
poor. Most probably the
Ensure torque wrench is
blanket has collapsed
used at appropriate setting.
though excessive use or
excessive initial tension.
Roller settings are not Check inker and damper
correct. roller settings; ensure roller
hardness is within
specification.
Replace rollers if necessary.
Inker rollers are not running Check run out on
true. reciprocating distribution
rollers. Replace if
necessary.

Page 8-20
Issue 00 – Jan 2006 Disposal

Disposal
Hazardous waste 9-2
Definition 9-2
Description And Storage 9-2
Describing The Waste 9-2
Keeping Waste Safely 9-2
Containers 9-3
Waste To Be Collected 9-3
Using A Waste Carrier 9-3

Page 9-1
Disposal Issue 00 - Jan 2006

Hazardous waste

DEFINITION
A waste is hazardous if it is classified as:
Highly flammable
Irritant
Harmful
Toxic
Carcinogenic
Corrosive

DESCRIPTION AND STORAGE


To ensure proper handling of waste it is important that it is properly and clearly described
and that this information is passed on to successive holders of the waste. The following
is a checklist of relevant questions:
can the waste be safely mixed with other waste?
does the waste need special containment?
can it be safely incinerated?
can it be safely buried in a landfill site?
can it be transferred from one vehicle to another?

DESCRIBING THE WASTE


Documentation must be completed signed and kept by all parties if the waste is
transferred. The documentation must state the quantity of waste transferred and how it
is packed - whether loose or in a container.
There must also be a description of the waste, either separately or combined as a single
document. The description of the waste should always mention any special problems,
requirements or knowledge.
It is essential to label drums and containers with a description of the waste.
The description should include the name of the substance or substances, the process that
produced the waste, and where appropriate chemical and physical analysis.
The description must provide enough information to enable subsequent holders to avoid
mismanaging the waste.

KEEPING WASTE SAFELY


Waste holders must safeguard against:
corrosion or wear of containers;
accidental spillage or leakage;
accident or weather allowing waste to escape;
waste blowing away or falling off during transport;
scavenging by vandals, thieves, children or animals.

Page 9-2
Issue 00 – Jan 2006 Disposal

CONTAINERS
Waste handed over to another person should be in an appropriate container and should
be clearly labelled.

WASTE TO BE COLLECTED
Waste left outside premises should be in containers that are strong enough to resist
wind, rain and animal disturbance - especially food waste.
All containers must therefore be secured or sealed e.g. drums with lids, bags tied up and
skips covered. Use of weather-proof labels is an important consideration where waste is
stored outside.
Waste should be stored in suitable containment areas until collection.

USING A WASTE CARRIER


In almost all circumstances anyone carrying waste in the course of their business or for
profit must be registered with the local Environment Agency.

Page 9-3
Disposal Issue 00 - Jan 2006

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Page 9-4