1200 Coater Manual PDF

⊕
1200F Coater Plus
Operators and Engineers Manual

Issue 01 – Jan 2005 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
Fountain lacquer feed system
Coating head
Film weight
Fountain roll
Application roller
Pressure roller and scraper
Lacquer circulation
Main drive
Infeed
Delivery
4 Setting
Sheet settings
Machine setting
Pressure roller
Roller removal
Washing up
Page 0-1
Contents Issue 01 - Jan 2005
5 IsoBlade System
6 Anilox System
7 Operating Information
8 Maintenance
Maintenance schedule
Recommended lubricants
Maintenance instructions
9 Disposal
Hazardous waste
10 Parts lists
How to order parts
Page 0-2
Issue 01 – Jan 2005 Contents
THIS PAGE LEFT BLANK
Page 0-3
Issue 01 – Jan 2005 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 1-9
Power consumption 1-9
Page 1-1
Purpose and Planning Issue 01 – Jan 2005
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
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:
Ÿ running the machine without the guards in place
Ÿ making adjustments while the machine is running
Ÿ reaching into the machine to clean, lubricate or adjust without first shutting off
power
Ÿ wearing clothes that can become entangled in the moving parts of the machine
Ÿ not concentrating when operating the machine
Ÿ allowing people to crowd around the machine when operating or maintaining
Ÿ poor communication between operators during make-ready
Ÿ cleaning moving parts while the machine is running
Ÿ wearing rings or watches when operating the machine
Ÿ allowing grease and oil to remain on platforms or on the floor around the machine
Ÿ 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
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
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
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.
voltage between the live conductors for the sum of the 2nd
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 500µs 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
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
Capabilities and performance data

Key:- F1 = Front register coater
F3 = Plain coater
FS = Free standing coater
IL = In line coater
Sheet size Max 1143× 965 mm

Min 660 × 508 mm
Sheet thickness Max 0.6 mm
Min 0.13 mm
Coating area – roller Max 1137 × 965 mm
Coating area – application Max 1137 × 960 mm
Application roller (spot) Dia 329 mm
Application roller (plain) Max Dia 339 mm
Min Dia 319 mm
Application roller Length 1168 mm
Soft rubber underlay Size 965 x 1143 mm
Thickness 6.35 mm
Pressure roller Dia 329 mm
Varnish tank Capacity 80 litres
Mechanical speed Max 7500 sheets per hour
Physical dimensions and weight

Weight – F1/FS 9150 kg
Weight – F1/IL 7100 kg
Weight – F2/FS 8650 kg
Weight – F2/IL 6600 kg
Overall length – F1/FS 6190 mm
Overall length – F1/IL 4100 mm
Overall width 2590 mm
Overall height 1710 mm
Page 1-8
Required utilities
Compressed air 4 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 30.0 SCFM
(Std 0.86m3/min)
Electrical power 30 Kw
kW power details are given for guidance only, and will vary with different voltages. In
specific cases consult Crabtree of Gateshead.
Page 1-9
Issue 01 – Jan 2005 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 01 – Jan 2005
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
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
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
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 unpacked 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
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
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
Page 2-8
Issue 01 – Jan 2005 Technical Description
Technical description
Introduction 3-2
⊕
1200F COATER PLUS 3-2
Fountain Lacquer Feed System 3-3

Check Duct and Feed Roll Pressure 3-3
Check Duct and Feed Roll to Applicator Roll 3-3
Setting Application Roller to Compression Roller 3-3
Setting Fountain to Application Roller 3-3
The Coating Head 3-3
Film Weight 3-4
Fountain Roll Pressure Setting 3-4
The Application Roller 3-4
Pressure Roller and Scraper 3-5
Lacquer Circulation 3-5
Main Drive 3-5
Coater Infeed 3-5
Delivery Unit 3-6
Page 3-1
Technical Description Issue 01 - Jan 2005
Introduction
1200F COATER PLUS⊕

The 1200F Coater PLUS⊕ has been designed and developed to produce a range of
coating machines each contributing to the specific and stringent requirements demanded
by the metal decorating industry today. Model designations are as follows.
Model F1: - A front register coater incorporating a feed table complete with sidelay
and front register cylinder employing front lays and grippers for accurate
registration of the sheet. This machine is capable of registering to a
tolerance of ±0.015 mm.
Model F3: - A plain coater incorporating a short feed table with conveyor belts and
adjustable sideguides.
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
Fountain Lacquer Feed System

Check Duct and Feed Roll Pressure
Adjust roll 1 and 2 away from application roll 3. At normal operating speed with the
minimum gap setting pour suitable quantity of white enamel coating between rolls 1 and
2 so that the complete roll coverage is seen. If roll pressure is uneven, greying should
occur at the heavy pressure side. The spring pressure on the light pressure side should
be increased by turning the small centre adjusting spindle clockwise by an amount not
exceeding 45°. The exercise should be repeated until a visible equal coating is seen
across the rolls. Total spindle adjustment should not exceed half a turn otherwise
damage to the spring washers can occur.
Check Duct and Feed Roll to Applicator Roll
Adjust roll 2 to roll 3 and provide a minimum gap setting. Similarly adjust roll 1 to roll 2.
Again at normal operating speed pour white enamel into the ducts of rolls 1 and 2 to
obtain fountain roll coverage. Greying of the application roll 3 will then occur at the
heavy pressure side if the roll pressure is not even. The large hexagon head on the
adjuster on the light pressure side should be turned clockwise again no more than 45° to
produce an improvement of equal coating over the roll. Repeat if necessary again
keeping total adjustment to within half a turn to avoid spring damage.
Setting Application Roller to Compression Roller
Using handwheel ‘ A’adjust application roller to compression ensuring roller is parallel
after adjustment. Initial pressure is obtained when a 8mm parallel strip of lacquer is
transferred to the compression roller when tripped using handle ‘
B’.
Setting Fountain to Application Roller
Adjust fountain assembly to application roller using handwheels ‘ C’and again ensure that
fountain is set parallel to application roller. Initial pressure is again obtained when a 8mm
parallel strip is transferred to the application roller when the fountain roller is tripped on
and off the application roller.
The Coating Head

The complete coating head is of radical design. It is capable of providing the most
exacting film weight and possesses a unique feature in that metering and transfer rollers
are controlled by external hardened and taper ground bearers. The thickness of the film
weight on the sheet can, therefore be set to very precise limits, the setting being
obtained by adjusting the relative positions of the tapered bearer plates by means of
convenient hand wheels and vernier type scales.
The 3 roller coating head comprises 2 rollers which, together with their end plates form a
reservoir into which lacquer is pumped and a transfer roller which carries the film of
lacquer from the 2 reservoir rollers to the rubber covered application roller. The transfer
roller is gear driven from the application roller. The surplus lacquer from the reservoir
passes into a drip tray mounted beneath the coating head from where it is returned to
the lacquer tank by gravity.
The drive to the coating head can easily be disengaged to eliminate gear and roller wear
when the coater is being used as an in line conveyor to transfer the sheet from the
printing machine to the oven, without applying varnish.
Whilst the machine is being washed up the drive is disengaged and the rollers are rotated
by means of a hand lever to the drive side of the coating head.
Page 3-3
Film Weight
The gap between the second 2 coating head rollers controls the coating film weight. The
gap between the first 2 coating head rollers is set to maintain material feed. Both gaps
are varied as follows: -
i. Release the bearing screw
ii. Turn the knurled knob in the desired direction
The drums are graduated in 0.0025mm divisions and the scale 0.025mm divisions
corresponding to the gap (i.e. 1 complete turn of a drum alters the roller gap by
0.025mm). Setting should always be completed by turning the drum in a clockwise
direction to take up backlash. The clamp screws should be locked after setting.
Tapered bearers are used at each end of the fountain rolls. The bearers have opposed
tapers and are maintained in contact by spring pressure operating on the roll bearer
blocks. Automatically lubricated felt pads are provided on the bearers.
Fountain roll scrapers are maintained on the roll ends by spring tension and remain set at
all times.
Fountain Roll Pressure Setting

Start the machine, feed coating material and run at idling speed. Bring the coating head
into engagement with the rubber application roller by pressing the manual control button
on the mimic panel this will establish the coating coverage. Adjustment of contact
pressure is made by turning the chrome hand wheel on the feedside until the roller is
fully covered. This by worm and worm wheel adjusts both sides together but individual
adjustment can be made by pulling the small hand wheel outwards away from the other
against the light spring pressure. Ensure that the dowel is re-engaged after adjusting.
Care is required to avoid excessive pressure which would cause coating material to flow
into the stencil and would also upset film weight control.
The Application Roller

The application roller consists of a lightweight aluminium body covered with the
appropriate covering to suit the particular lacquers and solvents used by the metal
decorator. The body is mounted on stub shafts so the rollers need to be stored on racks.
The application roller can be removed from the machine very easily. First position the
runner rails beneath the roller ends, then a single securing bolt is removed from the
feedside and offside bearings. The feedside sprocket is withdrawn from the driving spigot
and the roller ends are allowed to rest upon the runner rails and rolled back to the
appropriate stops to allow removal. Carrying handles are then inserted into the bolt holes
at either end of the roller and it can be lifted out of the coater for replacement.
The application roller is driven from the coater gearbox via the pressure rollers by means
of a hardened gear train. A handle is provided on the operator’ s side of the machine,
which permits the application roller to be raised or lowered without disturbing roller
pressure setting.
For spot coating an indicating scale and pointer is fitted so that the start of print can be
correctly aligned in relation to the register dogs of the rear register model. Provision is
also made so that the roller can easily be adjusted for circumferential register relative to
the frontlays or pushers.
Page 3-4
Pressure Roller and Scraper

The pressure roller is made from a chilled iron casting which gives an exceedingly hard
and durable surface. The roller is ground to a very smooth finish.
The surface of the pressure roller is cleaned using a specially designed scraper blade,
which is supported by a lacquer trough. The overflow level of the lacquer ensures that
the edge of the scraper blade in contact with the roller is always fully lubricated to give
an exceptionally clean roller.
Beneath the pressure roller and lacquer trough is a lacquer tray, which collects excess
lacquer and returns it by gravity to the lacquer tank. The scraper blade & lacquer
collection trays are easily removed for cleaning purposes.
Lacquer Circulation
Lacquer is lifted from the floor standing lacquer tank, by means of a pump, to the lacquer
reservoir formed by the first 2 rollers of the coating and their end plates. Surplus lacquer
is collected by drip trays and returned by gravity to the lacquer tank as is the surplus
lacquer from the scraper reservoir.
The pipe work incorporates valves, which allow for flow adjustment and allow the
operator to pump the lacquer from the tank to an external lacquer drum. All lacquer
trays, piping, valves, reservoir and pumps must be manufactured from corrosive resistant
materials. The lacquer pump must not run dry for any length of time. Failure to observe
this precaution will cause pump wear since the coating material provides lubrication
properties. Should it be required to run the machine dry for any reason then the pump
must be switched off.
Main Drive
The coating machine is driven by a variable speed drive mechanism through timing belts
and a brake unit to the main drive gearbox, then by gears to the pressure roller and
application roller and by shaft and gearing to the coating head.
The main drive gearbox can be fitted with power take off shafts for connecting to the
feeder and oven conveyor. The main drive motor is of sufficient power to drive the
feeder, coater and oven conveyor.
When the coater is used in-line with other equipment, a synchronising gearbox drive can
be supplied for coupling this to coater. The coater can be disconnected for independent
cleaning and setting up and also for hand feeding very short coating runs. Optionally an
intermediate feeder may be provided which allows the in-line coater to run independently
of the press.
The synchronising drive between the coater and the oven is normally provided by the
oven manufacturer.
Coater Infeed
On model F1 coaters the sheet is passed from the feeder onto slowdown belts, which
hold the sheet against back pushers. The sheet is controlled laterally during its travel by
adjustable sideguides, which are positioned by hand wheels. The sheet is then presented
by the back pushers to the module mounted register cylinder (which incorporates the
register lays and grippers). This, in conjunction with the sidelay mechanism, causes the
sheet to be registered with great precision. Sheet transport is then provided to the
coating roller nip by means of magnetic pulleys assisted by drop runners and/or inserts in
the register cylinder.
Page 3-5
Delivery Unit
Supplied with the coating machine is a delivery unit having a section which can be
pivoted into a vertical position for access to the application roller, pressure roller and
scraper. This section is counter balanced for minimum effort. The conveyor belts are
driven from an output gear, which forms part of the coating machine.
Page 3-6
Issue 01 – Jan 2005 Setting
Setting
Sheet Settings 4-2
PUSHERS 4-2
SIDEGUIDES 4-2
SIDELAYS 4-2
Machine Setting 4-3

Pusher Chains 4-3
Pusher Springs 4-3
Pusher Alignment 4-3
Front Register Cylinder Grip 4-3
Front Lay Clearance 4-3
Sidelay 4-3
Griper Cam 4-3
Roller Removal 4-4
Washing Up 4-4
Page 4-1
Setting Issue 01 - Jan 2005
Sheet Setting
Pushers
Crawl the gripper cylinder until open grippers appear at sheetline. Insert sheet of size to
be run and holding sheet forward onto frontlay faces, crawl cylinder to T.D.C(top dead
centre) position.
Advance pusher support bar fully forward by turning adjuster hand wheel fully anti-
clockwise.
Pull out pusher clutch hand wheel and turn pusher adjustment hand wheel to bring
pushers to contact sheet. Apply 4.5mm further pressure to ensrue pusher compression
on rear edge of sheet. The pusher clutch hand wheel should then be pushed in to lock
the clutch.
With the sheet held by the grippers, which are still at T.D.C position, rotate pusher
support bar hand wheel clockwise until pushers start to drop away from the rear edge of
sheet. This pusher movement will also result in partial relaxation of tension in the pusher
springs.
Tighten locking handle on pusher support bar adjuster.
Sideguides
Mark Centre line on sheet. Place sheet on feed table with the centre line the sheet moved
3mm over the centre line marked on the centre sheet support towards the fixed sidelay.
Bring in sideguide on fixed sidelay side to contact sheet. The lead-in sideguide on the
spring sidelay side should then be adjusted to within 3mm of the sheet and the follow on
sideguide set a further 3mm away from sheet as shown.
Sidelay
With the cylinder remaining at T.D.C position, place sheet with its marked centre line on
feedtable and bring edge of sheet on fixed sidelay side to contact sideguide. With the
sidelay forward against the stop plate and maximum spring pressure applied on the on
the vertical operating rod, adjust the fixed sidelay until the centreline on the sheet moves
to coincide with the centre line on the centre sheet support. With the sheet central to the
infeed and spring sidelay forward against its stop plate, adjust the spring sidelay to
contact the sheet edge and apply additional 4.5mm movement to ensure spring
compression.
Page 4-2
Issue 01 – Jan 2005 Setting
Machine Setting
Pusher Chains
Check pusher chains at regular intervals for sign of undue slack and tension if necessary.
Pusher Springs
Maintain a maximum gap of 1.5mm to obtain maximum pressure form springs.
Pusher Alignment
Place sheet with parallel front and rear edge on infeed and with pusher clutch
disengaged, advance pushers to sheet moving sheet up to rear edge of sidelay stretcher.
Check parallelism of sheet edges to stretcher and adjust pushers to square sheet. Repeat
for all 4 pairs of pushers. On rear register machine check and adjust for even pusher
spacing.
Front Register Cylinder Grip

With gripper cylinder at T.D.C position ensure that 0.05mm feeler is lightly held between
gripper blade and the rest block. Check all grippers and adjust if necessary.
Front Lay Clearance

Ensure that adequate clearance of 0.5mm exists between the cylinder front lay faces and
the clearance face on the rest of the blocks.
Sidelay
Turn gripper cylinder to T.D.C position. Set sidelay cam by removing the 3 cap head
screws and rotate cam to the mid position(sidelay in) and secure with 1 screw. Adjust
spring pressure by loosening locknut ‘ A’and screw rod to obtain 0.25mm gap on each
rod. Still at cylinder T.D.C position, remove cap screw and rotate feedside cam
clockwise(offside cam anti-clockwise) until sidelay block is about to leave stop plate.
Replace screws and lock up. Adjust cams so that spring sidelay is free of the sheet before
fixed sidelay begins to retract from the sheet.
Gripper Cam
Turn the gripper cylinder to T.D.C position where the gripper blades should be0.02mm
clear of the rest blocks. Advance cylinder 10mm to 12mm past the T.D.C position where
grippers should now start to open. Adjust gripper cam if necessary.
Page 4-3
Setting Issue 01 - Jan 2005
Roller Removal
Adjust application roller initially to clear slide bars. Slide in roller support bars bringing
roller ends down to contact bars. Take nip off bolt at feedside(operators side), loosen
driveside bolt which in turn pushes the roller across to the driveside of the machine. Pull
roller assembly by means of feedside hand wheel to clear driveside bolt. Remove
feedside bolt,roll out roller to end stops and remove. (see also section headed “The
Application Roller”)
Washing Up
When washing up at the end of a run, pump all remaining material from the tank back
into a collecting drum. Fill up the well of the lacquer tank with wash-up
solvent(approximately 4 to 5 litres). Circulate this through the system, including the
fountain rolls, to clean off all surplus lacquer. Remove the contaminated solvent by
pumping back into a separate drum.
Stop the machine and pump motor and disengage the fountain roll drive gear on the
drive side of the machine. The coating head rolls can now be cleaned by using the hand
lever provided to pull the rollers round.
Take out the lacquer trays and clean, also clean out the lacquer tank.
Under no condition should the coating head rolls be cleaned whilst they are running as
there is an inward running nip between the duct roll and the metering roll.
Clean the application roller and bottom cylinder, rotating them via the crawl button
provided at the rear of the machine.
Page 4-4
Issue 01 – JAN 2005 IsoBlade System
IsoBlade System
SCRAPER SYSTEM (PATENTED) 5-2

SCRAPER BLADE CHANGE 5-3
Changing the blade 5-3
Replacing the blade and bedding-in 5-4
BLADE GRINDING 5-5
INTRODUCTION 5-5
Notes concerning blade grinding 5-5
Notes concerning blade bedding in 5-5
SCRAPER BLADE GRINDING MACHINE 5-6
GRINDING 5-7
HONING 5-8
SETTING THE BLADE 5-9
View of Blade in Fixture 5-9
View of Blade in Setting Gauge 5-9
Blade Lock Out – Scraper not in use 5-10
SETTING THE SPRING BLADE 5-11
View of Spring Blade 5-11
OPERATION OF PNEUMATICS 5-12
ISOBLADE MAINTENANCE 5-13
WASH UP PROCEDURE 5-14
CHANGING THE SCRAPER BLADE 5-15
Page 5-1
IsoBlade System Issue 01 – JAN 2005
ISOBLADE SYSTEM (PATENTED)
Designed to clean the compression roller and remove any traces of coating residue. This
eliminates contamination to the back face of the coated sheet.
Pressure Control Valve
The blade is mounted in an aluminium holder, which rests on and is free to pivot on a
beam straddling the machine. The lacquer trough has a steel spring plate forming the
front face. This plate is forced against the blade by twin pneumatic cylinders acting on
the trough, which in turn forces the blade against the compression roller. This
arrangement has the major advantage in that the loading and consequently the wear
across the blade are equalised. A pressure control valve is used to set the applied force
between the blade and the compression roller. Scraping air pressure is adjustable and
can be set to a minimum value to give reliable scraping while maximising roll and blade
life.
Page 5-2
SCRAPER BLADE CHANGE

NOTE
The blade, blade holder and support beam MUST be regularly cleaned.
The reference height of the steel spring blade is a nominal size, see page 11 for details.
Once set this is not altered.
Changing the blade
Drain plug
1 Remove the scraper trough drain plug and allow the trough to drain.
2 Retract the trough by simultaneously pressing both pushbuttons on the rear feed-
side control station for a minimum period of five seconds.
3 Fit a protective cover onto the working edge of the blade.
WARNING
Sharp edge. Will sever hands.
Fit the protective blade cover to the blade before
handling. Fit and use the supplied handles to
carry the blade and holder. Always use protective
gloves.
Page 5-3
Replacing the blade and bedding-in

The blade and blade holder are mounted on the crossbeam with the M8 cap screw heads
facing the compression roller.
The holder is axially positioned between the blocks on the beam, the non-operator side
block is factory set to the edge of the compression roller and should be used as the
datum side.
1 Make sure the trough is in the retracted position.
2 Ensure the blade has its protective cover fitted to avoid damage to the blade’
s
edge and to prevent accidents.
3 Pick up the new blade & holder with the handles as described previously, making
sure the bolt heads will face the roller and the nuts or clips on the handles are
secure.
4 Move the blade holder into position by using the handles to manoeuvre the holder
under the trough and up on to the beam. The reverse procedure from removing
the blade. Take care to protect the blade.
5 Engage the blade on the beam with the drive side firmly against the datuming
(non-operator side) stop, with the pin engaging in the slot/hole of the blade holder.
6 Some versions of the blade holder (fitted with a hole) require the feed-side stop to
be moved and positioned to engage its pin into the blade holder’ s hole. The stop
should then be locked in position.
7 Remove the protective blade cover prior to operation on the blade against the
compression roller.
8 Simultaneously press both pushbuttons on the rear feed-side control station for a
minimum period of seven seconds to engage the trough.
NOTE
Air cylinder rod lengths are factory set so that at 80psi (5 bar) excessive movement of the
actuation levers are prevented. This limits the blade deflections to between 8 to 9mm at
the spring blade tip.
8 For bedding-in, start initially at 30 psi and run the roll slowly at first, building up
speed to 6,000 sph. After one minute increase the pressure to 40 psi. After a
further minute at this speed increase the pressure to between 50-60psi (3.5-4 bar).
If there are lines of coating showing on the roller caused by nicks in the blade,
increase the pressure further to 80 psi and run it for as long as it takes to clear the
line. Badly ground blades with nicks could take up to 1 hour to clean the roller.
10 Drop pressure to just stop lacquer passing. This may only be 20psi for running.
11 As the blade wears the pressure may be increased.
CAUTION
The blade will be damaged if the machine is run
with the blade pressurised and the trough empty
or filled to below the blade tip.
Page 5-4
Blade grinding
INTRODUCTION
The following should be read and understood before attempting to set a new blade or
grind an existing blade.
NOTE
The factors for the failure of a blade not to bed in are primarily:
1. The blade is being sharpened with an over generous grinding cut, de-tempering the
blade.
2. The blade is being asked to repeatedly bed in.
.
Notes concerning blade grinding

Dry blade grinding does not de-temper the blades providing the grinding cut does not
cause excessive sparking; i.e. the cut is very light. Depending on the degree of blade
wear it could take up to 1 – 1½ hours to grind a blade. Grinding direction is important,
away from the sharp edge and not towards it. If the blades have their tip discoloured this
would indicate possible softening of the tip. Blades should be de-burred after grinding
and should have no nicks.
Blades must be maintained in the hardest condition possible, otherwise the blades will
not last and the bed-in time will be excessive. Anything longer than 20 minutes to bed-in
would indicate possible blade hardness problems or the blade has nicks in it. Nicks of up
to 0.025 mm (0.001”) deep can take up to an hour to bed in for.
Those blades that bed-in the quickest will generally last the longest during normal
running.
Blade angle is not too important within limits providing the blades are always ground to
the same angle. Crabtree recommend 30 degrees. For further information refer to
Section 4 GRINDING. The honing angle is steeper at 31 to 32 degrees. The honing does
not change the angle of the blade it only removes the burr and polishes the knife edge.
For further information refer to Section 4 HONING.
Notes concerning blade bedding in

During the process of blade bedding-in the surface contours of the roller and blade edge
become microscopically matched, mating together perfectly. During this period of blade
bedding-in the blade and roller wear rates are extremely high possibly 10 times or more
that for normal running. The bedding-in period is therefore the most damaging to blade
and roller and should be minimised. That is it should be done only once per blade. Every
time the blade is moved away from the roller or is even slightly disturbed the blade has
to be bedded-in again at high wear rates. This will dramatically shorten the life of the
blade and the roller. If this is common practice then blades will often be worn out before
they are bedded-in.
Blades should not be moved or even microscopically disturbed once they have bedded-in.
It is therefore good practice, if there are many changeovers, to leave the blade against
the roller without reducing the air pressure. In this way it is guaranteed the blade will not
be disturbed and will not require bedding-in
A good indication as to whether the blade has been worn out is to measure the width of
the wear land across the tip of the blade. This is the worn mating surface with the roll. If
the wear land has increased to 0.008 inch (0.20mm) then the blade is worn and should
be reground. Less than 0.005 inch (0.13mm) and the blade could be used again.
Page 5-5
SCRAPER BLADE GRINDING MACHINE

The grinding machine allows the scraper blades to be re-ground on site. The blades are
ground dry, consequentially the rate of metal removal per disc traverse should be small,
sparking should be minimal.
Prior to operation the following checks should be made
1 The grinding machine must be fully supported on a flat surface.
2 The running track and clamping unit must be kept clean.
3 All bearings are to be regularly filled with grease.
4 Inspect the grinding wheel for any signs of damage and replace if necessary.
NOTE
To avoid burning the blades, we recommend only Crabtree supplied grinding wheels, to
guarantee the correct grade of grit and the correct resin bond.
GRINDING
NOTE
The grinding process could take 1 – 1 ½ hours depending on the degree of damage and
wear to the blade. Typically it should take between 30 to 40 minutes.
CAUTION
Blades are extremely sharp so protective gloves must be worn when working
with the blades.
When grinding eye protection must also be worn.
The grinding of a scraper blade is as follows
1. Clean the clamps on the grinder

2. Clean the blade to remove all dried coating from both sides and the bevel edge.
Failure to do this will contaminate the wheel.
3. Place the blade loosely into the clamps and blow both sides out with air, removing
and particles.
3. Set the blade to a height of 7mm (using the adjustable blade supports), measured at
each end to the fixed clamp bar top face. Clamp the blade from the middle two
clamps then the outer ones.
4. Set the grinding head to grind the blade at 30deg.
5. Using a small piece of 3 mm strip steel about 12 mm x 60 mm, or an Allen key,
adjust the grinding wheel at one end to just contact the strip while the strip is hand-
held and just touching the bevel face of the blade. Traverse the grinding wheel to
the other end of the blade and attempt to fit the strip in the same position.
Whichever end of the blade is tightest, lower that end, do not raise the blade
towards the wheel. Eventually the finger held strip will be found to be a snug fit
between the grinding wheel and both ends of the blade bevel. The blade is now set.
6. Without starting the grinding wheel, at one end adjust the grinding wheel to the
blade to within 0.5 mm of the blade. Make sure the grinding wheel does not contact
the blade.
Page 5-6
7. Start the carriage and traverse to the other end of the blade and check the gap
between the stationary wheel and the blade to be 0.5 mm parallel.
8. If the gap is not 0.5 mm adjust the blade down at the closest end. Never adjust the
blade up to the wheel to get it parallel.
9. Start the grinding wheel.
10. With the grinding wheel at one end, dress the grinding stone with the tool provided
or use a hard piece of grinding stone and lightly touch the wheel.
11. Start the carriage.
12. Adjust the grinding wheel gradually so that a light cut is applied to the blade. A good
guide is that at least half the blade will be lightly sparking with the first cut.
13. Adjust the blade height if the cut is only at one end of the blade. Again this is done
with the wheel stationary moving the blade down at the high end.
14. Taking small cuts grind (of not more than a 1/16 of a turn of the handle) the blade
until the full length of the blade is being lightly ground.
15. Do not apply another cut until the first cut has largely sparked out.
16. The grinding wheel should be lightly dressed to remove metallic particles
approximately every 10 minutes of grinding.
17. When the full length is ground and a burr can be felt along the full length the wheel
should be dressed and a final cut should be made, this should be left to grind out,
with very few sparks.
18. Check that a burr can now be seen along the full length of the blade, attached at the
tip and folded over on the back face of the blade. All nicks should be removed.
19. Before honing check the blade carefully (& safely) with a printers glass to ensure all
of the wear land has been removed.
20. The blade must now be honed using a honing disk
Page 5-7
HONING
Honing of a scraper blade is as follows
1 The carriage should be stopped at the right hand side.
2 The grinding head should be raised and the honing wheel fitted.
3 The angle of the head should be increased by 1 to 2 deg to between 31 and 32
degrees.
4 Start the wheel and then the carriage.
5 Carefully adjust the handle brining into slight contact the disk and blade, a light
scraping sound will be heard when contact is made.
6 With the fine hand stone (Arkansas stone) running along the blade clamp and flat
face of the blade to lift the burr up into the path the honing disk so that the honing
disk removes the burr as it traverses.
7 No 6 is repeated until the burr is completely removed. This is a very important
process in developing a clean knife-edge.
8 Checking for burr removal can be done by lightly drawing a 0.25 to 0.3mm feeler
gauge edge along the blade. The feeler blade edge should be presented at 45
degrees to the edge and drawn alon the blade. First in one direction then the other.
Any nicks will catch the feeler.
9 On a long life blade a nick of 00.025 mm (0.001”) will take around one hour to bed-
in.
10 Check the blade to see if there is a need for any light hand dressing with a hand
stone.
11 Fit a safety strip to the knife sharp edge and remove from the grinding machine.
Page 5-8
SETTING THE BLADE

The blade will require resetting after regrinding or replacing. A fixture and setting gauge
are provided to accurately set the scraper blade, this fixture should be permanently
mounted on a bench or table. It is advisable to mount the setting fixture at an angle so
that the blade holder drops down on to the datum rollers.
1 Place the blade and holder on the fixture with the ‘V’of the holder against the two
end gauging blocks and clamp in position with the toggle clamp.
2 Remove the protective cover from the blade.
3 Loosen the clamp screws.
4 Turn the adjusting set screws to set the blade to the gauge.
5 Align the blade to the holder on the right hand (drive-side) edge, so that the blade
and holder edges are flush. (Some setting fixtures are fitted with a datum stop).
6 Retighten the clamp screws.
7 Replace the protective cover.
View of Blade in Fixture
Blade Holder
Clamp Screw (9 Off) Datum Stop
Toggle Clamp
End Gauge Block
View of Blade in Setting Gauge
Setting Gauge
Blade
Holder
Clamp Screw
Adjusting Screw
End Gauging Block
Page 5-9
BLADE LOCK OUT – WHEN SCRAPER NOT IN USE (NOT APPLICABLE TO

FASTREADY COATER)
When the scraper blade is not in use it can be locked away from the compression roller
Strap in vertical position

locks blade away from
compression roller
The strap is held in place through friction force so by sliding away from the blade holder
to a horizontal position, the blade can then be applied to the compression roller.
IMPORTANT NOTE
The strap must be moved to the horizontal position before the pneumatic
sequence for applying the spring blade can be initiated
Page 5-10
SETTING THE SPRING BLADE

The thin spring blade is mounted to the lacquer trough. It is factory set and should
never be adjusted. If for some reason it should be removed or replaced it is re-set to a
nominal height of 76 mm. This is the exposed length of the blade, protruding from the
trough. The spring blade should be finally positioned so that the tip just touches the
angled edge of the bevel on a pre-set scraping blade, when in the scraper ‘
ON’position.
Spring blade/Blade
Relationship
Spring blade tip
on land of bevel
View of Spring Blade

(Feed-side End Plate Removed for Clarity)
End Plate
Trough
Spring Blade
76mm nominal
Page 5-11
OPERATION OF PNEUMATICS (NOT APPLICABLE TO FASTREADY COATER)
Sequence of Operation
1. Press both switches simultaneously and keep depressed for FIVE seconds
2. The blade will now be deflected against the compression roller
3. If the sequence is interrupted before the time delay has elapsed (i.e. releasing one of
the switches) the cylinders will exhaust and the scraper trough will return to its rest
position – you should now follow on from step 1 again
4. When the trough is engaged it can be returned to its rest position by pressing both
switches simultaneously and then releasing again
5. The system is now ready to commence sequence again
Page 5-12
ISOBLADE MAINTENANCE
One of the biggest issues, is that of cleanliness on critical components.
1. Coating should be kept off the pneumatic rams.

2. The pivot surface on the top of the support beam and drive-side datum stop should
be wiped clean every blade change as a matter of procedure. This is not an
option; it is critical that this is kept clean.
3. The back of the spring blade should be wiped clean to base metal every time the
blade is changed. Lacquer build up here causing leakage and poor force
transmission from the spring blade.
4. Monthly, the spring blade deflection should be checked to be 8 mm at its tip (at 80
psi and more), say every PM day. This should check for any problems with sticking
rams and the associated degrading scraping performance.
5. Customers should be encouraged to inspect their own blades, knowing them to be
good before they are installed. Use the blade inspection procedure outline in the
blade grinding section.
6. Blades should have protection fitted at all times until the blade and holder is finally
installed against the scraper cylinder. This is necessary to avoid damage to the
delicate blade edge as the blade is installed and also as it is removed. Any damage
to the blade as it is removed will increase the amount of subsequent grinding, cost
more and shorten blade life. Of course safety is also an issue here.
7. To keep a regular stock of blade protectors to replace those that become damaged.
8. The aluminium setting gauges used in blade setting should not be used too heavily
as they cut easily. They are used as a simple setting gauge, 0.5 mm accuracy is
more than adequate. It is important that operators are well trained on blade setting,
in that it is better to have the gauge slack than tight on the blade. Also operators
need to be clear over the use of the side datum pin for aligning the blade to the edge
of the holder at the drive side.
9. The blades should be allowed to bed-in for at least 45 minutes before attempting to
change to another blade. Providing all the nicks in the blades are controlled to be
less than 0.0005” and the blades are carefully protected all blades should bed-in in
less than 45 minutes.
10. Spare blades should always be held in reserve fully assembled and ready for use, to
save time and to avoid having to assemble a blade holder under time pressure.
11. All blades should be clearly marked with both part number and individual
identification. Ideally the customer should keep a log of blade performance to flag
up any potential scraping problems.
12. The handles used for installing and removing the blade should be occasionally dipped
in solvent to clean them. It is important the toggles remain loose, to fall and lock the
blade holder on, safety issue.
Page 5-13
WASH UP FOR AN ISOBLADE SYSTEM
NOTE
The following procedures require protective gloves and clothing to be worn.
1. Run down the lacquer coating system starting at the head. This requires the
chamber or rollers to be drained of lacquer. The surface lacquer should be taken
away by the rubber roller on to the bottom cylinder.
2. Add solvent to the lacquer coating system to flush the rollers or anilox system.
Use a solvent that will not contaminate the lacquer in the scraper trough.
3. Disengage the coating head from the rubber application roller to allow the
transfer of the coating and solvent to the scraped bottom roller.
4. When the application roller and head rollers have largely cleaned stop the
machine. These rollers may then be removed if required.
5. With the machine stopped the lacquer trough may now be drained to remove the
lacquer. Ensure all relevant protective gloves and clothing are worn.
6. The bottom roller may be slowly crawled with machine inch function, to clean the
bottom cylinder. One revolution should be sufficient, prolonged running in this
condition may damage the blade.
7. Moving the scraper blade out of contact with the roller should be avoided if
possible; otherwise some degree of re-bedding in will have to take place.
Therefore ideally the air pressure should not unnecessarily be removed from the
pneumatic cylinders.
8. If the blade is held precisely and rigidly between the 2 stops on the support
beam it may be possible to remove the air pressure from the spring blade,
without unduly disturbing the scraping blade. There will of course be some
limited re-bedding in of the scraper blade when the spring blade pressure is re-
applied. In order to prolong blade life it is recommended to only disturb the
blade a minimum number of times. That is, do not withdraw the trough if at all
possible. NOTE: It is possible to re-bed in long life blades a number of times
without wearing the blade out completely, however re-bedding a blade does
shorten blade tip life.
9. The spring blade and the trough can now be wiped with solvent and cloths to
remove all traces of lacquer and solvent.
10. The bevel edge of the scraper blade should be carefully wiped with solvent and a
cloth, taking care not to disturb it in any way and certainly do not move it out of
contact with the roller.
11. If the trough and spring blade have been backed away, this is the time the
trough cheeks and spring blade can be thoroughly cleaned. Make sure all parts
of the spring blade, trough are clean and free from all dried coating. The trough
should now be re-engaged with the scraper blade.
12. When finished replace the plug in the trough and fill with the new coating for the
next job.
NOTE
The machine should not be run with the blade against the cylinder and the trough empty
as this will damage the cylinder and blade.
Page 5-14
CHANGING THE BLADE ON AN ISOBLADE SYSTEM
NOTE
When the scraper blade requires changing the opportunity should be taken to clean the
trough cheeks, spring blade, scraper blade holder, the scraper blade support beam and
stops. Make sure all parts of the blade, trough and support beam are clean and free from
all dried coating.
The machine should not be run with the blade against the cylinder and the trough empty
as this will damage the cylinder and blade.
It is more efficient to plan the blade change while a job changeover has to be done.
Procedure
1. Stop the machine.
2. Proceed as for a job changeover, including wearing the protective gloves and
clothing.
3. Drain the trough and retract it.
4. It is recommended suitable protective gloves and clothing is worn during this
procedure.
5. Using the supplied handles pass these over the trough. This procedure requires
2 people, one person for each handle.
6. Locate toggles in blade holder holes at each side and ensure the toggles drop to
lock the blade on.
7. Before lifting the blade and holder ensure the blade protection strip is fitted.
8. Loosen operator side clamp.
9. Move the blade holder to first to the operator side to disengage drive side
location pin by sliding along the beam.
10. Lift the non-operator handle first up to raise this side of the blade holder up and
towards the trough and follow through with the operator side handle. Drawing
the blade and holder over the trough. The blade holder should be guided over
the top of the trough between the side cheeks.
11. The blade holder should be place down on a level surface before the handles are
removed.
12. See procedure for changing the blade and setting it in the blade holder.
13. When the scraper blade is changed this is the time the trough cheeks, spring
blade, scraper blade holder, the scraper blade support beam and stops can be
thoroughly cleaned. Make sure all parts of the blade, trough and support beam
are clean and free from all dried coating.
14. Before replacing the blade and blade holder back on to the support beam ensure
the blade holding handles are securely fitted with the toggles engaged and the
blade protective strip is fitted.
15. The installation of the blade is the reverse of removal, described above. The
person holding the operator’ s side handle enters the blade holder over the
Page 5-15
trough. The other person follows through with the other end, finally lowering
this end down on to the beam.
16. Slide the holder towards the non-operator side to engage the location pin of the
datum stop in the side of the blade holder.
17. Move the adjustable stop firmly up towards the blade holder locating the pin and
locking in position.
18. Remove the protective strip and press the blade towards to roller to make tip
contact.
19. The trough can now be engaged and filled to continue with the changeover
procedure.
Page 5-16
Page 5-17
Issue 01 – JAN 2005 ANILOX Coating System
Anilox Coating Head

Technical Description 6-2
GENERAL 6-2
ANILOX ROLLER 6-3
DOCTOR BLADES & SEALS 6-4
SIDEFRAMES 6-6
ADJUSTMENT MECHANISMS 6-7
LACQUER RETURN 6-8
Operator Setting 6-9
SETTING ANILOX ROLLER TO APPLICATION ROLLER 6-9
SETTING CHAMBER BLADES TO ANILOX ROLLER 6-10
Operator Maintenance 6-12
REPLACING CHAMBER SEALS 6-12
REPLACING BLADES 6-14
CHANGING THE ANILOX ROLLER 6-16
CLEANING THE UNIT 6-19
Factory Settings 6-20
SETTING THE CHAMBER HEIGHT 6-20
SETTING THE PNEUMATIC STOPS 6-22
SETTING THE CHAMBER STOPS 6-24
Maintenance,cleaning & inspection 6-25
Page 6-1
ANILOX Coating System Issue 01 – JAN 2005
1.0 Technical Description
GENERAL
CAUTION
The coating head must not be ran without an anilox roller fitted.
Unless, the drive to the coating head is disengaged.
The Crabtree Anilox Coating Head allows a precise coating film weight to be applied
accurately and consistently to the sheet. The anilox head comprises of a chamber
fitted with scrapers top and bottom, and an anilox roller etched with the required cell
pattern. In order to achieve the desired film weight thickness the correct anilox roller
must be used with the applied film weight being a function of the anilox roller cell
pattern the specific gravity, viscosity and percentage of solids of the coating material.
During operation, the doctor blade chamber is filled with coating material from the tank
partially submerging the anilox roller. The cells of the anilox roller fill with material and
the excess is scraped from the surface by the doctor blade, leaving the precise amount
of coating in the cells. On contact with the application roller the material is released
from the cells onto the roller and subsequently applied to the sheet. Coating material
that is not used is re-circulated through the system back into the tank.
Page 6-2
ANILOX ROLLER
The anilox roller is engraved with thousands of microscopic cells over its surface. Each
cell is identical and therefore holds the same amount of coating. There are various
types of cell patterns in general use, these include:
1 Quadrangular cell
2 Pyramid cell
3 Hexagonal cell
4 Tri-helical cell
In order to achieve the correct film weight for a particular type of coating the correct
anilox roller must be chosen. This depends upon several factors including the cell
pattern, the solid content and specific gravity of the coating material. If in doubt about
the correct roller to use contact Crabtree of Gateshead for further information.
The journal ends of the Crabtree anilox roller have precision couplings for accurate
running at high speed. A steel ring is filled to each end of the roller, on which the roller
should be supported during storage. An M12 tapped hole is provided in the rings for
lifting purposes.
Page 6-3
DOCTOR BLADES AND SEALS
The doctor blade chamber is a precision-machined component that holds coating

material and houses the scraping blade at its optimum-working angle. It is designed
to allow the scraping blade to be positioned in precisely the same position every time it
is replaced. The blade located at the bottom of the chamber merely contains the
coating material within the chamber. Whereas the top blade accurately doctors the
coating from the anilox roller ensuring the cells contain the desired amount of coating.
Top doctor blade
Seal
Spring clips
Bottom doctor blade
Sealing of chamber
Seals are provided within the chamber to prevent leakage from the ends of the
chamber during operation. These seals contact the external diameter of the anilox
roller and doctor blades totally enclosing the coating material within the chamber. The
coating material is pumped into the chamber through an inlet at the centre and is
drained away through two manifold blocks positioned close to the ends.
The doctor blade chamber can be rotated away from the anilox roller if the scraping
blade needs replacing or for cleaning purposes. This is achieved using the pneumatic
cylinders located on each side of the main frame. The chamber will return to exactly
the same position when rotated back due to the pivot lever contacting pre-set stops
and therefore no further adjustments are necessary before resuming coating.
Page 6-4
Pneumatic cylinder
Pre-set stop Chamber pivot
Anilox chamber pivot
Page 6-5
SIDE FRAMES
The anilox head comprises of a complete assembly mounted between two side frames
that attach to the coater via a pivot pin at each side. The standard Crabtree
adjustment mechanism is mounted onto brackets attached to the side frames and is
used to provide the adjustment between the application roller and the anilox roller.
A bearing housing is mounted in each of the side frames. This bearing provides
support and an accurate mounting for the anilox stub shafts, which are used to mount
the anilox roller.
Fastened to the rear of each of the side frames is an adjusting hand knob for setting
the correct pressure between the chamber doctor blades and the anilox roller.
The coating lacquer trays are mounted between the inner side frames on slideways for
easy removal.
Anilox/Application
adjustment
Chamber adjustment
knob
Bearing housing
Side frame
General view on FS frame
Page 6-6
ADJUSTMENT MECHANISMS
A slide adjustment mechanism is used to set the anilox chamber and hence the doctor
blades axially to the anilox roller and is operated via a hand knob on each of the side
frames. The hand knob turns an adjustment screw, which passes through a tapped
hole in the pivot block. Turning the handle moves the chamber and doctor blades
forwards and backwards within the aperture in the side frame. The pivot block carries
a mounting bar that accurately locates the anilox chamber via three quick release
knurled screws. The chamber should be adjusted parallel to the anilox roller by rotating
both hand knobs simultaneously to prevent the slides from locking up.
Excessive pressure should not be applied to the doctor blades, as this will greatly
reduce the life of both the anilox roller and the blades.
Adjusting hand knob
Pivot block
Chamber pivot Slide way
Chamber adjustment
The coater adjustment handwheel is used to set the anilox roller to the application
roller, see separate coater manual for detailed setting instructions.
Page 6-7
LACQUER RETURN
The lacquer is re-circulated through the chamber back to the tank via a return
tray.
The return tray is used primarily to return the lacquer to the tank but it also
catches any drips that may occur if the anilox chamber is overpressuried. An
additional function of this tray is to catch any coating mist generated from the
application roller, preventing it from contaminating the sheet. This mist is known
to occur with certain coatings during long production runs. The tray is mounted
on a slideway at each end and hence is pulled back towards the infeed for quick
removal.
Page 6-8
2.0 Operator Setting
SETTING THE ANILOX ROLLER TO THE APPLICATION ROLLER
CAUTION
Excessive contact pressure on the anilox roller may result in
premature failure to the anilox roller bearings.
The anilox and application rollers should be set so there is an even pressure
between the rollers along the entire length of the rollers. Any eccentricity of the
application roller needs to be compensated for in the pressure between the
application roller and the anilox roller. To achieve this the following setting
procedure should be followed.
1. Trip the anilox roller onto the application roller.
2. Adjust the contact pressure across the full length of the roller by turning the
outer hand wheel clockwise to reduce pressure and counter-clockwise to
increase pressure.
3. Adjust the contact on the driveside of the roller by pulling the inner knurled
adjustment screw outward and rotating anti-clockwise to reduce pressure and
clockwise to increase the pressure.
4. Return the knurled adjustment to the centre position after adjustment.
5. Adjust the contact on the feedside of the roller by pulling outwards and holding
the inner knurled adjustment screw then rotating the outer hand wheel anti-
clockwise to reduce pressure and clockwise to increase the pressure.
6. Return the knurled adjustment to the centre position after adjustment.
7. Adjust the pressure between the anilox and the application roller until the
coating coats the application roller fully, then increase the pressure by a further
quarter of a turn of the knurled adjustment screw.
NOTE
If swelling occurs on the application roller, retract the anilox roller from the
application roller and reset.
Page 6-9
SETTING THE CHAMBER BLADES TO THE ANILOX ROLLER
CAUTION
Excessive pressure on the doctor blades will result in
reduced scraping efficiency and premature blade wear.
The angle of the anilox Chamber to the anilox roller is set such that the bottom
blade contacts the roller before the top doctoring blade. This is done so that the
top blade can be adjusted clear of the roller while the bottom blade always
remains in contact with the roller to seal in the coating. To adjust the blades
relative to the roller the following procedure should be followed.
1. Rotate both the adjusting hand knobs in a clockwise direction until the top
blade is touching the anilox roller.
2. Turn on the lacquer pump to introduce coating into the doctor blade chamber.
3. Turn the flow control lever to set the flow into the chamber.
NOTE
Do not set the flow at full pressure as this will cause flooding.
4. Start the anilox roller rotating.
5. Rotate both the adjusting hand knobs until the desired scraping pressure is
achieved, this should be the minimum amount of pressure to maintain the
doctoring effect of the blade on the roller.
NOTE
Adjust the hand knobs simultaneously so as to maintain the chamber
parallel to the anilox roller and prevent it from locking up.
Page 6-10
Adjustment hand knob

for anilox chamber
Anilox roller to application

roller adjustment hand wheel
Inner hand wheel adjusts

DS roller nip pressure
Chamber adjustment hand knob
Page 6-11
3.0 Operator Maintenance
REPLACING CHAMBER SEALS
WARNING
Sharp edges. Will cut hands. Always fit a protective cover and
wear protective gloves when handling a chamber fitted with
blades.
The end seals in the chamber will require replacing when they become worn or
damaged and allow coating to pass. The seals can either be replaced in situ on
the machine or by removing the chamber from the machine. To replace the seals
the following procedure should be followed.
1. Ensure the machine has stopped and the chamber is fully drained, if not
check the pump is stopped and the chamber drain handles are rotated
towards the FS frame.
2. Using the pneumatics rotate the chamber into its retracted position.
3. Fit a protective cover to each blade.
4. Loosen the three-knurled clamp screws at the rear of the anilox chamber and
lift the chamber clear of the machine via the lifting handles.
5. Using the supplied circlip pliers remove the outer sprung clip.
6. Remove the seal by rotating to clear the blades.
7. Fit the new seal, ensuring the lip is fitted to the inside of the chamber.
8. Replace outer sprung clip using the circlip pliers.
9. Refit the chamber into the machine and tighten the three-knurled clamp
screws.
10. Remove the protective cover from the blades and trip the chamber to the
anilox roller using the pneumatics.
11. Check the position of the doctor blade relative to the anilox roller and adjust
if necessary (see section 2.0).
12. Check the chamber drains handles are towards the DS frame, the chamber is
Page 6-12
now ready to fill with coating and run.
If both blades are removed from the chamber then the seal can be removed
without the need to remove the outer sprung clip.
Outer spring clip The seal lip is fitted

to be removed towards the inside of
the chamber
Fitting of chamber seal
Page 6-13
REPLACING BLADES
WARNING
Sharp edges. Will cut hands. Always wear protective gloves
when handling blades, and fit a protective strip when
tightening blade-clamping screws.
Periodically the doctor blade should be checked for signs of wear. The doctor
blade must be replaced if the smooth internal bevel is worn or shows signs of
damage. The blades can either be replaced in situ on the machine or by
removing the chamber from the machine. To change a blade the following
procedure should be followed.
1. Ensure the machine has stopped and the chamber is fully drained, if not
check the pump is stopped and the chamber drain handles are rotated
towards the FS frame.
2. Using the pneumatic cylinders rotate the chamber into its retracted position.
3. Loosen the three-knurled clamp screws at the rear of the anilox chamber and
lift the chamber clear of the machine via the lifting handles.
4. Fit a protective cover to the blades.
5. Loosen the blade clamping screws using a 10mm A/F spanner.
6. Remove the old blade by gently pulling the blade down from the clamp.
7. Fit the new blade, this should have been previously been cut to the correct
length and fitted with a protective cover.
8. Position the new blade under the clamping strip with the bevelled edge facing
INWARDS.
9. Ensure the blade is pushed back into the step in the blade housing.
10. Re-tighten the blade clamping screws to a maximum torque of 4 Nm.
11. Repeat this procedure for the other blade.
12. Replace the chamber into the machine and retighten the three knurled
screws.
Page 6-14
13. Remove the protective covers from the blades.
14. Using the pneumatic cylinders rotate the chamber to its original position.
15. The setting of the doctor blade to the anilox roller should be checked and
adjusted as in section 2.0 prior to running.
10mm A/F spanner
Blades fitted with protective

covers
Replacement of doctor blades
Page 6-15
CHANGING THE ANILOX ROLLER

Removal
CAUTION
Take extreme care when changing the anilox roller. Collisions
will seriously damage the engraved cell pattern on the surface of
the roller.
1 Retract the anilox roller from the application roller, using the trip lever.
2 Partially loosen the draw bolts on both of the stub shafts (about a
quarter turn only), then disengage the drive to the Aniilox head at the
bevel gearbox. This allows the roller to be turned by hand.
3 Remove the top drip tray. The indexing plunger is on the FS. Retract and
twist the plunger and lift the tray away from the pins on the DS.
4 Thoroughly clean the anilox roller, and wrap the protective blanket
around the roller.
5 Fit the M12 eyebolts into the rings on the ends of the roller.
6 Advance the roller support bars by turning both handles in towards the
centreline of the machine.
7 Bring the hoist equipment into position. Place the shackles into the
eyebolts, and take the weight of the roller on the hoist.
8 Slacken the draw bolts on the DS ends of the stub shafts, and pull the
bolt fully back. To hold it in the fully back position, unscrew the bolt
(turning counter-clockwise) a further half turn.
9 At the FS, pull the stub shaft to move the roller so that the ring is against
the stop block on the FS – the movement is about 8mm. Slacken the
draw bolts on the FS ends of the stub shafts, and pull the bolt fully back.
To hold the bolt in the fully back position, unscrew it (turning counter-
clockwise) a further half turn.
10 Lift out the anilox roller, taking care not to damage the roller and place
the roller on to a roller trolley or roller racks. Support the roller on the
rings at the roller ends. Fit the end cover plates to protect the couplings
during storage.
Page 6-16
WARNING The coating head must not be ran without an anilox

roller fitted, unless the drive to the coating head is disengaged.
Replacement of the Anilox Roller
1. Inspect the anilox roller, ensuring that its surface is clean. Remove the end
cover plates (if fitted) and check that the couplings are clean and free from any
debris. Note that dirt in the coupling teeth will cause excessive run-out of the
roller, and general operating problems.
2. Screw the M12 eyebolts into the anilox roller end rings.
3. Inspect the anilox head couplings, ensuring that they are clean and free from
any debris. It may be beneficial to use an airline to blow away any foreign
material. Ensure that the O-ring seals are in place. (spare O-rings are provided)
4. Ensure that the FS stub shaft is retracted, that both the draw bolts in the stub
shafts are fully retracted, and that both sets of roller support bars are
advanced.
5. Lift the anilox roller into the machine and lower it carefully on to the support
bars. Keep some tension on the hoist.
6. Screw in the DS draw bolt, pulling the roller axially into the coupling - this is
easier if the bevel gear drive to the head is re-connected.
7. Push in the FS stub shaft to engage the couplings. Screw in the FS draw bolt to
lock the stub shaft to the roller. (If the operator chooses to fit this stub shaft
first, toggle holes are provided in the stub shaft endplate to ensure the draw
bolt can be fully tightened.)
8. Retract both sets of support bars.
9. Lower the hoist, and remove the lifting slings and the eyebolts. Refit the top
drip tray
Notes on the Storage of Rollers.
1. Support the rollers on the rings at the end of the rollers, not on the body of the
roller.
2. Fit the end cover plates to keep dirt out of the coupling teeth.
Page 6-17
FS draw bolt
FS stub shaft
Support bar operating handle
FS Stub shaft assembly
Plunger on FS
Top drip tray

Drive side stub shaft showing
the support bars, the coupling
teeth and the central draw bolt
Page 6-18
CLEANING THE UNIT
WARNING
Hazardous substances. Will damage eyes, respiratory tract and
skin. Always wear protective clothing when cleaning.
WARNING
Sharp edges. Will cut hands. Fit a protective cover to the blades
and always wear protective gloves when cleaning the chamber.
1. Pump solvent through the chamber whilst the unit is still running in the
coating position (this will clean the pipework, doctor blade chamber, blade
and anilox roller).
2. Stop the coater and the lacquer pump.
3. Fully open the drain pipes at each end of the doctor blade chamber by
rotating towards the FS frame, to drain the system.
4. Remove the infeed pipe from the back of the doctor blade chamber.
5. Retract the doctor blade chamber using the pneumatic cylinders and fit
protective covers to the doctor blades.
6. Thoroughly clean the anilox roller.
7. Thoroughly clean the doctor blade chamber, this can be carried out in situ or
by removing the chamber from the machine. This should be carried out with
the chamber seals removed (see section 3.0).
8. Inspect the chamber seals and doctor blades for signs of wear and replace
where necessary.
9. Thoroughly clean the lacquer catchment trays and down chutes.
Page 6-19
Factory Settings
WARNING
Sharp edges. Will cut hands. Always fit protective covers and
wear protective gloves when handling a chamber fitted with
blades.
SETTING THE CHAMBER HEIGHT
The chamber height is factory set at Crabtree of Gateshead, however if it needs

to be reset for example after a major strip down and overhaul the following
procedure should be applied.
1. Fit the end seals to the chamber.
2. Fit the chamber into the three mounting bars and secure with the knurled
screws.
3. Trip the chamber onto the anilox roller using the pneumatics.
4. By looking through the cut out in the side frame determine if the chamber
needs to be raised or lowered by comparing the anilox roller diameter to the
profile of the seal.
Seal profile to be
matched to that of the
roller
Setting the height of chamber to the anilox roller
Page 6-20
5. Adjust the height of the chamber by slackening the securing screws and
tapping the chamber up or down with a plastic hammer. This will cause the
mounting bars to move on the slots in the bars. There are three sets of two
securing screws to attach the mounting bars to the beam.
Mounting bar securing screws
6. Once the chamber seals have been matched to the roller diameter the
securing screws should be fully tightened. Check that the mounting bars are
square to the chamber by removing and refitting the chamber. If the
chamber is difficult to remove / replace then the mounting bars should be
adjusted square.
Page 6-21
SETTING THE PNEUMATIC STOPS
The pneumatic stops are factory set at Crabtree of Gateshead, however if they
need to be reset for example after a major strip down and overhaul the following
Checking of the stops
1. Using the pneumatics, trip the chamber onto the anilox roller.
2. Set the chamber to the anilox roller (see section 2.0) so that the bottom
blade just contacts the roller. If set correctly the top blade should be clear of
the anilox roller by between 0.25mm to 0.5mm.
Setting of the FS stop
3. Remove the pneumatic cylinder cover.
4. Using the pneumatics pivot the chamber clear of the anilox roller.
5. Slacken the clamping screw on the eccentric stop.
6. Using a 22mm A/F spanner rotate the eccentric, this alters the position where
the chamber pivot bracket contacts the top and hence alters the angle of the
chamber.
Chamber pivot
bracket Clamping screw
Eccentric stop adjusted

with a 22mm A/F spanner
Setting of the eccentric stop
Page 6-22
7. Tighten the clamping screw to lock the eccentric, trip in the chamber and
recheck the position of the doctor blades to the anilox roller.
8. Repeat steps 5 to 7 until the desired clearance of top to bottom blade is

achieved.
9. Refit the pneumatic cylinder covers.
Setting of the DS stop
10. Setting the DS stop should be carried out at the same time as setting the FS
stop.
11. Remove the pneumatic cylinder cover.
12. Slacken the clamp screw and adjust the eccentric until it just contacts the
chamber pivot arm and retighten the clamp screw.
13. Refit the pneumatic cylinder cover.
Page 6-23
SETTING THE CHAMBER STOPS
The chamber stops are used to limit the movement of the chamber towards the
anilox roller. If this stop is not fitted correctly then the chamber could damage
the anilox roller when the chamber is pivoted away from the roller.
Screw used to limit the

travel of the chamber
Setting the chamber stops
The chamber stops are factory set at Crabtree of Gateshead, however if they
need to be reset for example after a major strip down and overhaul the following
1. Set the chamber doctor blades to the anilox roller (see section 2.0).
2. At this nominal run position adjust the stop so the head of the screw is 3mm
from the bottom face of the slideway.
3. Tighten the nut to lock the screw in position.
4. Repeat steps 2 and 3 for the stop on the other side of the machine.
Page 6-24
5.0 Maintenance, cleaning and inspection
MAINTENANCE SCHEDULE
LOCATION MAINTENANCE TASK FREQUENCY GENERAL

TO BE PERFORMED COMMENTS
(See Instructions for
12 MONTHLY
further details)
3 MONTHLY
6 MONTHLY
MONTHLY
WEEKLY
DAILY
Bearing end Grease the grease * FS and DS
caps nipples Bearing caps
Anilox roller Replace *
bearings
ROUTINE CLEANING AND INSPECTION SCHEDULE
LOCATION CLEANING TASK TO FREQUENCY GENERAL

BE PERFORMED COMMENTS
(See Instructions for
further details) 12 MONTHLY
3 MONTHLY
6 MONTHLY
MONTHLY
WEEKLY
DAILY
Scraper blade Inspect and replace if *

worn
Anilox unit Wash with solvent * Wear suitable
and thoroughly clean protective
clothing.
Anilox roller Remove and wash in *
a cleaning bath Avoid contact
with solvents
Anilox Strip down and *
pipework thoroughly clean
Page 6-25
BEARINGS
Grease nipple for FS

bearing
Position of FS grease nipple
1. Apply grease using a grease gun to the grease nipples located on the FS and
DS bearing end caps, as per the time intervals given in the maintenance
schedule.
Page 6-26
Issue 01 – JAN 2005 Operating Information
Operating information
Modes of operation 7-2
Pre-start checks 7-2
Pre-start warning 7-3
Full line starting 7-3
Re-start after a crash 7-3
Crawl 7-3
Sequential line starting 7-3
Location of pre-start warning device 7-3
Timing charts 7-4
Start-up procedures 7-5
Instructions for normal running 7-6
FEEDER 7-6
COATING HEAD 7-6
Emergency procedures 7-7
Shut-down procedures 7-7
Alarms 7-7
Fault diagnosis and correction 7-8
GENERAL FAULTS 7-8
Page 7-1
Operating Information Issue 01 – JAN 2005
Modes of operation
Note: The coater can be either in line with press units or free standing.
During printing/coating process the 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 there is power to the coater (and feeder).
4 Ensure all other line equipment is operational.
Page 7-2
Pre-start warning
There are 4 situations when the coating 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 coating unit that had stopped as a result of the crash will begin to flash.
After 3 seconds the siren will stop indicating that the coating unit that had 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 7-3
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 started if the inkers
have not synchronised 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 7-4
Start-up procedures
1 Switch on the main power supply.
2 Press the ‘
Power on’pushbutton on the coater 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 Check the feeder stack is loaded and is in the run position.

6 Check the coating head and ensure there is a supply of coating.
7 To start the coater, press the START and SPEED UP pushbuttons together. The
coater will start and speed up to 2000 sph. The START FEEDER lamp will flash when
the line is ready to feed sheets.
8 Select run with oven at the coater console.
9 Press START FEEDER at the press console. The START FEEDER lamp will remain lit
during sheet feeding.
Page 7-5
Instructions for normal running
FEEDER
1 Visually check the stack level
2 Replenish as required.
COATING HEAD
1 Visually check for coating being delivered to the head.
Page 7-6
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, etc.
3 Shut off the compressed air supply at the shut off valve.
4 Inform site supervision.
Shut-down procedures
1 Press the STOP FEEDER pushbutton at the press console or the delivery.
2 Press the SLOW DOWN pushbutton at the coater console until the coater speed is at
idle.
3 Press the STOP LINE pushbutton at the coater console.
4 Wash-up the coating head. 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 last
sheet has been fed by the feeder. 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 7-7
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.
Page 7-8
Issue 01 – Jan 2005 Maintenance
Maintenance
Maintenance schedule 8-2
Air Filter Units 8-2
General Maintenance 8-3
Recommended lubricants 8-5
Maintenance instructions 8-6
Main Drive Gearbox Lubrication 8-6
Scraper Blade 8-6

Coater Brake Settings 8-7
Objective 8-7
Checking 8-7
Adjustment 8-7
Re-checking settings 8-7
Page 8-1
Maintenance Issue 01 – Jan 2005
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
DAILY
details)
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
Drain traps Open and drain off *
any moisture
Oil atomiser Check and top up as * Turn OFF air
reservoirs required supply when
topping up
reservoirs
Page 8-2
LOCATION MAINTENANCE TASK FREQUENCY GENERAL

TO BE PERFORMED COMMENTS
(See Maintenance
12 MONTHLY
instructions for further
3 MONTHLY
6 MONTHLY
MONTHLY
details)
WEEKLY
DAILY
General Clean and remove *
surplus spillage
outside trays. Inspect
all belts. Clean down
feed table sheet
supports and magnet
surfaces
Fountain side- Check correct settings *
scrapers to rolls
Fountain Examine for *
bearer felt contamination
wipers
Application roll Grease *
silencer gear
Dropwheels Clean rotating element * Replace tyres if
worn
Pre-register Check magnet pulley *
section chain drive for correct
tension and lubricate
Check gripper cam *
and follower for undue
play and lubricate
Inspect and secure nip *
screws in outer gripper
Infeed Examine pusher chain *
tension
Oil pusher runner *
support bars
Check side guide chain *
tensioners and belt
tensioners
Pushers Check pusher latch *
springs
Lightly oil side blocks *
Pusher chains Lightly oil *
Clutch for Inspect for undue play * Pull out knurled
pusher drive ring and rotate
clockwise to
take up wear
Page 8-3
Sidelay Inspect linkage and oil *

Check sidelay *
spools(bearings) for
free movement
Check sidelay cams *
and followers for
undue play. Lubricate
Lacquer Inspect telescopic * Strip clean and
pipework fitting for undue reassemble if
leakage necessary
Pneumatic Check water filter and *
pipework empty if necessary
Check lubricator bottle *
level
Solvent system Check pipe fittings and *
tighten as necessary
Check flexible pipes *
for deterioration and
replace as necessary
Inspect and clean *
solvent pump gauze
filter
Motor drive Check for correct *
belts tension
Automatic Top up tank with oil As necessary
lubrication
Clean tank and check *
pump unit
filter
Coater main Replace with fresh oil *
drive gearbox
Page 8-4
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
Main Gearbox: Use B.P. Energol type CS460

Auto Lubrication System: Use Shell oil type T220
Air Line Lubricators: Use Shell oil type T22
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.
Page 8-5
Maintenance instructions
Main Drive Gearbox – Lubrication
The main drive gearbox on a coater is to be filled via the oil filler located on top of the
gearbox. The initial fill of lubrication requires 10 litres of oil only.
The level of oil within the gearbox is indicated by the sight glass at the bottom of the
gearbox on the side towards the coater delivery. In certain instances this may be
obscured by the guarding. The main glass window on the front of the gearbox is not an
indication of the level of oil within the gearbox.
On initial fill of oil, the oil level within the gearbox will be towards the top of the oil sight
glass. Under running conditions oil is pumped from the lower section of the gearbox into
the upper chamber and this will cause the indicated oil level in the sight glass to drop
slightly.
A level of oil can be seen through the top window, the level of oil being controlled by a
“Weir effect”due to the design of the gearbox casting.
Under no circumstances should oil be added to the gearbox so that the oil level in the top
chamber is caused to rise. Overfilling the gearbox in this manner will cause failure of the
seals and possible contamination of the brake linings.
The gearbox oil level should be check on a monthly basis and topped up if necessary in
accordance with these instructions. The gearbox oil should be drained and replaced every
12 months.
Scraper Blade
The scraper blade fitted to the Crabtree coater must be both sharp and correctly
sharpened. The scraper blade is mounted in the holder on the lacquer trough. The
purpose of the scrapper is to remove excess coating or lacquerso that on the next
revolution of the bottom cylinder(compression roll) a clean surface is presented to the
back of the sheet being processed.
The sharpened scraper blade must be free from hollows or nicks. A scraper blade which
takes a long time to bed in loses its edge during the bedding in and may result in poor
scraping thereafter. A scraper blade which has nicks in when installed will not bed in and
damage the surface of the roll.
Blades must be sharpened as described above, this can be performed on a Crabtree
blade grinder which is especially designed and manufactured to ensure correct blade
profile. Any other grinding machine can be used provided that the contour of the blade is
correct.
When sharpening the scraper blade dry grinding should be used. Grinding of the blade
should continue until the blade sparks out, the blade is sharp and the correct contour is
achieved. Before removal of the blade from the grinding machine, any burr on the back
of the blade should be removed using a carborundum stone. Failure to remove the burr
will result in damage to the bottom roll.
Before the sharpened blade is removed from the grinding machine, the plastic safe edge
must be fitted to the blade. The plastic safe edge ensures there is no danger of injury to
personnel and damage to the blade can not occur during handling. The plastic safe edge
should remain on the blade until the blade is mounted in the coating machine and the
blade is ready for setting.
Page 8-6
Coater Brake Settings

Objective
The coater brake should be adjusted so that the coater will come to a standstillfrom top
speed within 1 complete revolution of the main cylinders.
Checking
To check the brake setting the coater should be run without lacquer and without the
scraper blade being engaged.
A reference point needs to be selected, this can be the gripper cylinder on a front register
coater or a small piece of self adhesive tape placed onto the bottom cylinder of a rear
register or plain coater to determine point of revolution. Once a given position of cylinder
revolution is determined, the coater can be stopped by pressing the stop button. The
amount of rotation of the coater can then be judged by looking at “the stopped” position
of the reference point. This test should be repeated 3 times to be certain that a
representative reading is obtained. The stopping point should not exceed 1 revolution but
not be less than ¾ of 1 revolution.
Adjustment
If the above testing does not stop the coater as described the brake should be adjusted.
To adjust the brake the main drive pulley should be removed. See supplier
documentation.
Having set the brake as described, replace the main drive pulley.
Re-checking settings
The stopping characteristics of the coater should be tested as described in checking to
ensure that the coater stopping performance is satisfactory. If not, re-check the brake
settings and adjust.
The brake setting should be re-checked every 6 months. If the brake setting is incapable
of stopping the coater within 1 revolution the brake should be overhauled or replaced.
Page 8-7
Issue 01 – Jan 2005 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 01 – Jan 2005
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 01 – Jan 2005 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 01 – Jan 2005
Page 9-4
Issue 01 – Jan 2005 Parts Lists
Introduction
The terms and abbreviations OFFSIDE (O.S.) and FEEDSIDE (F.S.) refer to the respective
sides of the machine; the feedside being the operator’
s side (the left side when looking in
the direction of sheet travel).
How to order parts

We rely on your co-operation to be able to deliver spare parts quickly and according to
your specification. When placing orders for spares:
1 Always quote the machine serial number and the year of construction.
2 Quote the part number and description together with the catalogue page
number e.g. Page 7-2.
3 Please quote the exact address and forwarding instructions.
Orders may be placed by:

TELEPHONE: (0) 191 487 5071
TELEFAX: (0) 191 487 3997
E-MAIL: [email protected]
POST: Spares Department
Crabtree of Gateshead
Kingsway
Team Valley Trading Estate
GATESHEAD
Tyne & Wear
NE11 0SU
Page 10-1
Parts Lists Issue 01 – Jan 2005
Parts catalogue
Page 10-2

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⊕

1200F Coater Plus

Operators and Engineers Manual

1 Purpose and Planning

2 Handling, Installation, Storage and Transit

THIS PAGE LEFT BLANK

Purpose and planning

Health and Safety

MOVING PARTS CAN CAUSE SEVERING, CRUSHING AND ENTANGLEMENT

HAZARDOUS SUBSTANCES CAN CAUSE SKIN AND RESPIRATORY

SHARP EDGES CAN CAUSE SEVERING AND CUTTING

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

HIGH PRESSURE FLUIDS CAN CAUSE DAMAGE SEVERE PERSONAL

ELECTRICAL SHOCK CAN CAUSE BURNS OR DEATH

LIFTING EQUIPMENT CAN TRAP AND CRUSH

Voltage 90 … 110% nominal steady state voltage

AMBIENT AIR TEMPERATURE

Capabilities and performance data

Sheet size Max 1143× 965 mm

Physical dimensions and weight

Handling, installation, storage and

Preparation of site and services

Reception and handling

Packing case side Internal packing

Nail remover Foil bag

Prise open the lid with the ‘jemmy’

Removal of preservative coating

Storage of equipment not to be used immediately

THIS PAGE LEFT BLANK

Fountain Lacquer Feed System 3-3

1200F COATER PLUS⊕

Fountain Lacquer Feed System

The Coating Head

Fountain Roll Pressure Setting

The Application Roller

Pressure Roller and Scraper

Machine Setting 4-3

Front Register Cylinder Grip

Front Lay Clearance

SCRAPER SYSTEM (PATENTED) 5-2

ISOBLADE SYSTEM (PATENTED)

Pressure Control Valve

SCRAPER BLADE CHANGE

Changing the blade

Replacing the blade and bedding-in

Notes concerning blade grinding

Notes concerning blade bedding in

SCRAPER BLADE GRINDING MACHINE

The grinding of a scraper blade is as follows

1. Clean the clamps on the grinder

SETTING THE BLADE

View of Blade in Fixture

Clamp Screw (9 Off) Datum Stop

End Gauge Block

View of Blade in Setting Gauge

BLADE LOCK OUT – WHEN SCRAPER NOT IN USE (NOT APPLICABLE TO

Strap in vertical position

SETTING THE SPRING BLADE

View of Spring Blade