March 2010 1K101\202 Ins\Iss 15

THE K CONTROL COATER

MODEL NOS. K101 & K202

INSTALLATION & WORKING INSTRUCTIONS

R K Print Coat Instruments Ltd Litlington, Royston, Herts, SG8 0QZ

United Kingdom Tel: +44 (0) 1763 852187 Fax: +44 (0) 1763 852502

email: sales@rkprint.com Web: www.rkprint.com

R

K101\202 Ins\Iss15 2 March 2010

R RK Print Coat Instruments Ltd., Royston. Hertfordshire, SG8 OQZ, England. Tel : +44 (0) 1763 852187 Fax : +44 (0) 1763 852502

EC DECLARATION OF CONFORMITY

This machinery has been designed and manufactured in accordance with the following transposed harmonised European standards :- BS EN 292-1 Safety of machinery – Basic concepts and general principals for design – Part 1: 1991 Basic terminology and methodology. BS EN 292-2 Safety of machinery – Basic concepts and general principals for design – Part 2: 1991 Technical principles and specifications. BS EN 292-2 Safety of machinery – Basic concepts and general principals for design – Part 2: 1995 Technical principles and specifications – Amendment 1. BS EN 349 Safety of machinery – Minimum gaps to avoid crushing of parts of the human body. 1993 BS EN 953 Safety of machinery – Guards – General requirements for the design and 1997 construction of fixed and moveable guards. BS EN 954-1 Safety of machinery – Safety related parts of control systems – Part 1: 1996 General principles for design. BS EN 60204-1 Safety of machinery – Electrical equipment of machines – Part 1: 1997 General requirements. (IEC 60204-1 : 1997) BS EN 1050 Safety of machinery – Principles for risk assessment. 1996 A technical documentation file for this machinery is retained at the manufacturer’s address.

Web site : WWW. RKPRINT.COM

Description of machine : Printing and Coating Unit Model : K Control Coater Serial Number : Year of manufacture :

Signed : Date : 02/02/05 Name : Mr. T.R. Kerchiss Position : Managing Director Being the responsible person appointed by the manufacturer and employed by RK Print Coat Instruments Ltd.,

T

C C

We hereby declare that the following machinery complies with the MACHINERY DIRECTIVE 2006/42/EC

LOW VOLTAGE DIRECTIVE 2006/95/EC EMC DIRECTIVE 2004/108/EC

OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of June 1998 on the approximation of the laws of the Member States relating to machinery,

enacted in the United Kingdom by The Supply of Machinery (Safety)Regulations 2006

March 2010 3 K101\202 Ins\Iss 15

INSPECTION CERTIFICATE & SPECIFICATION

ALSO AVAILABLE IN FRENCH & GERMAN

MACHINE SERIAL NO: ..........................

Please quote this number when ordering spares and accessories

MACHINE : K101 K202 KPP KLOX KPA

TYPE : 220/240 Volt 110/120 Volt Pneumatic

ELECTRIC UNITS

MOTOR SERIAL NO :

GEAR BOX RATIO :

HIGH SPEED STROKETIME (10) : Secs

MID SPEED STROKETIME ( 5) : Secs

SLOW SPEED STROKETIME ( 1) : Secs

PNEUMATIC UNITS

MOTOR SERIAL NO :

GEAR BOX RATIO :

HIGH SPEED STROKETIME : Secs

MINIMUM STROKETIME : Secs

AT 5.5 BAR (80 PSI)

INSPECTED BY:................. DATE: ...........

K101\202 Ins\Iss15 4 March 2010

ANNEX A THE SAFE USE OF RK INSTRUMENTS & MACHINERY IMPORTANT It is essential that all comments made in this, Annex A, are carefully studied and understood* by the following persons - before putting the equipment into operation: a) The person or persons responsible for those members of staff who will be involved in

the installation, commissioning, operation and maintenance of the equipment. b) All persons whose duties will involve the installation, commissioning, operation or

maintenance of the equipment. *If any comment/instruction is not fully understood, do not use the equipment - contact RK or your nearest RK representative for clarification. 1. BASIC MACHINE DETAILS 1.1. Name and address of manufacturer. RK Print-Coat Instruments Ltd Litlington Royston, Herts SG8 0QZ, U.K. Name of your RK representative (where applicable). 1.2. Description of machine Name and/or model no ........................ Serial no: ................................... Year of manufacture: ......................... 1.3. Dangers when using the equipment. The machine detailed in 1.2 (above) is designed and manufactured in

accordance with current European and UK national standards but must only be used:

1.3.1. For the application for which it is intended - See paragraph 1.4 and 1.3.2. With all safety features properly fitted and adjusted

Continued/

March 2010 5 K101\202 Ins\Iss 15

ANNEX A 1.4 Proper use of the equipment

The machine detailed above (1.2) is intended for the following (dependent upon the equipment and accessories supplied).

(a) The application of liquid printing inks, paints, varnishes, adhesives and other

surface coatings using wire wound meter bars. (b) The application of paints and similar coatings using gap applicators. (c) Production of flexographic printing proofs using the Klox attachment.

� Machines fitted with an electric drive motor should not be used in areas having a hazardous classification.

If the machine is used for any other purpose or if the instructions given in the installation and working instructions manual are not observed, it will be considered as improper use and RK Print Coat Instruments Ltd will not be liable for any resulting damage or injury to persons.

1.5 Modifications to the equipment

Modifications must not be made without written agreement from RK Print Coat Ltd. Replacement parts must be obtained from RK Ltd to ensure that these meet the appropriate safety standards.

2. SAFETY INFORMATION

2.1. � This symbol is used in the instruction manual to draw your attention to an instruction or guideline when non observance could result in injury, damage to the equipment or both.

2.2. Electrical Equipment

Work on electrical equipment must be carried out only by a qualified electrician. Electrical equipment which is connected to the power supply via a plug and wall socket must have the plug removed from the socket before commencing maintenance work. Electrical equipment which is directly connected to the power supply (i.e. excluding a plug and socket connection) must be fed via a lockable, switched fused isolator (supplied by the customer) and locked in the "off" position before commencing maintenance work.

3. NOISE LEVEL

The continuous noise level from this equipment does not exceed 70dB (A), 4. DECLARATION OF CONFORMITY The required EC Declaration of Conformity is enclosed.

K101\202 Ins\Iss15 6 March 2010

MODEL NOS K101 AND K202 GENERAL COMMENTS Your new machine will have been supplied having one or more of the following available alternatives. 1. As a CONTROL COATER (model K101 or K202) it is fitted with a bar

coating head and uses wire wound metering bars to control the coating weight applied.

Both models are identical except that the K202 can produce a wider coating area - see page 15.

2. As a PAINT APPLICATOR (model K101 only) it is again fitted with the

bar coating head but instead of using wired metering bars, it employs a pushbar to drive a gap applicator along the substrate being coated.

3. As an AUTOMATIC KLOX (model K101 only) it is again fitted with the

bar coating head but instead of using wired metering bars, it employs a Klox head to produce printing proofs using the flexographic technique.

From the foregoing it will be appreciated that the owner of any model K101 alternative can convert to either or both of the others by purchasing additional accessories thus increasing the versatility of the machine as required. In the notes which follow, bracketed numbers e.g. (1/3) indicate the illustration and item being referred to. Thus (1/3) refers to figure 1/speed adjustment dial.

March 2010 7 K101\202 Ins\Iss 15

CONTENTS SUBJECT PAGE NO. E.C. DECLARATION OF CONFORMITY 2 INSPECTION CERTIFICATE 3 THE SAFE USE OF RK MACHINERY

� PLEASE STUDY BEFORE INSTALLATION 4 & 5

GENERAL COMMENTS 6 INSTALLATION OF BASE UNIT - ELECTRIC DRIVE VERSION 9 INSTALLATION OF BASE UNIT PNEUMATIC DRIVE VERSION 11 BAR COATING 13-15 PAINT APPLICATOR 16-21 BIRD TYPE APPLICATORS 18-19 CUBE & 4 SIDED APPLICATORS 19 MICROMETER ADJUSTABLE FILM APPLICATOR (MAFIA) 20-21 AUTOMATIC KLOX 22-23 COATING BEDS/PLATENS - ALTERNATIVES AVAILABLE 24 COATING BEDS - FOAM/RUBBER/MELINEX (F/R/M) 25 FLOAT GLASS 25 VACUUM 26 MAGNETIC 27 HEATED 28-29 DRIVE CABLE REPLACEMENT 30-32 ADJUSTING CARRIAGE REVERSE SPEED 32 ADJUSTING OVERLOAD CLUTCH 34-35 CIRCUIT DIAGRAMS 36-38

ILLUSTRATIONS FIGURE NO SUBJECT PAGE NO 1 DRIVE BASE BEFORE HEAD FITTED 8 2 FILTER REGULATOR (PNEUMATIC VERSION) 10 3 BASE UNIT WITH BAR COATING HEAD FITTED 12 4 BAR COATING HEAD 14 5 SIDE PLATE EXTENSION 14 6 PAINT APPLICATOR - PUSH BAR IN SETTING POSITION 16 7 PAINT APPLICATOR - BIRD APPLICATOR, WORKING POSITION 16 8 DRIVE ASSEMBLY 30 9 CHECKING OVERLOAD CLUTCH 34

K101\202 Ins\Iss15 8 March 2010

FIG 1

DRIVE BASE BEFORE COATING HEADS ARE FITTED

March 2010 9 K101\202 Ins\Iss 15

INSTALLATION OF BASE UNIT ELECTRIC VERSION

� NOTE Electric version machines should not be used in areas having a hazardous classification

� Check that voltage shown on the inspection certificate and on the label at the back of the machine is correct for your supply. (See also *NOTE* below).

Fit an appropriate plug to mains trailing lead (if not already fitted). The wires in the mains lead(s) are coloured using one (or both) of the

following codes. EUROPE U.S.A. Brown - Live(L) Black - Live (L) Blue - Neutral(N) White - Neutral(N) Green & Yellow - Earth(E) Green - Earth(E)

� WARNING THIS EQUIPMENT MUST BE EARTHED

� Ensure that the left hand rotary switch in the control panel is in its central

“stop” position. Switch mains supply on at the wall socket. Locate the “no volt release” switch at the back of the machine - left hand side. Switch this no volt switch on. Note that this switch will automatically revert to its off position should there be a supply failure or other line fault. Check that the control panel red indicator light(1/2) is also illuminated. Adjust SPEED dial(1/3) to “5” and reset for subsequent tests as required). Turn rotary switch (1/1) to FWD (forward) to drive carriage down the machine. ▲ CAUTION— Before Operating ensure hands are well clear of all moving parts. Turn rotary switch (1/1) to REV (reverse) to return carriage to the start position. This reverse speed is factory set, but see page 32 for adjustment instructions. *NOTE* If for any reason, the supply voltage is changed, it is necessary to: A) Connect the link(s) as shown on circuit diagram 3010-002 and B) Replace the “No Volt Release Switch” with one suitable for the new supply voltage. INSTALLATION

K101\202 Ins\Iss15 10 March 2010

FIG 2 FILTER REGULATOR UNIT - - PNEUMATIC VERSION MACHINE

DRIP RATE REGULATOR PRESSURE REGULATOR

PRESSURE GAUGE

AIR SUPPLY TO MACHINE

AIR SUPPLY

LUBRICATOR FILTER

FIXING BRACKET

March 2010 11 K101\202 Ins\Iss 15

INSTALLATION - PNEUMATIC VERSION We recommend a minimum supply pressure of approximately 5.5 bar (80 PSI). The unit uses up to 35 litres (1.2 ft3) of air per cycle at a flow rate of 12 litres/second (26 ft3 /min) when operating at maximum speed. The filter/regulator/lubricator unit (see figure 2 opposite) is supplied as a separate loose item, complete with bracket for wall or bench mounting as near to the machine as possible. It can also be fitted to the back platen support but if this position is used care must be taken to avoid damaging the unit during installation or if the machine is moved. The lubricator bowl must be removed and filled with the oil provided (Silkolene, Silair GP22 or equivalent). Please also refer to the note below re maintenance. The lubricator unit drip rate has been adjusted in our factory to one drip every 3 minutes and should need no further attention. However, if adjustment becomes necessary, carefully rotate the drip rate regulator on top of the unit using a screwdriver. Note: Clockwise rotation reduces drip rate.

� Use of incorrect oil or drip rate can cause operating difficulties and/or damage. Connect the air supply via a 8mm (5/16") hose to the 1/4” BSP port in the filter unit. Then connect between the push in elbow fitting on the lubricator to the similar push in fitting in the back of the machine base. Regulate the air pressure below the minimum normally available to prevent fluctuations in speed. Adjust SPEED control valve on control panel to desired speed. Turn rotary switch to FWD (forward) setting to drive carriage down the machine. ▲ CAUTION— Before Operating ensure hands are well clear of all moving parts. Turn rotary switch to REV (reverse) to bring carriage back to the start position. This speed is regulated independently of the forward speed. MAINTENANCE Once a week, check that the lubricator bowl is full (oil specification above) and that the filter element is clean. To clean filter element: Unscrew the bowl to remove Remove any foreign matter with an air gun or wash with soapy water. Rinse with fresh water, allow to dry. Re-assemble bowl.

� NOTE: The filter element supplied is intended only to ensure the final air conditions required for the machine. It is incapable of conditioning the air in your complete system. We recommend that an intermediate filter having a 50µm element (preferably fitted with an automatic drain device) should be fitted in the air supply line at a maximum distance of 5.0m from the machine.

K101\202 Ins\Iss15 12 March 2010

FIG 3

BASE UNIT WITH

BAR COATING HEAD FITTED

4

3

6

7

5

1

2

March 2010 13 K101\202 Ins\Iss 15

With the base unit overhanging a bench, loosen the 2 front screws securing the bottom cover plate and insert the bar rack(3/1). Re tighten screws and push the bar rack flush to the bench. Insert the solvent tubes and place any coating bars and the setting bar in the slots provided. Fit the left and right hand sides(3/2 and 3/3) of the coating head complete with the weights and latches, to the carriage of the base unit using the 4 - M5 screws provided. Substrate/coating bed thickness 20 - 40 mm See notes under “choice of latching assembly pivot points” on page 17). ADJUSTMENT 1) Select and fit a coating bed or platen(3/4) (See "Coating Bed and Platens" - Page

24). 2) Place a sheet of spoils paper and substrate under the spring clip (3/5) (see page

15 for sizes). 3) Select the calibration rod(3/6) - this has a collar at one end and a centrally reduced

diameter. The words "calibration rod" are engraved at one end. 4) Slacken the 2 knurled locking screws located on each side of the coating head and

insert the calibration rod by raising the latches until the bar engages and the catches lock. Ensure that the reduced diameter is located centrally on the coating bed, apply light finger pressure to the centre of the bar to ensure that it is level, and retighten the 2 knurled locking screws. Remove the calibration rod by lifting the pegs on the locking catches. Repeat as above for substrate thickness changes of more than 2mm (.080").

OPERATION 1) Select the required coating bar(3/7) and slide into the latch mechanism. NOTE: It should be possible to slide the coating rod into the latch mechanism

without any pressure and without lifting the lateral weights. 2) Adjust the SPEED control knob as required. 3) Apply a few grams of one or more coating fluids in front of, but not touching the

coating rod and immediately rotate switch to FWD (forward).

▲ CAUTION— Before Operating ensure hands are well clear of all moving parts. 4) Remove the bar and wipe any excess coating onto the spoils paper and place the

bar into the partly filled solvent tube . 5) Remove coated substrate and spoils paper and return carriage by rotating switch

to REV (reverse). AUTOMATIC KLOX HEAD - Available for model 101 only.

K101\202 Ins\Iss15 14 March 2010

FIG 4 BAR COATING HEAD

FIG 5 SHOWING SIDE PLATE EXTENSION FITTING

March 2010 15 K101\202 Ins\Iss 15

BAR COATING HEAD SPECIFICATION DIMENSIONS (MAXIMUM)

STANDARD COATING BARS Special bars with intermediate or higher wet film deposits are manufactured to customer requirements. When ordering additional bars, always specify model no. (101 or 202) SOLVENT TUBES fill with approximately 150cc (5fl.oz) of the appropriate solvent to clean the bars. IMPORTANT NOTE

� Solvent tubes are manufactured from aluminium and the use of ALKALI cleaners is therefore NOT RECOMMENDED. ACCURACY & REPEATABILITY - BS5750 etc 1. If repeatability is of utmost importance e.g. computer colour matching etc., then it

is recommended that one bar of each wire size used is kept as a standard. Then at monthly intervals all bars in use are checked against the standard to ensure that they are within the tolerance that you require. This system may be used for BS5750 or ISO9000.

2. Ensure that bars are always cleaned thoroughly immediately after use with a soft

lint free wipe.

MODEL 101

MM

INS

MM

INS

COATING AREA

170 x 250

6.5 x 10.0

325 x 250

12.75 X 10.0

SUBSTRATE SIZE

170 x 310

6.5 x 12.0

325 x 310

12.75 X 12.0

SPOILS PAPER

190 x 380

7.5 x 15.0

345 x 380

13.5 X 15.0

MODEL 202

BAR NO

COLOUR CODE

WIRE DIAMETER mm Inches

0 White 0.05 0.002 4 0.00015 1 Yellow 0.08 0.003 6 0.00025 2 Red 0.16 0.006 12 0.0005 3 Green 0.31 0.012 24 0.0010 4 Black 0.51 0.020 40 0.0015 5 Horn 0.64 0.025 50 0.0020 6 Orange 0.76 0.030 60 0.0025 7 Brown 1.00 0.040 80 0.0030 8 Blue 1.27 0.050 100 0.0040 9 Tan 1.50 0.060 120 0.0050

WET FILM DEPOSIT micron Inches

K101\202 Ins\Iss15 16 March 2010

FIG 6 PAINT APPLICATOR - PUSHER BAR IN SETTING POSITION

FIG 7 PAINT APPLICATOR - BIRD APPLICATOR IN WORKING POSITION

March 2010 17 K101\202 Ins\Iss 15

K101 PAINT APPLICATOR This instrument is a further variant of the successful K101 range of machines and is directed primarily at the paint industry for use with gap applicators. Other products such as adhesives, plastisols etc. may also be coated. As standard, the machine is supplied with a model K101 base unit, carriage assembly, coating head side plates (6/1), latching assembly and a float glass bed (6/2) for perfect flatness and ease of cleaning. An attachment is also supplied for use when employing bird type film applicators. In addition to the float glass bed mentioned above, a number of alternatives are available and listed on page 24. CHOICE OF LATCHING ASSEMBLY PIVOT POINTS Two pivot points are provided: Lower pivot point (4/1) and Upper pivot point (4/2) The lower pivot point (4/1) is used for substrate thickness up to 20mm. The upper pivot point (4/2) is used for substrate thickness from 20 to 40mm and when using the vacuum bed. To alter pivot point, remove the M5 countersunk socket screws from the outside face of each side plate and move the complete assembly to the new position required. Replace screws. SIDE PLATE EXTENSION When using the standard, the vacuum or the magnetic beds, these are fitted directly on to the machine's platen and the side plates (4/3) are fixed directly on to the carriage as shown in figure 4. However, when using a heated bed, side plate extensions (5/1) must be fitted - see figure 5.

K101\202 Ins\Iss15 18 March 2010

K101 PAINT APPLICATOR CONTINUED K BIRD TYPE APPLICATORS These fixed gap applicators produce a coating width of 100mm and are available with standard gaps of 25, 50, 75, 100, 150 or 200µm. It should be remembered that they will produce a wet film thickness approximately equal to one half of the gap size. PREPARATION 1. With the machine switched 'on' move coating head to the back of the

machine by turning rotary switch to 'rev' (reverse). 2. Position sheets of spoils paper and substrate and hold in place using the

spring clip (6/6) (or with the vacuum or magnetic device in the case of alternative beds). See page 19 for paper sizes.

3. Pivot the cam latches (6/7) to the back of the coating head - as shown in

figure 6. These will rest on stop pins (6/8). 4. Loosen knurled thumb screws (6/9). 5. Insert 'L' shaped pusher bar (6/10) in to the "U" slots in the retaining

plates (6/11). 6. Rotate pusher bar (6/10) until the short leg of the 'L' is resting on the

substrate - as shown in figure 6. 7. With the fingers of one hand gently pushing down on the 'L' piece,

tighten both knurled thumb screws with the other hand. 8. Now rotate the 'L' through 90� until it is in the position shown in figure

7. 9. Carefully slide the chosen bird applicator (shaded in figure 7) under the

'L' making sure that it is correctly positioned sideways. 10. Swivel the cam latches (6/7) to the front of the machine when the L

shaped pusher bar will be firmly held in place. Check that there is a small gap between weight arms (6/12) and stop pins (6/8).

Continued/...

March 2010 19 K101\202 Ins\Iss 15

K101 PAINT APPLICATOR CONTINUED RK BIRD TYPE APPLICATOR - Continued OPERATION 11. Adjust the speed control knob as required. 12. Place a suitable amount of paint (or other coating material) on the substrate

in front of the applicator and immediately rotate switch to 'for' (forward). 13. When the machine stops automatically, remove and clean the applicator

with the appropriate solvent. 14. Remove substrate/test panel. 15. Return carriage to start position by rotating switch to rev (reverse). COATING AREA/PAPER SIZES CUBE AND 4-SIDED APPLICATORS The “L” shaped pusher bar mentioned on page 18 can be adjusted to suit the height of the applicator chosen when it is rotated to its position shown in fig 7 and then used as described for bird type applicators. Cube applicators coat a width of 41mm 4 sided applicators coat a width of 60mm.

MM INS

COATING AREA 100 X 250 3.9 X 10.0

SUBSTRATE SIZE 170 X 310 6.5 X 12.2

SPOILS PAPER 190 X 380 7.5 X 15.0

K101\202 Ins\Iss15 20 March 2010

K101 PAINT APPLICATOR CONTINUED MICROMETER ADJUSTABLE FILM APPLICATOR HEAD - (MAFIA) This unit incorporates an adjustable spreading blade with micrometers to accurately set the substrate/blade gap up to 10,000µm in 10µm increments. The wet film thickness achieved is approximately equal to the gap setting. COATING BED The standard float glass bed will normally be found satisfactory but any of the alternative beds (page 24) can be used for special purposes. PREPARATION The unit can be used in two different modes - with or without pressure between the unit and the substrate. For operation with pressure proceed to instruction No. 1. For operation without pressure proceed to instruction No. 9. 1. Place a sheet of spoils paper and substrate under the spring clip (see page 21 for

paper dimensions). 2. Select the calibration rod - this has a collar at one end and a centrally reduced

diameter. 3. Slacken the 2 knurled locking screws (6/9) located on each side of the coating head

and insert the calibration rod by raising the retaining plates (6/11) until the rod engages and the cam latches (6/7) lock. Ensure that the reduced diameter is located centrally on the coating bed, apply light finger pressure to the centre of the rod to ensure that it is level, and retighten the 2 knurled locking screws. Remove the calibration rod by lifting the pegs on the cam latches (6/7). Repeat as above for substrate thickness changes of more than 2mm (.080").

4. Engage the MAFIA into the latches on the machine. Adjust the micrometers to the

required gap. They are preset to zero and can be adjusted in steps of 0.01mm from 0-10mm.

5. Adjust the SPEED control knob as required. 6. Apply a few grams of the coating mix in front of the knife and immediately rotate

the switch to FWD (forward). ▲ CAUTION— Before Operating ensure hands are well clear of all moving parts. 7. Remove the MAFIA by lifting the latches and clean using the appropriate solvent. 8. Remove coated substrate and spoils paper and return carriage by rotating switch to

REV (reverse).

March 2010 21 K101\202 Ins\Iss 15

K101 PAINT APPLICATOR CONTINUED MICROMETER ADJUSTABLE FILM APPLICATOR HEAD (MAFIA) - (Continued) FOR OPERATION WITHOUT PRESSURE 9. Place a sheet of spoils paper and substrate under the spring clip (6/6). 10. Slacken the 2 knurled locking screws (6/9) and insert the MAFIA by raising

retaining plates (6/11) until the bar on each side of the MAFIA engages and the cam latches (6/7) lock. Apply light finger pressure to the top of the MAFIA to ensure that it is level, and retighten the 2 knurled locking screws.

11. Adjust the micrometers to the required gap. They are preset to zero and can

be adjusted in steps of 0.01mm from 0-10mm. 12. Adjust the SPEED control knob as required. 13. Apply a few grams of the coating mix in front of the knife and immediately

rotate the switch to FWD (forward). ▲ CAUTION— Before Operating ensure hands are well clear of all moving parts. 14. Remove the MAFIA by lifting the latches and clean using the appropriate

solvent. 15. Remove coated substrate and spoils paper and return carriage by rotating

switch to REV (reverse). COATING AREA/PAPER SIZES MM INS

COATING AREA 100 X 250 3.9 X 10.0

SUBSTRATE SIZE 170 X 310 6.5 X 12.2

SPOILS PAPER 190 X 380 7.5 X 15.0

K101\202 Ins\Iss15 22 March 2010

INSTALLATION If necessary fit the left and right hand sides of the coating head(4/3) to the carriage of the base unit using the 4 - M5 screws provided. OPERATION 1) Select and fit a suitable coating bed. (See "Coating Beds/ Platens" Page 24). 2) Place a sheet of spoils paper and substrate under the spring clip(6/6). (See

below for sizes). 3) Slacken the 2 knurled locking screws(6/9) located on each side of the head.

Take the Klox frame without rollers and engage the tie bar into both latches. The jig plate must now be slid under the unit to raise it parallel to the bed. Tighten the 2 knurled locking screws(6/9) and remove jig plate and frame.

4) Insert a rubber roller into the frame and then an engraved roller, placing a

weight on each end. 5) Insert the frame into the latches on the machine. 6) Adjust the SPEED control knob as required. 7) Apply a few grams of ink or coating between the rollers and immediately

rotate switch to FWD (forward).

▲ CAUTION— Before Operating ensure hands are well clear of all moving parts. 8) Remove the frame from the latches and place rollers into the partly filled

solvent tubes in the cleaning rack. Refer to the use of solvents on page 23. 9) Remove sample and return carriage by rotating switch to REV (reverse). PRINTING PRESSURE The rear of the frame consists of a steel block - to increase the impression additional blocks may be added as required using the screws provided. SPECIFICATION

Continued/...

COATING AREA 110 X 210mm (4.5” x 8.25”)

SUBSTRATE SIZE 170 X 310mm (6.5” x 12”)

SPOILS PAPER 190 X 380mm (7.5” x 15”)

March 2010 23 K101\202 Ins\Iss 15

AUTOMATIC KLOX HEAD - Available for Model 101 only CLEANING & STORAGE It is essential that both the engraved and rubber rollers are carefully cleaned between tests using an appropriate solvent (see below) and lint free cloth or tissue. This is best carried out using the specially designed Klox cleaning and storage rack (supplied as standard with the Automatic Klox System).

� NEVER Leave rubber rollers with the rubber in contact with a supporting surface as this will cause flats to form on the rubber rendering them unusable. When using both solvent and water based inks, we recommend that a separate rubber roller is always used for each type. SOLVENTS The rubber rollers are covered with E.P.D.M. rubber (50o shore hardness) which has excellent resistance to cellosolve, meths, methanol, I.P.A (alcohols) and to MEK, acetone, cellosolve, acetate keystones and esters.

� However, the following solvents should not be used toluene, xylene, benzene, naphtha (aromatics), white spirit, petrol, paraffin, hexane (aliphatics), C.T.C., chloroform, methyl chloride (chlorinated solvents). RUBBER ROLLERS As standard the rubber rollers will print a width of approx 115mm. An alternative "wide shoulder" roller prints approx 84mm wide and is recommended when printing on to slippery substrates such as polythene. STANDARD QCH TYPE ENGRAVED ROLLERS

TYPE REFERENCE SCREEN CELLS/LINEAR INCH

CELL VOLUME MM³/INCH²

400/5 400 2.8

200/12 200 6.6

180/14 180 10.7

140/10 140 13.0

100/18 100 25.2

K101\202 Ins\Iss15 24 March 2010

COATING BEDS/PLATENS - ALTERNATIVES AVAILABLE

TYPE: RECOMMENDED FOR: FITTED AS STANDARD ON:

SEE ALSO PAGE:

3 part (F/R/M) bed Foam/Rubber/Melinex Rubber/Melinex Rubber only Melinex only

Most substrates & coatings Papers & liquid inks Papers & liquid inks Rigid substrates - glass etc & when using gap applicatiors.

Control Coater Automatic Klox

25

Float Glass Use with gap applicators Paint Applicator 25

Vacuum Bed Type A (Rubber faced)

Coating onto delicate & stretchy substrates (e.g. aluminium foil, polythene etc).

26

Vacuum Bed Type B (Aluminium face)

Rigid substrates (e.g. Paint charts) using gap applicators

26

Magnetic Bed Coating onto magnetic substrates (e.g. tin plate)

27

Heated bed Products to be coated at elevated temperatures

28/29

March 2010 25 K101\202 Ins\Iss 15

COATING BEDS & PLATENS CONTINUED FOAM/RUBBER/MELINEX (F/R/M) BED This is the most commonly used bed and is supplied as standard on the K101 Control Coater, K202 Control Coater and the K101 Automatic Klox. One or more of the three plies are used to suit the work being carried out - see also Page 24 - and the bed is held by two fixing screws which pass through the spring clip and clamp plate (3/5), the bed and then into the platen (3/4) FLOAT GLASS BED Supplied as standard on the K101 Paint Applicator, this bed provides a perfectly flat surface which is easily cleaned and is especially recommended when using gap applicators. Fixed by two screws which pass through the spring clip and clamp plate (3/5), the glass bed and then into the platen (3/4).

K101\202 Ins\Iss15 26 March 2010

COATING BEDS & PLATENS CONTINUED VACUUM BED - TYPES A AND B TYPE A. Recommended when coating on to delicate and stretchy substrates (eg alumium foil, polythene etc) A rubber faced bed connected to a vacuum pump holds the material perfectly flat. Vacuum is applied from the edges of the substrate only. TYPE B. A smooth aluminium faced bed with vacuum applied via multiple holes over the entire surface. Suitable for more rigid substrates. Especially recommended when coating on to paint charts with gap applicators. REFER TO NOTES ON PAGE 17 REGARDING: a) The use of the upper latching assembly pivot point and b) The use of side plate extensions. INSTALLATION 1. Remove rubber, foam or melinex or any other coating bed together with the

paper clamp leaving platen clear. 2. Align the four stainless steel bushes with relevant tapped holes in platen. NOTE: This applies to model K101 only. 3. Attach 4mm dia. nylon tube to the miniature pneumatic fitting. 4. Align vacuum bed with stainless steel bushes (model K101 only). Attach vacuum bed to platen with the four M4 cap screws provided. 5. Connect 4mm nylon tube to Vacuum Pump.

� IMPORTANT NOTE: If the machine is to be used in an area having a hazardous classification (and is therefore fitted with a pneumatic drive - see page 11) the vacuum pump must be installed in a non-hazardous area as its electric drive motor is non-flameproof.

6. Place substrate under the spring clip, switch on vacuum pump and smooth out

substrate to ensure even coating of same. 7. Place bar coating rod in latches and proceed as for normal bar coating

methods. (see Bar Coating Head operation Page 13).

March 2010 27 K101\202 Ins\Iss 15

COATING BEDS & PLATENS CONTINUED K101 MAGNETIC BED INSTALLATION REFER TO NOTES ON PAGE 17 REGARDING THE USE OF THE UPPER LATCHING ASSEMBLY PIVOT POINT: 1. Remove rubber, foam, melinex or any other coating bed together with the paper

clamp leaving platen clear. 2. Remove the two M5 countersunk socket screws from the OUTSIDE face of the

carriage side plates and place latch assemblies into the top M5 tapped holes in the side plates, refitting the M5 screws.

3. Carefully place magnetic bed* centrally on platen and align the two aluminium

clamps with the four tapped holes in the platen. Attach same using the four M4 x 25 long cap screws provided.

*Note that strips of melinex are fixed to the underside of the base plate with

double sided pressure sensitive adhesive tape. These strips protect the main platen on the machine and should not be removed. Ensure that melinex strips are clean before fitting the magnetic bed on the machine.

4. Place 2 or 3 layers of soft tissue on top of the magnetic bed. Position the tin

plate etc to be coated on the tissue. Insert large Allen key provided into the hexagon hole towards the rear of the magnet and turn the key anticlockwise to magnetise the bed and clamp the material.

5. Place bar coating rod in latches and proceed as for normal bar coating. (see Bar

Coating Head operation - page 13) When using a magnetic bed for bar coating, special non-magnetic wired bars are required.

� IMPORTANT NOTE:- Always ensure that sufficient coating material is used so that the coating rod sits on top of the material to be coated at the start and finish position. Damage to the coating rod will result unless this procedure is followed.

� Magnetic beds are manufactured from mild steel and should be protected from rust/corrosion by wiping all exposed surfaces with a light oil or spraying with a silicone based lubricant aerosol.

K202 MAGNETIC BED Procedure as above except that two magnets are provided with this unit mounted side by side.

K101\202 Ins\Iss15 28 March 2010

COATING BEDS & PLATENS CONTINUED HEATED PLATEN

� NOTE: The heated platen should not be used in areas having a hazardous classification. INSTALLATION REFER TO NOTES ON PAGE 17 REGARDING: a) The use of the upper latching assembly pivot point and b) The use of side plate extensions. 1. Remove both sides(4/3) of bar coating head from the carriage plate. Now proceed to instruction Nos 2 and 3 for Model No. 101 or instruction Nos 4 and 5 for Model No 202 2. (MODEL 101 ONLY) Align the four spacer bushes provided with the appropriate tapped holes in the

platen. 3. (MODEL 101 ONLY) Place heated platen assembly over the four spacer bushes and attach to platen

using the four M4 screws and washers provided.

� IMPORTANT NOTE:- To allow for the expansion of the heated platen, oversize holes are provided in the platen assembly. When fitting the heated platen the large washers must be used in conjunction with the M4 screws. Also to allow the platen to expand, the fixing screws must only be lightly tightened. Now proceed to instruction No. 6

4. (MODEL 202 ONLY) Screw four M4 x 10 cap head screws (supplied as loose items) into the base

platen. 5. (MODEL 202 ONLY) The model 202 heated platen is supplied as a complete assembly including glass

working surface, heater mat, insulation plate and spacer bushes. Simply place the complete assembly with its spacer bushes over the 4 x M4 cap head screws mentioned in instruction No. 4. No further fixing is necessary. Now proceed to instruction No. 6.

6. Fix the two side plate extensions (5/1) to the carriage plate with the four M5

screws provided, as indicated in figure 5 - page 14. 7. Refit the bar coating head assemblies to the upper tapped holes of the side plate

extensions.

March 2010 29 K101\202 Ins\Iss 15

COATING BEDS AND PLATENS CONTINUED HEATED PLATEN continued 8. Connect temperature controler to the heated platen using the appropriate

two pin and three pin plugs. 9. Connect unit to mains electricity (see page 9 for colour coding of cables).

� WARNING THIS EQUIPMENT MUST BE EARTHED A circuit diagram, drawing no 450B-5 will be found at the back of this manual. 10. To Set the Temperature Turn the rotary switch to “on”. The top row of the digital display will now indicate the heater mat temperature. The bottom row will indicate the set point. Set the required temperature as follows:-

Press the � button—the green display should show SET 1.

Hold the � button and use the � or � buttons to adjust the set point value you require. It should be noted that the digital temperature display indicates the heater

mat temperature which is higher than the actual platen surface tempera-ture. In particular, this applies to the model 202 due to the insulation properties of the glass working surface fitted. The temperature difference can be corrected by adjusting the set point.

The platen has been designed for continuous use with working surface

temperatures up to a maximum of 150ºC. 11. Open paper clip using insulated plate and insert substrate to be coated. 12. Proceed as for bar coating (see page 13).

K101\202 Ins\Iss15 30 March 2010

B

10 9 8 3

7

6

4

1

2

13

11

7mm

12

5

FIG 8 DRIVE ASSEMBLY WITH COVER PLATE REMOVED

March 2010 31 K101\202 Ins\Iss 15

KCC MODEL 101 & 202 INSTRUCTIONS FOR FITTING REPLACEMENT DRIVE CABLE

1. � Switch off power and remove plug from wall socket. 2. Remove solvent tubes and bars from the storage rack. 3. Turn the machine upside down and support it on wooden blocks between

the bench and black sheet metal casing so that the carriage is free to move (paragraph no.16 over).

4. Refer to Fig. 8. Loosen two screws (8/1) and remove storage rack. 5. Remove all 8 cover plate fixing screws. Remove cover. 6. Remove hexagon nut and washer (8/2) which clamps cable to the

carriage. 7. Loosen the clamping screw in the right hand cable clamp (8/3) using a

2.5mm hexagon key. Do not disturb the position of the left hand cable clamp (8/4).

8. Remove the old cable from the machine. 9. Loosen hexagon nuts (8/5) and (8/6) and adjust the position of the cable

adjustment pulley (8/7) until approximately half of the thread protrudes through nut (8/5) as shown in the figure.

10. Insert the nipple at one end of the new cable into the slotted hole

provided in the left hand cable clamp (8/4). 11. Rotate the left hand cable clamp (8/4) in the direction of arrow 'A' shown

while, at the same time, tensioning the cable lightly with your free hand. Continue to rotate until approx 10 cable turns have been wound onto the cable shaft (8/8).

12. While holding the left hand clamp stationary, feed the remaining cable

over the cable adjustment pulley (8/7) and then from under the pulley back to the right hand cable clamp (8/3) passing the cable underneath the cable shaft.

13. Insert the remaining cable nipple into the slotted hole in right hand clamp

block (8/3). 14. Now hold clamp block (8/3) stationary while rotating clamp block (8/4)

until the remaining loose cable is wound onto the cable shaft. Continued/...

K101\202 Ins\Iss15 32 March 2010

15. Clamp block (8/3) should now be tightened onto the cable shaft after repositioning it to the 7mm dimension shown between the block and the shoulder on the cable shaft.

16. Slide the carriage until the clamping stud (8/2) is approx midway along its travel as

shown in Fig. 8. 17. Pull the lower cable run until there is an equal length of cable wound on the left and

right hand side of the cable shaft. This means that 6 turns are visible on the left hand side.

18. Place the cable into the slot in clamping stud (8/2) and replace the clamping washer

and hexagon nut. Tighten nut. 19. Tension the cable by means of hexagon nut (8/5). Avoid excessive tension. Lock

adjustment pulley in position by tightening nut (8/6). 20. Replace cover plate and storage rack. 21. Turn machine over to its normal working position, connect power supply and test

run the machine. 22. Order a further spare cable so that it is readily available for future use when required. INSTRUCTIONS FOR ADJUSTING CARRIAGE REVERSE SPEED

1. � Switch off power and remove plug from socket. 2. Remove solvent tubes and bars from the storage rack. 3 Turn the machine upside down and support it on wooden blocks between the bench

and black sheet metal casing so that the carriage is free to move. 4. Locate the potentiometer access hole (8/13) in the base cover plate. Use a screwdriver to adjust the potentiometer. As standard, this is factory set to give a reverse speed of 4 seconds, to increase this

speed, rotate the potentiometer clockwise. 5. Check that the new reverse speed is as required after reconnecting the power supply

and operating the “Reverse-Off-Forward” Rotary Switch in its reverse (Rev) position. ▲ CAUTION— Before Operating ensure hands are well clear of all moving parts.

6. � Make further potentiometer adjustments if necessary after disconnecting power supply.

� CAUTION Do not connect the power supply unless the inner cover (8/12) is fitted and fixed with screws (8/11) as high voltage connections would be exposed.

March 2010 33 K101\202 Ins\Iss 15

BLANK PAGE

K101\202 Ins\Iss15 34 March 2010

4

2

3

1

`A'

`B'

10

30 - 40

FIG 9 CHECKING OVERLOAD CLUTCH TORQUE SETTING

A B

MODEL101/KPP/KLOX/KPA 190 MM 150 MM

MODEL202 370 MM 310 MM

March 2010 35 K101\202 Ins\Iss 15

MODEL 101 & 202 INSTRUCTIONS FOR ADJUSTING OVERLOAD CLUTCH The drive pulley (figure 8, Part No. 9) incorporates an overload clutch which is designed to protect the drive motor. The allowable torque has been factory adjusted before despatch of your machine from our works and under normal working conditions, this setting will need no further attention. However, after many hours of machine use, and particularly if the movement of the carriage appears to have become erratic, the torque should be checked( and re-adjusted if necessary) as follows: 1. Prepare a piece of timber (9/1) having dimensions approximately those

shown on Figure 9 and with a saw-cut slot at each end. 2. Move the carriage (9/2) to the start position (as shown in fig. 9) and

remove any coating/printing head thus exposing the 4 x fixing holes (9/3).

3. Using the two front fixing holes in the carriage and two of the head

fixing screws, attach a length (approx 1.1m) of strong cord, nylon or similar to the carriage and hold the cord apart with the timber as shown.

4. Using a spring balance, pull the carriage along its complete travel and

note the balance reading which should be between 5 and 6kg when the carriage is moving (a higher reading is required to start the movement from rest). If the reading is incorrect adjust the clutch as follows.

5. � Switch off power and remove plug from wall socket. 6. Remove solvent tubes and rods from the storage rack. 7. Turn the machine upside down and support it on wooden blocks

between the bench and black sheet metal casing so that the carriage is free to move.

8. Refer to Fig. 8 Loosen 2 screws (8/1) and remove storage rack. 9. Remove all 8 cover plate fixing screws(8/1). Remove cover. 10. Hold pulley (8/9) stationary and with a tommy bar rotate the adjusting

ring (8/10). Clockwise (as arrow 'B') increases the clutch torque. Make this adjustment in small steps and check the torque with the spring balance (as instruction No. 4 above). Make further adjustments if necessary until the spring balance reading falls within 5-6kg.

11. � Replace cover plate and storage rack.

K101\202 Ins\Iss15 36 March 2010

March 2010 37 K101\202 Ins\Iss 15

K101\202 Ins\Iss15 38 March 2010