★
EM 260/ 340/ 410/ 510 UV flexo printing unit BG 03
Contents
Description .............................. 1
1. Safety................................. 2
2. Technical Data ..................... 3
2.1 Service connections ................ 4
2.1.1 Pneumatic connections ..................4
2.1.2 Electrical connections ....................5
3. Operation ............................ 6
3.1 Operating and auxiliary equipt. . 6
3.1.1 Plate cylinder................................6
3.1.1.1 Establishing the printing length ....9
3.1.2 Anilox roller ...............................16
3.1.3 Ink roller ....................................17
3.1.4 Plate roller mounting plate
(19403 U03) ..............................18
3.1.5 Ink box......................................19
3.1.6 Doctor.......................................20
3.1.7 Printing plate..............................20
3.1.8 PE-Foam adhesive foil..................21
3.1.9 Ink............................................21
3.2 Operating elements ........... 22
* = When using Easy Change see the operating instructions „Easy Change BG 03“
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3.3 Setting up........................ 24
3.3.1 Installing the UV flexo printing
unit ................................................... 24
3.3.1.1 Changing stations .................... 25
* 3.3.2 Fitting and removing anilox roller 26
* 3.3.2.1 Fitting anilox roller................. 26
* 3.3.2.2 Removing anilox roller ........... 26
* 3.3.3 Fitting and removing ink roller.... 27
* 3.3.3.1 Fitting ink roller..................... 27
* 3.3.3.2 Removing ink roller................ 28
3.3.4 Fitting and removing ink box ........ 29
3.3.4.1 Fitting ink box ......................... 29
3.3.4.1.1 Mounting of scrapers............. 30
3.3.4.2 Removing ink box .................... 30
3.3.5 Fitting and removing doctor.......... 31
3.3.5.1 Fitting doctor .......................... 31
3.3.5.2 Removing doctor...................... 31
3.3.6 Plate cylinder ............................. 32
3.3.6.1 Preassembling plate cylinder ...... 32
3.3.6.2 Fitting plate cylinder ................. 33
3.3.6.3 Removing plate cylinder ............ 34
3.3.7 Fitting and removing protective grill35
3.3.7.1 Fitting protective grill................ 35
3.3.7.2 Removing protective grill........... 35
3.3.8 Setting the printing axis parallel .... 36
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Contents
3.4 Inserting web ................... 37
3.5 Starting up ...................... 38
3.5.1 Setting the doctor angle...............38
3.5.2 Proof printing .............................39
3.5.2.1 Setting the ink quantity.............40
3.5.2.2 Fine setting the printed image ....41
3.5.2.3 Setting the register...................42
3.5.2.3.1 Cross register .......................42
3.5.2.3.2 Longitudinal register ..............42
3.5.3 Process printing ..........................43
3.6 Shutting down ................. 43
3.6.1 Shutting down for a short period...43
3.6.2 Shutting down at end of shift .......44
3.6.2.1 Shutting down with UV ink .......44
3.6.2.2 Shutting down with waterbased ink
.........................................................45
3.6.3 Shutting down for a longer period .46
3.6.4 Shutting down a printing unit .......46
3.7 Malfunctioning ................. 47
* = When using Easy Change see the operating instructions „Easy Change BG 03“
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4. Care and maintenance......... 49
4.1 Qualification of staff ......... 49
4.2 Care................................ 49
4.2.1 Anilox roller ............................... 49
4.2.2 Ink roller .................................... 51
4.2.3 Ink box...................................... 52
4.2.4 Doctor....................................... 53
4.2.5 Plate cylinder ............................. 54
4.2.6 Impression cylinder ..................... 55
4.2.7 Printing unit ............................... 56
4.2.8 Cleaning fluid ............................. 57
4.3 Maintenance .................... 58
4.3.1 Anilox roller running on................ 58
4.3.1.1 Drive chain.............................. 58
4.3.1.2 Driving gearwheels
(anilox roller continued running). 59
4.3.1.3 coupling hub ........................... 59
4.3.2 Drive gears ................................ 60
4.3.3 Centering element....................... 60
4.4 Fast wearing parts ............ 61
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EM 260/ 340/ 410/ 510 UV flexo printing unit BG 03
Description
In the UV printing unit, ink is applied to the
web by means of a flexible printing plate,
referred to below as the "plate".
The plate is secured to the printing cylinder by
means of double sided foam rubber adhesive
foil. The printing cylinder with its stuck-on
printing plate is inserted into the printing unit
from above and located as near to the
impression cylinder as necessary to ensure
that during printing, the ink is transferred from
the plate to the web, evenly and without
squeezing.
In order to achieve precise inking of the plate,
an anilox roller is incorporated in the printing
unit. This determines the amount of ink to be
transferred.
The ink is transferred from the ink tray to the
anilox roller via an ink roller. In order to
ensure that this provides a precisely defined
amount of ink to the plate, a pneumatically
controlled doctor is located in the printing unit
which wipes off superfluous ink from the
anilox roller.
To prevent the ink (water-soluble ink) from
drying on the anilox roller, the anilox roller and
ink roller are separately driven during
stoppages.
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All arsoma machines have a uniform drive and
frame arrangement which enables various
printing processes to be combined on the
machine. UV flexo printing units can be
inserted at various positions in the machine.
Each UV flexo printing unit can be drawn from
the machine base towards the operating side,
enabling a quick change of printing process
and quick access to the UV flexo printing unit
for maintenance work. For this purpose,
insertion erection trolley BG 22 should be
used.
The UV flexo printing unit allows the use of all
common inks encountered in flexo printing
(water-soluble ink, UV hardening ink). The
web path downstream from the UV flexo
printing unit depends on the ink used. UV
inks require a UV drying operation.
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EM 260/ 340/ 410/ 510 UV flexo printing unit BG 03

1. Safety
Please observe the general safety instructions
at the beginning of this manual.

Caution:
Risk of explosion!
Water-soluble inks must never be dried by UV Caution:
drying. Risk of injury through the doctor.
The doctor is razor-sharp! Always wear
Caution: protective gloves when carrying out any work,
When changing printing units, only the e.g. cleaning or replacing the doctor.
transport equipment which has been specified
for this purpose may be used. The
instructions for changing the printing unit in
accordance with regulations must be
followed.

Caution:
When changing the printing unit, work
carefully and secure it against dropping down.

Caution:
When carrying out cleaning, there is a danger
of cleaning cloths or hands being drawn into
turning rollers.

Caution:
There is risk of injury when changing the
anilox roller.
Because of the heavy weight of the anilox
roller, fitting or removing it must be done
carefully.

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2. Technical Data

EM 260 EM 410 EM 510 EM 340

Web width max. 258 mm 413 mm 516 mm 343 mm
[10,125”] [16,25”] [20,25”] [13,5“]
Printing width max. 254 mm [10”] 407 mm [16”] 510 mm [20”] 337 mm
[13,25“]
Printing length min. 228,6 mm [9”]
max. 609,6 mm [24”]
Printing length increment 3,175 mm [1/8”]
Register adjustment cross ± 5 mm
longitudinal unendlich
Printing speed max. 150 m/min [492 ft/min]
Web thickness min. 80 ¿m [3,25 mil]
(standard) max. 180 ¿m [7 mil]
Web thickness with special min. 20 ¿m [0,8 mil]
impression cylinder max. 500 ¿m [19,5 mil]
increment range max. 100 ¿m [3,9 mil]
Doctor engagment force
max 360 N at 6 bar [88 psi] air pressure

Dimensions: EM 260 EM 410 EM 510 EM 340

Length: 431 mm [17“]
Width: 722 mm [28,5“] 877 mm [34,5“] 977 mm [38,5“] 807 mm [31,8“]
Height: 437 mm [17,2“]
Weight: 160 kg [353,13 lb] 180 kg [397,25 lb] 200 kg [441,5 lb]

Optional items:
• incorporation of register control BG 27
• incorporation of nip roller BG 23 (09^ 23 S28)
• incorporation of chamber doctor system
• use of negative doctor with manual engagement
• double gearing of impression cylinder, (e.g. DIN
A4 format)
• incorporation of an ink roller with special coating

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2. Technical Data
2.1 Service connections
2.1.1 Pneumatic connections
The UV flexo printing unit must be supplied
with cleaned and oiled compressed air at 6
bar.
Three compressed air hoses join the
connections at the UV flexo printing unit to
the connections at base frame BG 10.
The black hose with plug-in nipple (6 mm dia.)
is connected to distribution network c
(continuous air supply in run mode) and
provides the pneumatic cylinder with
compressed air for engaging the plate roller.
In run mode, the function "engage plate roller"
is in operation.
The black hose without plug-in nipple (6 mm
dia.) is connected to distribution network d
(continuous air supply when machine stopped)
and provides the pneumatic cylinder with
compressed air for disengaging the plate
roller. When the machine is stopped, the
function "disengage plate roller" is in
operation.
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The blue hose without plug-in nipple (6 mm
dia.) is connected to distribution network e
(continuous air supply) and provides the
pneumatically engaged doctor continouosly
with compressed.
After the pneumatic connections have been
made, tumbler switch 79 must be set to the
position "plate cylinder DOWN", by pushing
the tumbler switch down. If this switch is not
carried out, the pneumatic cylinders will not
generate any engaging force during running
mode or inching mode. This can lead to
possible incorrect operation of the UV flexo
printing unit.
Note:
Tumbler switch 79 must be in the position
"plate cylinder DOWN"
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2. Technical Data
2.1.2 Electrical connections

The anilox roller motor requires a 400 V 3-

phase supply. The socket (X 2) for the square
4-pin plug is located on the drive cover of
base frame BG 10.

The socket (X 3.6) for the round 9-pin plug

which transmits signals to the units BG 27
(automatic register control) is located on the
drive cover of base frame BG 10.

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3. Operation

3.1 Operating and auxiliary equipt.

3.1.1 Plate cylinder

The ready-to-print plate cylinder consist of the The following parts are delivered with the UV
following parts: flexo printing unit:

• Plate (printing plate); thickness: 1.7 mm Description: arsoma code

Double-sided foam rubber foil; thickness: trunnion 094 03 452
0.38 mm spring thrust 194 03 U39
bearing
63 two trunnions thrust bearing 194 03 U40
64 two bearer rings plate cylinder 093 03 444 (EM 260)
65 spring thrust bearing shaft
66 plate cylinder 091 03 444 (EM 340)
67 plate cylinder shaft 094 03 444 (EM 410)
68 thrust bearing 092 03 444 (EM 510)
69 gearwheel Table 1
70 Register ring for register control
(optional item)
71 Register ring for register presetting
(optional item)

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3. Operation
The following parts are not part of the items
supplied with the UV flexo printing unit as these
parts depend on the format length (printing
length).

Description arsoma code

bearing ring 094 03 441
gearwheel straight gearing: 094 03 450 (milled)
helical gearing: 094 03 451 (milled)

helical gearing for

inreased quality: 194 03 170 (ground)
register ring 194 03 079
ATS BG 27 for register control

register ring 094 03 453

BDS BG 67 for register presetting

plate cylinder 093 03 926 (EM 260)

091 03 926 (EM 340)
094 03 926 (EM 410)
092 03 926 (EM 510)
Table 2

When ordering parts which depend on the format
length, the format length must always be given.
All relevant dimensions can then be calculated
from this.
The calculation for the diameter of the plate
cylinder is based on the the following
assumptions: standard printing plate (printing
plate thickness = 1.7 mm), standard adhesive foil
(adhesive foil thickness = 0.38 mm) and a
compression of 0.05 mm.

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3. Operation

Sample calculation:
outside diameter of plate cylinder da:
format length LF = 12" = 304,8 mm
z x 3.175
da = -2xH=
no. of teeth on gearwheel z = π

8 teeth 8 teeth 96 x 3.175

LF x = 12" x - (2 x 2.03) =
1" 1" π

z = 96 teeth da = 92.96 mm

printing plate thickness a = 1.7 mm

adhesive foil thickness s = 0.38 mm
compression p = 0.05 mm

normal height:
H=a+s-p=

1.7 mm + 0.38 - 0.05 mm = 2.03 mm

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3. Operation
3.1.1.1 Determination of printing length

The format length is selected in steps of 1/8" = Note:

3,175 mm. The minimum format length is 9" = 1 tooth of the gearwheel (094 03 450,
228.6 mm corresponding to a gearwheel with 72 094 03 451 or for increased quality 194 03 170)
teeth (094 03 450, 094 03 451 or 194 03 170). corresponds to a length step of 1/8" = 3.175 mm
The maximum format length is 24" = 609.6 mm
corresponding to a gearwheel with 192 teeth Note:
(094 03 450, 094 03 451 or 194 03 170). The diameters of the plate cylinder given below
The corresponding outside diameter of the plate are based on the following values:
cylinder da is:
• printing plate thickness: a = 1.7 mm
• format length 9” = 228.6 mm • adhesive foil thickness: s = 0.38 mm
outside diameter = 68.706 mm • compression: p = 0.05 mm
• format length 24” = 609.6 mm
outside diameter = 189.982mm
• format length 12” = 304.8 mm
outside diameter = 92.961 mm

The format lengths of plate cylinders which are

possible are listed in the following table together
with the corresponding number of teeth and the
outside diameter of the plate cylinder.

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3. Operation
Table 3

Format length Number of Outside diameter

teeth (plate cylinder)
LF LF Z da
" mm mm

9 228.592 72 68.706
9 1/8 231.767 73 69.716
9¼ 234.942 74 70.727
9 3/8 238.117 75 71.738
9½ 241.292 76 72.748
9 5/8 244.467 77 73.759
9 3/4 247.642 78 74.769
9 7/8 250.817 79 75.780
10 253.991 80 76.791
10 1/8 257.166 81 77.801
10 1/4 260.341 82 78.812
10 3/8 263.516 83 79.823
10 1/2 266.691 84 80.833
10 5/8 269.866 85 81.844
10 3/4 273.041 86 82.855
10 7/8 276.216 87 83.865
11 279.391 88 84.876
11 1/8 282.566 89 85.886
11 1/4 285.740 90 86.897
11 3/8 288.915 91 87.908

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3. Operation

format length Number of Outside diameter

teeth (plate cylinder )
LF LF Z da
" mm mm

11 ½ 292.090 92 88.918
11 5/8 295.265 93 89.929
11 ¾ 298.440 94 90.940
11 7/8 301.615 95 91.950
12 304.790 96 92.961
12 1/8 307.965 97 93.971
12 ¼ 311.140 98 94.982
12 3/8 314.314 99 95.993
12 ½ 317.489 100 97.003
12 5/8 320.664 101 98.014
12 ¾ 323.839 102 99.025
12 7/8 327.014 103 100.035
13 330.189 104 101.046
13 1/8 333.364 105 102.057
13 ¼ 336.539 106 103.067
13 3/8 339.714 107 104.078
13 ½ 342.889 108 105.088
13 5/8 346.063 109 106.099
13 ¾ 349.238 110 107.110
13 7/8 352.413 111 108.120
14 355.588 112 109.131
14 1/8 358.763 113 110.142

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3. Operation

Format length Number of Outside diameter

teeth (plate cylinder)
LF LF Z da
" mm mm

14 1/4 361.938 114 111.152

14 3/8 365.113 115 112.163
14 1/2 368.288 116 113.174
14 5/8 371.463 117 114.184
14 3/4 374.637 118 115.195
14 7/8 377.812 119 116.205
15 380.987 120 117.216
15 1/8 384.162 121 118.227
15 1/4 387.337 122 119.237
15 3/8 390.512 123 120.248
15 1/2 393.687 124 121.259
15 5/8 396.862 125 122.269
15 3/4 400.037 126 123.280
15 7/8 403.211 127 124.291
16 406.386 128 125.301
16 1/8 409.561 129 126.312
16 1/4 412.736 130 127.322
16 3/8 415.911 131 128.333
16 1/2 419.086 132 129.344
16 5/8 422.261 133 130.354
16 3/4 425.436 134 131.365
16 7/8 428.611 135 132.376

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3. Operation

Format length Number of Outside diameter

teeth (plate cylinder)
LF LF Z da
" mm mm

17 431.786 136 133.386

17 1/8 434.960 137 134.397
17 1/4 438.135 138 135.407
17 3/8 441.310 139 136.418
17 1/2 444.485 140 137.429
17 5/8 447.660 141 138.439
17 3/4 450.835 142 139.450
17 7/8 454.010 143 140.461
18 457.185 144 141.471
18 1/8 460.360 145 142.482
18 1/4 463.534 146 143.493
18 3/8 466.709 147 144.503
18 1/2 469.884 148 145.514
18 5/8 473.059 149 146.524
18 3/4 476.234 150 147.535
18 7/8 479.409 151 148.546
19 482.584 152 149.556
19 1/8 485.759 153 150.567
19 1/4 488.934 154 151.578
19 3/8 492.108 155 152.588
19 1/2 495.283 156 153.599
19 5/8 498.458 157 154.610

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3. Operation

Format length Number of Outside diameter

teeth (plate cylinder)
LF LF Z da
" mm mm

19 ¾ 501.633 158 155.620

19 7/8 504.808 159 156.631
20 507.983 160 157.641
20 1/8 511.158 161 158.652
20 ¼ 514.333 162 159.663
20 3/8 517.508 163 160.673
20 ½ 520.683 164 161.684
20 5/8 523.857 165 162.695
20 ¾ 527.032 166 163.705
20 7/8 530.207 167 164.716
21 533.382 168 165.726
21 1/8 536.557 169 166.737
21 ¼ 539.732 170 167.748
21 3/8 542.907 171 168.758
21 ½ 546.082 172 169.769
21 5/8 549.257 173 170.780
21 ¾ 552.431 174 171.790
21 7/8 555.606 175 172.801
22 558.781 176 173.812
22 1/8 561.956 177 174.822
22 ¼ 565.131 178 175.833
22 3/8 568.306 179 176.843

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3. Operation

Format length Number of Outside diameter

teeth (plate cylinder)
LF LF Z da
" mm mm

22 ½ 571.481 180 177.854

22 5/8 574.656 181 178.865
22 ¾ 577.831 182 179.875
22 7/8 581.006 183 180.886
23 584.180 184 181.897
23 1/8 587.355 185 182.907
23 ¼ 590.530 186 183.918
23 3/8 593.705 187 184.929
23 ½ 596.880 188 185.939
23 5/8 600.055 189 186.950
23 ¾ 603.230 190 187.960
23 7/8 606.405 191 188.971
24 609.580 192 189.982

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3. Operation
3.1.2 Anilox roller

Apart from the plate cylinder and the doctor, The assembled anilox roller in arsoma UV
the anilox roller is one of the most important flexo printing units consists of the following
components of the UV flexo printing unit. parts:
The anilox roller determines the inking of the
web and because of this, the anilox roller 30 coupling hub 094 03 366
must be treated with utmost care. 31 ball bearing LAG-R 025
32 compensating bush
Various parameters must be taken into ATS 094 03 482
account when selecting the anilox roller, some 33 anilox roller 094 03 419
of which are listed below: [EM 410]
093 03 419
• anilox angle (in degrees) [EM 260]
• screen (lines/cm) 092 03 419
• scoop volume (cm³/m²) [EM 510]
• finish of the anilox roller 091 03 419
• screen of plate [EM 340]
34 compensating bush
Because of the large number of parameters, BDS 094 03 483
we cannot make a recommendation for 35 ball bearing LAG-R 025
selection of an anilox roller at this point. We
recommend that you consult your anilox roller When assembling the anilox roller, the
manufacturer about your particular location of the compensating bushes
application. ATS/BDS must be taken into account.

In order to prevent the ink in the anilox cells

from drying out, the anilox roller continues to
be driven during stoppages.

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3. Operation

3. Operation
3.1.3 Ink roller
The ink roller transfers ink from the ink tray to
the anilox roller. In order to ensure proper ink
transfer from the ink roller to the anilox roller,
the ink roller should be checked for damage
periodically.
To prevent damage, the ink roller must not be
in contact with the anilox roller during dry
running (operating without ink).
Note:
When fitting the ink roller into the UV flexo
printing unit, care must be taken to ensure
that the ink roller and anilox roller run in line
with one another.
Note:
Use of anti-foaming agents (mainly with UV
inks) can lead to swelling up of the ink roller.

The assembled ink roller in arsoma UV flexo

printing units consists of the following parts:

40 ball bearing LAG-S 012

41 ink roller 094 03 418 [EM 410]
093 03 418 [EM 260]
092 03 418 [EM 510]
091 03 418 [EM 340]
42 ball bearing LAG-S 012
shaft circlip D471-A 25x1.2
43 coupling hub 194 03 437
82 distance ring 133 07 018

Note:
Clamping ring 45 and set screw 46 are part of
ball bearing 42.

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3. Operation

3.1.4 Plate cylinder mounting plate

(194 03 U03)

The plate cylinder mounting plate enables the

plate cylinder to be fitted quickly and easily to
the plate cylinder shaft. The plate cylinder
mounting plate for the UV flexo printing unit
consists of the following parts:

Plate cylinder mounting plate

194 03 065
four feet 194 03 066
four guide strips 194 03 067
spring box 194 03 068
two distance sleeves 194 03 069
two clamping lugs 194 03 070
two studs 194 03 071
insert bush 194 03 072
spanner for plate cylinder
assembly 094 03 413
two knurled nuts D 466 - M 6
two compression springs GUT-D 018

One off plate cylinder mounting plate

(194 03 U03) is provided with each machine.

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3. Operation
3.1.5 Ink box
The ink box for the UV flexo printing unit
The ink box stores the ink required for consists of the following parts:
printing. The box can be filled in two ways:

a) Manually 1. ink box cover (48) not shown

If the ink is manually poured in, the - two cover clips 094 03 104
overflow valve is used as a plug (parts 49 - cover 194 03 933 [EM 410]
and 50). The overflow opening must be 193 03 933 [EM 260]
closed. When filling manually, the operator 192 03 933 [EM 510]
is responsible for the level of the ink. 191 03 933 [EM 340]
- bow type handle GAN-B 001
a) Pump operation
When pump operation is used, the ink 2. Ink box (9)
pump transfers ink from an ink container 47 ink tray 094 03 901 [EM 410]
into the ink box. Excess ink runs back into 093 03 901 [EM 260]
the ink container via the overflow valve. 092 03 901 [EM 510]
For this purpose, the overflow opening 091 03 901 [EM 340]
must be open. The ink supply pipe is hung 49 ink tray stopper 094 03 073
from the ink box and a return funnel with 50 sealing sleeve 094 03 034
hose is attached below the overflow valve
by means of a spring. inking tank insert
Pump operation ensures that the ink is 194 03 367 [EM 410]
continuously circulated, thus preventing the 193 03 367 [EM 260]
ink from drying. 192 03 367 [EM 510]
191 03 367 [EM 340]

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3. Operation
3.1.6 Doctor
The doctor device serves to provide uniform
inking from the anilox roller to the plate
cylinder. The doctor blade removes excessive
ink from the anilox roller so that the anilox
cells of the anilox roller are "full to the brim".
To prevent the doctor from lifting off the
anilox roller as a result of the scraped off ink,
the doctor is set at a negative angle.
In UV flexo printing units, thin section doctors
are used. When fitting the doctor, the correct
position of the chamfer must be observed.
The basic equipment of the UV flexo printing
unit includes a pneumatically operated doctor
device. The engagement pressure can be
adjusted to suit the requirements.
The doctor for the UV flexo printing unit
consists of the following parts:
56 thin section doctor blade (ceramic
coating): MEY-D 013 [EM 260]
MEY-D 014 [EM 410]
MEY-D 015 [EM 510]
MEY-D 018 [EM 340]
59 doctor shaft 094 30 032 [EM 410]
093 30 032 [EM 260]
092 30 032 [EM 510]
091 30 004 [EM 340]
60 doctor clamps 094 30 005 [EM 410]
093 30 005 [EM 260]
092 30 005 [EM 510]
091 30 005 [EM 340]
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61 pressure plate 094 30 033
3.1.7 Printing plate
The printing plate is very important in the
flexographic process because on the one hand
it must accomodate the height and
concentricity variations which occur and on
the other hand it must ensure that the printed
impression is sharply defined.
Printing plates used in UV flexo printing units
should have a plate thickness of 1.7 mm.
Together with the PE foam adhesive foil and
under the necessary compression this results
in a standard height of 2.03 mm for the
printing plate and foam adhesive foil. The
outside diameter of the plate cylinder is
calculated on the basis of this standard
height.
If thin plates with a plate thickness of 1.14
mm or 0.76 mm are used, the difference in
height must be accomodated by a thicker PE
foam adhesive foil with a standard plate roller.
When ordering a plate cylinder, the printing
plate thickness and PE adhesive foil thickness
must always be given. This ensures that you
get the correct outside diameter and thus the
desired printing length for your plate cylinder.
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3. Operation
3.1.8 PE foam adhesive foil
The PE foam adhesive foil effects the
connection between plate cylinder and plate.
In addition, the PE foam adhesive foil must
take part of the engagement pressure
between plate cylinder and impression
cylinder, otherwise the plate would be unduly
heavily loaded.
Thus, the function of the PE foam adhesive
foil, simply expressed, is as follows:
1. Establish connection between plate and
plate cylinder
2. Compensate for concentricity and height
variations
The thickness of the PE foam adhesive foil
should be 0.38 mm as standard.
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
3.1.9 Ink
In UV flexo printing units water-based,
solvent-based and UV hardening printing inks
can be used. The decision on the type of ink
depends on the specific application.
Caution:
Water-based inks must not be dried by means
of a UV drying unit. Risk of explosion!
Caution:
UV hardening printing inks must not be dried
by means of hot air or warm air drying units
BG 14!
Risk of contamination.
UV hardening inks require UV radiation in
order to be hardened.
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3. Operation
3.2 Operating elements

1 locking screw, plate cylinder 29 adjusting bolt

2 feed screw, operating side 30 coupling hub
3 feed screw, drive side 31 ball bearing
4 cross register adjusting screw 32 compensation bush ATS
5 stop pin (base frame BG 10) 33 anilox roller
6 guide rails (base frame BG 10) 34 compensation bush BDS
7 funnel, ink tray 35 ballbearing
8 mounting spring 36 anilox roller lock
9 ink tray 37 fasteners
10 ink roller [completely preassembled] 38 mesh guard
11 anilox roller [completely preassembled] 39 lifting device - plate cylinder
12 doctor 40 self-clamping bearing
13 locking screw, ink roller 41 ink roller
14 retention screw, anilox roller lock 42 self-clamping bearing
15 horizontal adjustment screw 43 coupling hub
16 fixing screw doctor 44 ink roller lock
17 anilox roller drive "ON/OFF" 45 clamping ring of self-clamping bearing
18 tumbler switch, "doctor engagement 46 set screw
ON/OFF" 47 ink tray
19 sidewall 48 ink box cover
20 centering element 49 ink tray stopper
21 gearwheel guard 50 sealing sleeve
22 plate cylinder [fully assembledt]
23 impression cylinder
24 crank Note:
25 drive, "raise plate cylinder" When using Easy Change BG 03 several of
26 pressure regulator with gauge "doctor" the following parts will be omitted.
27 lifting device - anilox roller
28 end plate

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3. Operation
79 tumbler switch "printing cylinder
51 key UP/DOWN"
52 scraper 80 phase shifter gearbox
53 allen screw for securing ink box 81 drive chain
54 ink supply hose 82
55 silicon hose with funnel 83 anilox roller motor
56 doctor blade 84
57 doctor blade clamping screw 85
58 support plate 86 connecting shaft
59 doctor shaft 87 Scotch yoke
60 doctor clamp 88 spigot with thrust washer
61 pressure plate 89 clutch disk
62 mounting angle 90 bevel gear drive
63 spigot 91 register motor
64 cylinder bearer 92 drive chainwheel
65 spring thrust bearing 93 bearer plate
66 plate cylinder 94 clamping lug
67 plate cylinder shaft 95 spring box
68 thrust bearing
69 gearwheel
70 register ring (register control)
71 register ring (register presetting) Note:
(optional item) When using Easy Change BG 03 several of
72 key the following parts will be omitted.
73 plate cylinder mounting plate
74 stop pin
75 transport pin
76 cross piece
77 marking hole
78 switch "anilox roller motor ON/OFF"

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3. Operation
3.3 Setting up
3.3.1 Installing the UV-flexo printing unit
We recommend using our insertion erection
trolley BG 22 to install the UV flexo printing
unit by sliding it onto the desired base frame
BG 10.
When installing the UV flexo printing unit on
base frame BG 10, proceed as follows:
• Make sure that there is no web present in
base frame BG 10.
• Align the guide rails of insertion trolley BG
22 accurately with the guide rails of base
frame BG 10 (location and height)
Note:
To facilitate sliding the UV flexo printing
unit onto base frame BG 10, the green
slides and guide rails 6 should be lighly
greased.
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
• Slide UV flexo printing unit from indertion
erection trolley BG 22 onto base frame BG
10.
• Push insertion trolley BG 22 out of the
way.
Caution:
Risk of damaging UV flexo printing unit and
base frame BG 10. Make sure that UV flexo
printing unit is seated firmly on the base
frame and cannot tip over.
• Push the UV flexo printing unit further onto
the base frame until you notice a marked
resistance.
• Turn the counterpressure cylinder (23)
manually so that the mechanical coupling
will catch correctly.
Caution:
Risk of damaging pneumatic and electrical
connections. Make sure that these are not
nipped.
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3. Operation

• Turn cross register adjustment screw 4

3.3.1.1 Changing a station
until you can see stop pin 5.
If you need to change a station, i.e. replace a
Note:
UV flexo printing unit which is mounted on a
Stop pin 5 must snap out.
base frame BG 10 with another printing unit,
you must carry out the installation work
• Connect the pneumatic and electrical
described above in the reverse order.
connections (see item 2.1 "supply
connections" in this operating instruction).

After the UV flexo printing unit has been

installed, the operating and auxiliary
equipment can be fitted or removed. After
this, the web should be inserted (see item 3.4
"Insert web" of this operating instruction).

After the web has been inserted, fit plate

cylinder 22 and fit mesh guard 38 over it.
The UV flexo printing unit must now be
mechnically locked by turning lever 17 to the
back (towards the drive side). All the settings
required for printing can now be made.

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3. Operation

*Note: When using Easy Change see the operating instructions „Easy Change BG 03“

3.3.2 Fitting and removing anilox roller • Fold anilox roller locks 36 upwards.
• Push the fasteners down and tighten the
3.3.2.1 Fitting the anilox roller
retention screws with an allen key.
Caution:
Risk of injury to hands through their being 3.3.2.2 Removing the anilox roller
drawn in between rollers.
Please refer to item 3.3.2.1, Fitting the anilox
Before lifting the anilox roller into the UV flexo roller. Removing the anilox roller is done in
printing unit you should check whether the the reverse order.
anilox roller is fully prepared for fitting. The
anilox roller must be prepared in the following
way: Caution:
Risk of damaging the anilox roller.
When fitting the anilox roller, please proceed Because of the liability of damage to the
as follows: surface of the anilox roller and its heavy
weight, the removal operation must be carried
• Loosen the two retention screws with an
out with great care.
allen key and push fasteners 37 upwards.
• Fold anilox roller locks 36 down.
• Lift anilox roller 11 into the UV flexo
printing unit.

Note:
Bearings 31/35 must line up with anilox
roller locks 36.

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3. Operation

*Note: When using Easy Change see the operating instructions „Easy Change BG 03“

3.3.3 Fitting and removing ink roller Note:

Self-clamping bearings 40/42 must be in
3.3.3.1 Fitting ink roller line with ink roller locks 44.

Caution: • Close ink roller locks 44 together and

Risk of injury to hands through their being swing locking screw 13 down.
drawn in between rollers. • Align ink roller 10 to anilox roller 11.
Secure the printing machine against
unauthorized starting up. Note:
Ink roller 10 and anilox roller 11
Caution:
must run in line with one another. Before
Risk of damage to ink roller 10.
tightening clamping ring 45, lay a straight-
Ink roller 10 should not run with anilox roller
edge against ink roller 10 and anilox roller
11 in the dry state.
11 and align their end faces.
The ink roller should be fitted after completing
the fitting of the anilox roller. • Screw clamping ring 45 of self-clamping
bearing 40 on the operating side tight and
When fitting ink roller 10, please proceed in secure it with set screw 46.
the following sequence: • Tighten locking screw 13 lightly.
• Open ink roller locks 44 by turning locking Caution:
screws 13 anticlockwise Risk of damage to ink roller 10.
• Fold locking screws 13 upwards to allow Ink roller 10 should not run with anilox
ink roller locks 44 to open. roller
• Lay ink roller 10 in ink roller locks 44. 11 in the dry state.

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3. Operation

*Note: When using Easy Change see the operating instructions „Easy Change BG 03“

3.3.3.2 Removing the ink roller

Removal of the ink roller is carried out in the

reverse sequence.

Note:
Before removing ink roller 10 you should first
wipe off excess ink from this. Use a soft
cloth and the cleaning solvent specified in
item 4 "Maintenance".

Caution:
Risk of the cleaning material and hands being
drawn in between rollers.

Caution:
Risk of contaminating the UV flexo printing
unit and base frame BG 10.

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3. Operation

*Note: When using Easy Change see the operating instructions „Easy Change BG 03“

3.3.4 Fitting and removing ink box

If you insert the ink box complete with ink in
the UV flexo printing unit, ensure that the
overflow openings are closed off by means of
sealing sleeve 50.
Caution:
Risk of contamination through ink leakage.
• Push ink tray 47 upwards and fix it to the
UV flexo printing unit by turning allen
screw 53 clockwise.
• If there is no overflow valve present in ink
tray 47, this must now be fitted. Ink tray
stopper 49 must be plugged into the hole
on the operating side and sealing sleeve 50
pushed over the valve.

3.3.4.1 Fitting the ink box The ink tray can now be filled with ink.

When inserting ink box 9 in the UV flexo • After filling with ink, scrapers 52 must be
printing unit, please proceed in the following inserted.
order:

• Loosen the ink box fixing by turning allen

screw 53 anticlockwise using key 51.
• Slide ink tray 47 under ink roller 10 and
anilox roller 11.

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3. Operation
3.3.4.1.1 Mounting of scrapers 3.3.4.2 Removing the ink box

Scrapers (52) are to be mounted on both Removal of the ink box is carried out in the
sides of the tipping and screen rollers to reverse order.
prevent contamination by ink.

Important!
The scrapers may only be mounted when
there is ink in the ink duct because otherwise
they will overheat!
Remove the scrapers as soon as the printing
unit has been switched off.

• When fitting the scrapers, the spring must

be on the outside and the U-shaped
openning must point towards the screen
roller.
• Press in the spring by hand.
• First place the wiper over the screen roller
arbour (1) from below and then over the
tipping roller abour (10).
• The scrapers must lie flush against the side
of the rollers.

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3. Operation
3.3.5 Fitting and removing the doctor device
When fitting doctor device 12 or when
replacing the doctor blade, attention must be
paid to the position of the chamfer relative to
the anilox roller.
Caution:
Risk of cutting injury through the doctor.
Doctor blade 56 is razor sharp!
During all operations such as cleaning or
changing doctor 12 or doctor blade 56,
protective gloves must be worn. In case of
injury, a (medical) doctor should be consulted
immediately.
3.3.5.1 Fitting the doctor
When fitting doctor device 12, please proceed
in the following order:
Insert doctor 12 from above in mounting
angles 62.
Note:
Doctor 12 must rest with the side journals of
doctor shaft 59 lying in mounting angles 62.
Caution:
Risk of cutting injury from the doctor blade.
Doctor blade 56 is razor sharp!
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
• Secure doctor 12 in its working position
with fixing screws "doctor".
• Set doctor 12 to anilox roller 11 by
operating tumbler switch 18.
Caution:
The doctor should only be engaged during
continuous running of the anilox roller with
ink.
• Adjust the engagement force at pressure
regulator 26.
Note:
To keep wear on the doctor to a minimum
it should be as lightly set as possible
consistent with a good doctoring result.
3.3.5.2 Removing doctor device
Removal of doctor 12, is carried out in the
reverse order (see also item 3.3.5.1 "Fitting
the doctor").
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3. Operation
3.3.6 Plate cylinder
3.3.6.1 Plate cylinder preassembly
When assembling plate cylinder 22, please
proceed in the following order:
• Fit a spigot 63 into the tapped hole in the
end face of plate cylinder shaft 67 using
key 72. During this operation, plate
cylinder 67 should be held in a vice with
soft jaws.
Caution:
Risk of damging the plate cylinder shaft.
Use a vice with soft jaws.
• Place a cylinder bearer 64 on preassembled
plate cylinder shaft 67.
Note:
Pay attention to the location of stop pins
74. These must point to the outside.
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
• Fix the partly preassembled plate cylinder
shaft 67 to the plate cylinder mounting
plate using clamping lugs 73.
Note:
The centering pins must snap into the
corresponding holes in the spigots 63.
The stop pins 74 of the cylinder bearers
must lie in the grooves of plate cylinder
mounting plate 73.
• Slide spring thrust bearing 65 onto plate
cylinder shaft 67.
Note:
Pay attention to the attitude of thrust
bearing 65. The relieved side must point to
the plate cylinder.
Note:
The spring thrust bearing must be greased
with bearing grease before fitting.
• Slide the preassembled plate cylinder 66
onto plate cylinder shaft 67.
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3. Operation
Note:
Pay attention to the direction of plate
cylinder 66.
Gearwheel 69 must be mounted with its
register ring 70 pointing upwards.
Note:
The cylinder roller bearing in the inner part
of the plate cylinder must be greased with
bearing grease before fitting.
• Slide thrust bearing 68 onto plate cylinder
shaft 67.
Note:
Pay attention to the attitude of thrust
bearing 68. The relieved side must point
towards the plate cylinder.
Note:
The thrust bearing must be greased with
bearing grease before fitting.
• Slide the second cylinder bearer 64 onto
plate cylinder shaft 67.
Note:
Pay attention to the location of stop pins
74.
These must point towards the outside.
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
• Secure the parts which have been pushed
onto the plate cylinder shaft with the
second spigot 63. Screw spigot 63 into
the tapped hole in the end face of plate
cylinder shaft 67 and tighten this with key
72.
Plate cylinder 22 is now preassembled ready
to fit. By loosening the clampiong lugs, you
can remove preassembled plate cylinder 22
from the plate cylinder mounting plate.
3.3.6.2 Fitting the plate cylinder
During fitting of plate cylinder 22, mesh guard
38 should be disassembled (see item 3.3.7
"Fitting and removing mesh guard" in this
operating instruction).
During fitting of plate cylinder 22 in the UV
flexo printing unit, please proceed in the
following order:
• Make sure that lifting device 39 is at its top
dead center. If this is not the case, turn
this up using crank 24.
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3. Operation

• Lay preassembled plate cylinder 22 on the
support of lifting device 39.
Caution:
Risk of damaging the gearwheel.
Caution:
Danger of damaging the gearwheels!
• During lowering of lifting device 39, the
plate cylinder must be lightly turned
backwards and forwards to enable the
gearwheels to mesh properly.

Note: • Close the fastening mechanism by turning

There are three pins on each of the cylinder
bearers 64.
In each case, two of the pins, namely stop
pins 74 point to the outside. The third pin,
transport pin 75 points to the inside and
the outside. The transport pins on the
operating side (BDS)and drive side (ATS)
should be at the upper position and aligned
with slot "A".
• Lower lifting device 39 with crank 24.
Note:
Spigot 63 must be located in slot "A".
the locking screw, plate cylinder 1
clockwise.
3.3.6.3 Removing plate cylinder
Removal of plate cylinder 22 is carried out in
the reverse order (see also item 3.3.6.2
"Fitting plate cylinder").
Note:
After about 3 turns in the anticlockwise
direction, centering elements 20 will release
the stop pins 74 of the cylinder bearers.

• By turning the locking screws, plate

cylinder 1 clockwise, stop pins 74 are
engaged by the centering element and
clamped.

• Engage the gearwheels by further lowering

lifting device 39.

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3. Operation
3.3.7 Fitting and removing mesh guard

If the mesh guard is opened, the printing
machine can only be run in inching mode.
This protection device is fitted for your safety
and must therefore not be removed.
3.3.7.1 Fitting the mesh guard
When fitting mesh guard 38 into the UV flexo
printing unit, please proceed in the following
order:
• Hook mesh guard 38 with the forks on
either side onto the pivot shaft of lifting
device 39.
You can now close the mesh guard.
3.3.7.2 Removing the mesh guard
When removing mesh guard 38, please
proceed in the following order:

• Turn mesh guard 38 through about 100°
as if you were going to open it.
• Push mesh guard 38 from the drive side
onto the spigots at the pivot shaft of lifting
device 39.
Note:
The hole on the drive side of mesh guard
38 must be located on the spigot of the
pivot shaft.
• Open mesh guard 38 completely.
• Push mesh guard to the drive side from the
spigot of the pivot shaft of lifting device
39.
• Lift mesh guard 38 from the pivot shaft
and lay it on one side.
Note:
The printing machine can onyl be started in
run mode when the mesh guard is fitted
and closed.

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3. Operation
3.3.8 Setting the printing axis parallel

In order to achieve the best printing results, When the setting has been carried out, check
the axis of plate cylinder 22 must be parallel it again on the operating side. After this
to the axis of impression cylinder 23 and check has been carried out, the parallel setting
parallel to the axis of anilox roller 11, in both of the axes is complete. A first parallel
the horizontal and vertical planes. setting is carried out at the factory.
A setting bolt 29 is provided which enables
the relative position of the axes to be
established. If this can be entered into the
corresponding setting hole 77 (dia. d = 10
mm) about 40 mm, the "zero position" has
been reached.

When carrying out parallel setting of the axes,

please proceed as follows:

• Push setting bolt 29 into setting hole 77 on

the operating side and turn horizontal
adjusting screw 15 on the operating side
until setting bolt 29 can be pushed about
40 mm into the setting hole.
• Withdraw setting bolt 29 from the setting
hole and carry out the setting on the drive
side.

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3. Operation
3.4 Inserting web

The run of the web must correspond to the

sketch.

Insertion of the web is best carried out with

plate cylinder 22 and mesh guard 38
removed.
When inserting the web, please proceed in the
following order:

• Push the web from below through the

upper plate of base frame BG 10 and
through the base plate of the UV flexo
printing unit.
• Feed the web from the inlet side (ELS) of
the UV flexo printing unit between ink box
9 and cross piece 76 and feed the web
round impression cylinder 23.

Caution:
Risk of trapping fingers between ink box 9
and cross piece 76.

The subsequent web path depends on the

drying process used.

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3. Operation

3.5 Starting up

3.5.1 Setting the doctor angle

The angle of the doctor can be selected to Note:

suit the requirements (ink viscosity). There is The two doctor mounting pieces must be
a choice of two angles - approx. 36° and fixed in the same position to ensure that
approx. 41°. When selecting the doctor the doctor is mounted parallel to the anilox
angle, please proceed as follows: roller.

• Remove doctor 12 from the UV flexo • Tighten the fastening screws of doctor
printing unit. mounting angles 62.
• Insert doctor 12 into the UV flexo printing
Caution: unit.
Risk of injury from the doctor. The doctor
is razor-sharp!

• Undo the fixing screws of doctor mounting

angles 62 on the inner side of the UV flexo
printing unit.
• Set mounting angles 62 in the desired
position.

Note:
The upper position corresponds to a doctor
angle of approx. 41°.
The lower position corresponds to a doctor
angle of approx. 36°.
The postion of these two angles is
determined by pins.

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3. Operation
3.5.2 Proof printing Note:
The ink roller must not yet be moved up to
When proof printing, please proceed in the anilox roller 11 and the doctor must not be
following order: set against the anilox roller.

Note: • Move ink roller 10 up to anilox roller 11.

The proof printing opertion should be carried
out at creep speed (approx. 10 m/min) (see
operating instruction Drive station BG 09").
Note:
Do not start the creep speed at this point.
The printing machine should only be switched
on at the main switch of drive station BG 09.
• Engage the anilox roller drive.
To do this, lever 17 must be turned to the
inlet
side. The coupling hub needs about one
turn
in order to engage.
• Switch on the anilox roller motor by
pressing switch 78, "anilox roller motor
ON/OFF". The switch lights up and ink
roller 10 starts turning.
Ink roller 10 now transfers ink to anilox
roller 11.
to achieve this, turn the two locking
screws, ink roller 13 clockwise.
• Move doctor 12 up to anilox roller 11 by
operating tumbler switch 18.
Note:
Observe the surface of anilox roller 11; ink
doctoring must be performed evenly.
Note:
In order to keep the wear of the anilox
roller to a minimum, doctor 12 should be
set as lightly as possible consistent with a
satisfactory doctoring result.
• Insert the web into the UV flexo printing
unit
(see item 3.4 "Insert web")

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3. Operation
• Fit plate cylinder 22 to UV flexo printing
unit (see item 3.3.6.2 "Fitting plate
cylinder").
• Now start the printing machine at creep
speed at the operating panel of drive
station BG 09 (see operating instruction
"drive station BG 09".
Observe the printing result obtained during
proof printing. If your printed image is sharp
on the drive side and gets weaker towards the
operating side, a vertical resetting of the
printing axis on the operating side is
necessary. This must be done in the
following way:
• Turn feed screw 2 on the operating side
clockwise until the printed image is sharp
on the operating side.
Note:
This adjustment should be done very
carefully, as often some 1/100 mm is
enough to achieve the optimum printing
result.
One turn of the feed screw corresponds to
a feed of 0.1 mm.
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If your printed image is sharp on the operating
side and gets weaker towards the drive side,
a vertical resetting of the printing axis on the
drive side is necessary. This must be done in
the following way:
• Turn feed screw 2 on the drive side
clockwise until the printed image is sharp
on the drive side.
Note:
This adjustment should be done very
carefully, as often some 1/100 mm is
enough to achieve the optimum printing
result.
One turn of the feed screw corresponds to
a feed of 0.1 mm.
3.5.2.1 Setting the ink quantity
It is possible to achieve a limited increase of
inking from the plate to the web by increasing
the pressure between plate and web. When
carrying out this setting, please note that the
printing result must be carefully observed. If
the pressure is set too high, squeezed edges
appear on the printed image.
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EM 260/ 340/ 410/ 510 UV flexo printing unit BG 03
3. Operation
3.5.2.2 Fine adjustment of the print image
The print image should be evenly produced on
the web with a uniform colour shade. For this
it is necessary that the axis of the plate
cylinder lies parallel to the axis of the
impression cylinder. Furthermore there must
be a correct pressing force between plate and
web.
During proof printing, observe the print image
over the total web width. If adjustment are
made on the operating side, e.g.setting the
inking, it may be necessary to make an
adjusment on the drive side.
Note:
One turn of the feed screw BDS/ATS (2/3)
corresponds to a vertical feed of 0.1 mm.
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The following principle applies:
Feed screw, operating side 2 is used for
settings on the operating side. Turning
clockwise reduces the distance between the
axes of the plate cylinder and the impression
cylinder. This results in a higher pressing
force between plate and web. Turning
anticlockwise enlarges the distance between
the axes. This results in a lower pressing
force.
Feed screw, drive side 3 is used for settings
on the drive side. Turning clockwise reduces
the distance between the axes of the plate
cylinder and the impression cylinder. This
results in a higher pressing force between
plate and web. Turning anticlockwise
enlarges the distance between the axes. This
results in a lower pressing force.
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3. Operation
3.5.2.3 Register setting
3.5.2.3.1 Cross register
The cross register is set directly on the UV
flexo printing unit. The adjustment is
performed on cross register adjusting screw 4.
Turning clockwise causes shifting of the UV
flexo printing unit towards the drive side and
the print image is also shifted towards the
drive side. Turning anticlockwise causes
shifting of the UV flexo printing unit towards
the operating side and the print image is also
shifted towards the operating side.
The adjustment range is ± 5 mm. The
adjustment of the cross register can be carried
out both when the machine is stopped and
during running. It is advisable to carry out the
adjustment of the cross register during the
running operation as the effect on the print
image is then immediately visible.
3.5.2.3.2 Longitudinal register
The longitudinal register is adjusted from the
operating panel of drive station BG 09 (see
operating instruction "Drive station BG 09").
The adjustment range is infinite in both
directions.
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This adjustment range can however only be
achieved step by step. The maximum step
length is ± 499.95 mm. In this case ± 9999
must be entered on the operating panel of
drive unit BG 09 at the appropriate place.
The minimum step length is ± 0.05 mm. In
this case ± 1 must be entered on the
operating panel of drive unit BG 09.
The following formula is used to calculate the
value to be entered on the operating panel of
drive unit BG 09:
X = a x 20
X value to be entered
a desired longitudinal register
adjustment
Note:
Note the sign of the value to be entered:
+ longitudinal register adjustment in
web run direction
- longitudinal register adjustment in
direction opposite to web run direction
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3. Operation
3.5.3 Production run
After all necessary adjustments have been
made during proof printing and the desired
printing result has been achieved, the machine
can be run up to the required printing speed.
During a production run the following
functions must be monitored by the operator
of the printing machine:
• Ink level in the ink box, when manual ink
filling is used.
• Ink level in the ink container in the case of
pump operation.
Caution:
Risk of damage to ink roller 10.
Ink roller 10 must never be allowed to run
against anilox roller 11 in the dry state.
Caution:
Risk of damage to scraper 52.
Scraper 52 must never be allowed to run
against ink roller 10 and anilox roller 11 in
the dry state.
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* Note: When using Easy Change see the
operating instructions
„Easy Change BG 03“
3.6 Shutting down
When the machine stops, plate cylinder 22 is
automatically raised. This prevents the plate
cylinder from getting stuck to the web.
During this lifting operation, the gearwheels of
plate cylinder 22 and impression cylinder 23
remain engaged so that a loss of longitudinal
register is avoided.
3.6.1 Shutting down for a short period
During a short interruption of the printing
process, no measures need to be taken or
adjustments made to the UV flexo printing
unit.
Examples of short stoppages:
• splicing on a new web
• filling the ink box with ink
• removal of the finished wound roll
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
If water-soluble ink is used for the printing
process, when the stoppage continues for
some time this can result in the ink on plate
cylinder 22 drying off. If this occurs, it is
advisable to remove the dried-on ink from the
plate using a soft rag soaked in solvent. For
this purpose use a solvent recommended by
the ink manufacturer as given in section 4
"Care and maintenance".
Cleaning dried-on ink off the plate within the
UV flexo printing unit may only be carried out
in the inching mode.
Caution!
Risk of injury to hands through their being
drawn in between rollers.
3.6.2 Shutting down at end of shift
The steps to be performed at the end of a
shift depend on the ink used.
3.6.2.1 Shutting down with UV ink
At the end of the shift the machine must be
switched off (see also operating instruction
"Drive station BG 09").
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There are no special cleaning operations to be
carried out on the UV flexo printing unit
because UV inks harden only under the
influence of UV radiation. However, you
should take into consideration that UV
radiation can be generated by your lamps.
You should therefore protect all parts which
have been in contact with UV ink, such as ink
box 9, ink roller 10, anilox roller 11, plate
cylinder 22 and the printed web which has
not yet been dryed by UV drying unit BG 38
from the influence of such radiation. If the
UV flexo printing unit is exposed to this
radiation without protection, the UV ink can
harden and lead to costly cleaning work.
If these measures for protecting the reverse
side printing unit from UV radiation have been
carried out, then at the beginning of a new
shift and after a short running-in period, the
run operation can be continued.
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3. Operation
*Note: When using Easy Change see the operating instructions „Easy Change BG 03“
3.6.2.2 Shutting down with
based inks
If the end of the shift can be anticipated and
you are printing with a water-based ink, the
ink level in ink box 9 should be not be
increased but reduced as far as possible.
Remember that water-based inks dry out after
a short time. For this reason, certain
maintenance and cleaning work is necessary
at the end of a shift so as to avoid damage.
The following work must be carried out:
• Switch off the printing machine (see
operating instruction "Drive station BG
09").
• Dismantle mesh guard 38 (see item 3.3.7
"Fitting and removing mesh guard").
• Remove plate cylinder 22 from the UV
flexo printing unit and clean it with a
suitable cleaning fluid ( see item 3.3.6
"Fitting and removing plate cylinder" and
item 4.2 "Care".)
• Remove doctor 12 from the UV flexo
printing unit and clean it with a suitable
cleaning fluid or solvent (see item 3.3.5
"Fitting and removing doctor" and item 4.2
"Care").
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
water-
Caution
Risk of cutting injury !
The doctor blade is razor sharp. Wear
protective gloves during fitting and cleaning
work on the doctor.
• Remove ink box 9 from the UV flexo
printing unit and clean it with a suitable
cleaning fluid or solvent (see item 3.3.4
"Fitting and removing the ink box" and item
4.2 "Care".)
• Remove ink roller 10 from the UV flexo
printing unit and clean this with a suitable
cleaning fluid or solvent (see item 3.3.3
"Fitting and removing ink roller" and item
4.2 "Care").
• Remove anilox roller 11 from the UV flexo
printing unit and clean this with a suitable
cleaning fluid or solvent (see item 3.3.2
"Fitting and removing anilox roller" and
item 4.2 "Care").
After anilox roller 11 has been removed and
cleaned, get rid of any ink contamination
within the UV flexo printing unit, paying
particular attention to impression roller 23.
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3. Operation
Dried out remains of ink which are not
eliminated can cause damage. When cleaning
the UV flexo printing unit, use suitable
solvents and cleaning fluids (see item 4.2
"Care").
If the same job is to be printed in the next
shift you can prepare the UV flexo printing
unit for this straight away.
Please remember that in the dry condition, ink
roller 10 must not be engaged with anilox
roller 1. Note that the ink box must not yet
be filled with ink as this could dry out before
beginning of the next shift.
3.6.3 Shutting down for a longer period
If the UV flexo printing unit is to be shut
down for a longer period, it should be
removed from base frame BG 10 with the help
of insertion erection trolley BG 22 and given a
thorough clean. During this cleaning
operation you can check whether fast wearing
parts are worn out and replace them.
After the cleaning process has been
completed, the UV flexo printing unit can be
prepared for a new job.
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If you wish to store ink roller 10 separately,
this must be stored on its spigots. Avoid
storing on the rubber surface because this can
lead to damage.
3.6.4 Shutting down the printing unit
It is possible to shut down the UV flexo
printing unit so that plate roller 22 remains in
the raised position during the run operation.
Shutting down is carried out as follows:
• Operate tumbler switch 79 "printing
cylinder UP/DOWN"
Note:
This setting should only be carried out
when the machine is stopped.
Plate cylinder 22 is now locked in the raised
position. Lowering or engagement of plate
cylinder 22 does not take place during the run
operation.
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3. Operation
3.7 Malfunctioning
Fault Cause Remedy
• anilox roller and ink roller • anilox roller motor not • switch on anilox roller at push
do not continue to run switched on switch 78 of base frame BG
when machine stops 10
• free running-device defective • replace free-running device
• motor protection device
defective or incorrectly set
• 4-pin plug not plugged into • plug 4-pin plug into socket
socket
• couplings have been decoupled • engage couplings by turning
lever 17 in direction of drive
side
• ink not cleanly doctored • doctor pressure too low • set doctor pressure higher at
pressure regulator 26
• doctor damaged • replace doctor blade
• no further cross register • end of adjustment range has • carry out a completely new
adjustment available been reached setting of cross register
• no further longitudinal • 9-pin plug not screwed into • screw 9-pin plug X3.6 into
register adjustment socket X3.6 socket
available
• register motor defective • replace register motor
• print image has squashed • pressing force between plate • reduce pressing force by
edges and web too high turning feed screws 2 and 3
anticlockwise

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3. Operation

Fault Cause Remedy

• ink intensity gets weaker • plate cylinder axis not parallel • reset plate cylinder axis
towards one side (ATS, BDS) to impression cylinder axis using adjusting bolt 29 and
feed screws 2 and 3
• ink roller only up against • close ink roller lock properly
anilox roller on one side
• pneumatic cylinder defective • check pneumatic cylinder
and replace if necessary
• ink intensity uniformly weak • insufficient pressure between • increase pressing force by
over entire printing width plate and web turning feed screws 2 and 3
clockwise
• wrong anilox roller fitted • check anilox roller and
replace if necessary
• plate cylinder does not lift off • pneumatic valve in wrong • set pneumatic valve to
position correct position and then
reset plate cylinder (see item
3.5.2 "Proof printing")
• at operating panel, drive • disable the function "plate
station, "plate cylinder UP" cylinder UP" at operating
has been pressed and not panel and then reset plate
disabled before proof printing cylinder (see item 3.5.2
started "Proof printing".

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4. Care and maintenance
4.1 Qualification of staff
Cleaning and maintenance work may only be
performed by staff who are familiar with the
machine (see "General safety instructions",
item 1.1.5 "Responsibility of staff" at the
beginning of this manual).
4.2 Care
The UV flexo printing unit should always be
cleaned at the end of a job. During this
cleaning, signs of wear which may have taken
place should be looked for. Lubricating
materials which are removed during cleaning
must be replaced.
Particular attention must be paid to
gearwheels during cleaning. Ink remains
which are stuck on to the gearwheels must be
removed with a suitable cleaning fluid. After
cleaning has been completed, the gearwheels
must be sprayed with adhesive oil spray
(Klüber company´s Hotemp 2000).
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4.2.1 Anilox roller
When cleaning the anilox roller, please
proceed as follows:
• Remove anilox roller 11 from UV flexo
printing unit (see item 3.3.2 "Fitting and
removing anilox roller") and lay this down
on a soft surface.
Caution:
Risk of damaging the anilox roller!
Caution:
Risk of injury to the hands!
Take the heavy weight of anilox roller 11 into
account when removing it from the UV flexo
printing unit. It is advisable to use lifting
device 27.
• Remove coupling hub 30 by loosening the
clamping screw. Clean off any adherent
remains of ink, and grease it.
• Remove ball bearings 31/35 and remove
any adherent remains of ink.
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4. Care and maintenance

4. Care and maintenance

Caution:
Risk of damaging the ball bearings. The
lifetime lubricant of the ball bearings must not
be washed out. If necessary fit new ball
bearings.

• Remove the short and long compensation

bushes 32 and 34 and remove any
adherent remains of ink.
• Clean anilox roller 33 thoroughly using the
cleaning fluid recommended by the
manufactucturer of the ink and the anilox
roller.

Caution:
Risk of damaging the anilox roller. Only the
cleaning fluid recommended by ink and anilox
roller manufacturers may be used. Never use
sharp or pointed objects to remove ink
remains.

After anilox roller 33 has been cleaned it can

be prepared for a further application. This is
carried out in the reverse order.

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4. Care and maintenance

4. Care and maintenance

Caution:
4.2.2 Ink roller Risk of damaging the ink roller. Only cleaning
fluids containing ester or ketone may be used.
When cleaning ink roller 10, proceed as Never use sharp or pointed objects to clean
follows: ink roller 41.

• Remove ink roller 10 from UV flexo printing After ink roller 41 has been cleaned it can be
unit (see item 3.3.3 "Fitting and removing prepared for a further application. This is
ink roller"). carried out in the reverse order.
• Remove coupling hub 43 by undoing
clamping screw of the ink roller 10.
Pull self-clamping bearings 40 and 42 off ink
roller 10 and remove the shaft circlip from the
ink roller on the drive side. Clean any
adherent ink remains off the self-clamping
bearings.

Caution:
Risk of damaging the self-clamping bearings.
The lifetime lubricant of the self-clamping
bearings must not be washed out. If
necessary fit new self-clamping bearings.

• Clean ink roller 41 thoroughly using

cleaning fluid recommended by the ink
manufacturer. Use a soft cloth soaked in
solvent.

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4. Care and maintenance

4. Care and maintenance

4.2.3 Ink box

Cleaning the ink box should be carried out in If the supply of ink to the ink box is via ink
the following order: pump BG 33, proceed as follows:

• Lift ink box cover 48 from ink box 9 and • Close the overflow openings in ink tray
clean it thoroughly. Use a soft rag soaked stopper 49 with sealing sleeve 50.
in solvent using a solvent or cleaning fluid • Remove ink supply hose 54 and silicon
recommended by the ink manufacturer. hose with funnel 55.

Caution: Caution:
Risk of damaging the ink box cover. Risk of contamination of UV flexo printing unit
Never use sharp or pointed objects for and base frame BG 10.
cleaning the ink box cover. Use a rag to catch the ink drops.

• Remove scraper 52 from UV flexo printing The subsequent steps are identical for the two
unit (see item 3.3.4.2.1 "Removing methods of ink supply to ink box 9.
scraper") and clean off adherent ink
remains.

Caution:
Risk of contaminating the UV flexo printing
unit and base frame BG 10.
Use a rag to catch ink drops.

Caution:
Risk of damaging the scraper!
Never use sharp or pointed objects for
cleaning scraper 52.

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4. Care and maintenance

• Remove ink tray 47 from the UV flexo
printing unit and clean this of ink. Use
cleaning fluid or solvent recommended by
the ink manufacturer.
Caution:
Risk of damaging the ink tray, sealing
sleeve and ink tray stopper.
Never use sharp or pointed objects to clean
these parts.
Clean adherent ink remains off doctor 12.
Use the cleaning fluid or solvent
recommended by the ink manufacturer.
Caution:
Risk of damaging the doctor blade!
Use a soft rag soaked in solvent for
cleaning. Never use sharp or pointed
objects for cleaning.

After the components of ink box 9 have been

cleaned, this can be prepared for a further
application. This work is carried out in the
reverse order.
4.2.4 Doctor
When cleaning doctor 12, proceed as follows:
• Remove doctor 12 from the UV flexo
printing unit (see item 3.3.5 "Fitting and
removing doctor").
After doctor 12 has been cleaned it can be
used for a further application in the UV flexo
printing unit (see item 3.3.5 "Fitting and
removing doctor").
Note:
When fitting doctor 12 it should not yet be
engaged with anilox roller 11.

Caution:
Risk of injury to the hands!
The doctor is razor sharp. For your own
safety wear safety gloves during fitting and
cleaning.

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4. Care and maintenance
4.2.5 Plate cylinder
When cleaning plate roller 22, proceed as
follows:
• Remove the plate cylinder from the UV
flexo printing unit (see item 3.3.6 "Fitting
and removing plate cylinder").
• Remove plate cylinder 22 (see item 3.3.6.1
"Plate cylinder preassembly".
• Clean off adherent ink remains from the
components of plate cylinder 22. Use the
cleaning fluids or solvents recommended by
ink manufacturer.
Note:
When cleaning the components, special
attention should be paid to cylinder bearer
64 and gearwheel 69.
Caution:
Risk of damaging the plate. Use one of the
cleaning fluids or solvents recommended by
the plate manufacturer.
Never use sharp or pointed objects for
cleaning.
TN_ _0104/Operating instruction 19^ 03 S26-e /19.02.01
Caution:
Risk of damaging the thrust bearings. The
thrust bearings must be greased with
bearing grease after cleaning (see item 4.3
"Maintenance").
Caution:
Risk of damaging the components.
The components may only be cleaned with
a soft rag soaked in solvent. Never use
sharp or pointed objects for cleaning.
If you are preparing plate cylinder 66 for
relining with a new plate, make sure that any
remnants of adhesives of the old foil are
removed before sticking on the double-sided
foam rubber adhesive foil. Use one of the
cleaning fluids or solvents recommended by
the manufacture for cleaning off adhesive
remains from plate cylinder 66.
Caution:
Risk of damaging the plate cylinder.
Use a soft rag soaked in solvent to clean
adhesive remains from plate roller 66. Never
use sharp or pointed objects for cleaning.
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4. Care and maintenance

After the plate cylinder has been cleaned, a
new double-sided foam adhesive foil can be
stuck onto it. The new plate is then fixed to
this.
You can now proceed with the preassembly
of plate cylinder 22 (see item 3.3.6.1 "Plate
cylinder preassembly". When this has been
completed, plate cylinder 22 can be fitted to
the UV flexo printing unit (see item 3.3.6
"Fitting and removing plate cylinder").
Remove gearwheel guard 21 by loosening
both allen screws and clean off dried-on ink
remains. For this a cleaning fluid or solvent
recommended by the ink manufacturer should
be used (see item 4.2.8 "Cleaning fluids").
Caution:
Risk of damgaging the impression cylinder and
the gearwheels. Impression cylinder 23 and
the gearwheels must only be cleaned with a
soft cloth soaked in solvent.

4.2.6 Impression cylinder Caution

Risk of injury to hands through their being
Dried ink remains on impression cylinder 23 drawn in between the gearwheels.
can cause damage to the web and dried ink
remains on the gearwheels can influence the
running characteristics of the gearing in a
negative way. UV flexo printing unit should
not be stationed on base frame BG 10 during
cleaning of impression cylinder 23 (see item
3.3.1 Fitting and removing UV flexo printing
unit").

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4. Care and maintenance
Note:
After cleaning the gearwheels, spray them
with adhesive/spray oil (Hotemp 2000, Klüber
company). This avoids excessive wear due to
dry running of the gearing (see also item 4.3
"Maintenance").
• Fasten gearwheel guard 21 with allen
screws in the UV flexo printing unit.
4.2.7 Printing unit
Special attention should be given to the bearer
plates and centering elements 20 during this
cleaning work. These must be free from
dried-on ink remains to ensure proper
functioning. The UV flexo printing unit should
not be stationed on base frame BG 10 during
cleaning.
When cleaning the printing unit, please
proceed as follows:
• Make sure that all auxiliary equipment has
been removed (see item 3.3 "Setting").
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• Clean the bearing surfaces of the bearer
plates and centering elements 20 with a
soft cloth soaked in solvent. A cleaning
fluid or solvent recommended by the ink
manufacturer should be used for this.
Caution:
Danger of damaging the bearer plates and
centering elements 20. These must only
be cleaned with a soft cloth soaked in
solvent. Never use a sharp or pointed
object for cleaning.
Note:
After cleaning, centering elements 20 must
be greased to avoid excessive wear.
• Clean the gap between base frame and
bearer plate. This gap must not contain
any dried-on ink remains as this could lead
to problems with engagement of the plate
cylinder with the web.
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4. Instandhaltung
• 4.2.8 Cleaning materials
• Remove ink remains from UV flexo printing
unit. A cleaning fluid or solvent Ink roller 10 must never be cleaned with sharp
recommended by the ink manufacturer or pointed objects. Only a soft rag soaked in
should be used for this. solvent should be used. Only use the
following solvents:
Caution:
Risk of damage. • Cleaning fluids containing ester
Only use a soft cloth soaked in solvent for
cleaning the UV flexo printing unit. • Cleaning fluids containing ketone
It must never be cleaned with sharp or
pointed objects. The following cleaning fluids must not be
used as these damage ink roller 10:
After the UV flexo printing unit has been
cleaned it can be prepared for a further • solvents containing mineral oil
application (see item 3.3 "Setting").

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4. Care and maintenance
4.3 Maintenance
For your own safety, only carry out
maintenance work when the printing machine
has been switched off. Attach a warning
notice "Attention! Maintenance work" to
secure it additionally against unauthorised
starting up.
4.3.1 Anilox roller continued running
To ensure proper functioning of the continued
running function of the anilox roller, the
following maintenance work must be carried
out regularly:
4.3.1.1 Drive chain
Drive chain 81 must be sprayed with adhesive
oil (Hotemp 2000, Klüber company). during
this maintenance work, the tension of drive
chain 81 should be checked. If the tension is
too low, proceed as follows to restore the
correct tension:
• Remove the cover of the anilox roller drive
on the inlet side by loosening the seven
allen fixing screws.
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• Loosen the four allen fixing screws of
anilox roller motor 83.
Note:
The fixing screws are situated on the
gearwheel side of the plate.
• Push anilox roller motor 83 towards the
inlet side of UV flexo printing unit until
drive chain 81 is adequately tensioned.
• Tighten the two allen fixing screws of
chain tensioner 82.
• Tighten the four allen fixing screws of
anilox roller motor 83.
Note:
The anilox roller motor must lie parallel to
the edge of the plate.
• Secure the cover of the anilox roller drive
with the seven allen fixing screws.
After drive chain 81 has been tensioned it
should be sprayed with adhesive oil (Hotemp
2000, Klüber company).
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4. Instandhaltung
4.3.1.2 Driving gearwheels
(anilox roller continued running)
The gearwheels of the continued running
function must be checked for suffient
lubrication every 40 operating hours. Please
proceed as follows:
• Remove the cover of the anilox roller drive
on the inlet side of the drive cover by
loosening the seven allen fixing screws.
• Lubricate the gearwheels with adhesive oil
(Hotemp 2000, Klüber company) and refit
the cover.
4.3.1.3 Coupling hub
The coupling hub of ink roller 10 and anilox
roller 11 and Scotch yoke 87 of the anilox
roller drive must be checked for damage every
40 operating hours. During this check, the
coupling must be greased to avoid excessive
wear.
When replacing Scotch yoke 87,
proceed as follows:
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• Remove the cover of the anilox roller drive
on the inlet side of the UV flexo printing
unit by loosening the seven allen fixing
screws.
• Uncouple the anilox roller drive by turning
lever 17 towards the operating side (BDS)
of the UV flexo printing unit.
• Loosen the clamping screws of spigot 88
which holds Scotch yoke 87 in clutch disk
89.
• Remove spigot 88 and Scotch yoke 87
from clutch plate 89.
Note:
There are two compression springs within
the coupling which center the Scotch yoke.
Fitting the Scotch yoke is carried out in the
reverse order.
please
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4. Care and maintenance

4.3.2 Drive gearing 4.3.3 Centering element

The drive gears of the UV flexo printing unit
must be cleaned after each job change and
sprayed with adhesive oil (Hotemp 2000,
Klüber company). If the UV flexo printing unit
is positioned on the printing machine but used
only as a deflection unit and not as a printing
unit, the drive gears must be sprayed with
adhesive oil (Hotemp 2000, Klüber company)
every 100 operating hours.
To enable the drive gears to be oiled, the
following steps must be carried out:
The four centering elements 20 center the
plate cylinder within the UV flexo printing unit
with the help of the cylinder bearers and
bearer plates. To ensure proper functioning of
centering elements 20, these must be greased
at regular intervals. Centering elements 20
must be cleaned after each job change.
Centering elements 20 must be greased after
every 100 operating hours. Locking screw 1
should be greased at the same time.

• Remove gearwheel guard 21 by loosening

the two allen fixing screws.
• Spray the gearwheels with adhesive oil
(Hotemp 2000, Klüber company) and turn
the gearwheels two or three times.
• Secure gearwheel guard 21 with the two
allen fixing screws.

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EM 260/ 340/ 410/ 510 UV flexo printing unit BG 03

4. Care and maintenance

4.4 Fast wearing parts

The following parts are subject to increased

wear. During cleaning and maintenance work
on the UV flexo printing unit, these parts
should be examined for wear.

Subassembly Description arsoma code Quantity

• anilox roller ball bearing LAG-R 025 2

• ink roller self-clamping bearing LAG-S 012 2

ink roller 094 03 418 (EM 410) 1

093 03 418 (EM 260) 1
092 03 418 (EM 510) 1
091 03 418 (EM 340) 1
• doctor thin section doctor MEY-D 014 (EM 410)
(ceramic coating) MEY-D 013 (EM 260) 1
MEY-D 015 (EM 510)
MEY-D 018 (EM 340)
• plate cylinder spring thrust bearing 194 03 U39 1

thrust bearing 194 03 U40 1

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EM 260/ 340/ 410/ 510 UV flexo printing unit BG 03

4. Care and maintenance

Subassembly Description arsoma code Quantity

• anilox roller drive roller chain MÄD-R 002 1

link MÄD-R 012 1

chainwheel z = 26 094 03 423 1

chainwheel z = 13 094 03 371 1

flat belt SCA-E012 1

• coupling hub Scotch yoke 094 03 369 2
• gearwheel drive gearwheel 094 03 151 1
z = 74

impression cylinder 094 03 152 1

gearwheel z = 104
• impression cylinder ball bearing LAG-R 025 2

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