87 15inch Wagner Coater

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Transcript of 87 15inch Wagner Coater

Packaging Operations

Sheet CoaterWagner

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Human Resources ______________________________________________________To add value and lead by example

Training & Development Broomfield, Colorado 80021

Ball Packaging Operations

NoteThis manual has been developed for use with Ball training programs. It covers basic machine principles, concepts, and typical procedures. It is not meant to replace Original Equipment Manufacturer (OEM) manual(s). Do not use it when ordering partsrefer to the OEM manual for your specific machine and model.

ImportantPlant Standard Operating Procedures (SOPs) or Work Instructions (WIs) should always take priority over a typical procedure in this training manual, as they will be specific to your plant and machinery.

Proprietary NoticeThis material contains subject matter that is proprietary to Ball Corporation, and that is protected under the copyright laws as unpublished works, under the trade secret laws, and under the terms of written license agreements with Ball Corporation. No portion of these materials may be copied or used for any purpose except as permitted under any written license agreement with Ball Corporation.

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SECTION

PAGE

Specifications5 Safety Limit Switch Arrangement 7 Principles of Operation..8 Material Flow Diagram.................................................................................................10 Backlash Gear Arrangement..........................................................................................11 Operating Controls and Procedures Chart ....................................................................12 Install Composition Roller.............................................................................................13 Setting and Adjustments26 Isoblade Scraper System27 Suggested Coating Handling Procedures..45 Changeover Instructions ................................................................................................44 Preventive Maintenance....................................................................................................47 Line Greasing47 Troubleshooting...............................................................................................................48

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Description and PurposeThe Wagner 15 x 44 Sheet Coater is a machine used to apply coatings to sheets through a series of rollers, at a precise time in precise locations and specified thicknesses. The coater is used for straight coating applications behind an automatic feeder.

CapacitiesMinimum sheet size 19" x 24" wide Maximum sheet size 42" x 42"

Speed RangesMaximum 100 sheets per minute Minimum 50 sheets per minute Rate of feed is determined by the coating material and bake time.

Basic Dimensions and WeightsApproximate dimensions 14' long x 7' wide x 8' high Approximate weight 23,000 pounds

Motors and Drives DataDrive unit is furnished to specific requirements of the whole system. Drives must be synchronized. Normal ratings: 1,800-2,400 rpm 10 hp. Services (see Basic Assembly L115000-36 for locations) Air 45 PSI minute Exhaust Optional by customer

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Figure 1

Figure 2

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Drawing D107100-18Note: There is no standard wiring diagram for the coater alone. The coater is wired into the system for the complete line.

Figure 3

Switch1 2 3 4 5 Jam stops Hand wheel guard Composition roller guard Composition roller gear guard Composition roller lift

When any micro switch is energized, coater stops operating.

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1 2 3 4 5 6

When the sheets reach the coater from the sheet feeder, slow-down magnets control the sheet to achieve a gentle takeover by the coater lug fingers. Lug fingers take the sheet to the register fingers. Register fingers take the sheet to side gauges that register the sheet precisely. The upper roller, or composition roller, applies the coating, which has been fed by the anilox roller. The lower roller, or scraper roller, acts as a backup. The sheet passes over the discharge rollers and out.

Note: The minimum stopping period should be one complete revolution of the composition roller; at 100 sheets per minute, this would be 0.6 seconds.

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Figure 4Sheet Coater Wagner

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Material Flow Diagram

Isoblade Scraper ArrangementCoating is applied to the scraper roller through a separate connection from pump to lubricating channel assembly. Paint scraper removes coating material. Thinner is applied to the scraper roller through the felt pad bar assembly and is removed by the thinner scraper.

ISOBLADE SCRAPER

Figure 5

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Backlash Gear Arrangement

Figure 6 The backlash gear arrangement consists of a hardened steel plate gear mounted on the upper intermediate gear and in mesh with the hardened composition roller gear. The plate gear is centered around the hub of the upper intermediate gear and should bear against the lead surface of the composition roller gear tooth while the upper intermediate gear tooth is driving the composition roller gear. This scissor action eliminates the backlash between the gears.

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There are three spring housings, each with an adjusting screw, and the pressure can be determined only by experience and is dependent on the speed of operation and the pressure on the composition roller. This pressure should not be so great that it causes binding of the teeth, nor so small that the scissor action is ineffective.

Operating Controls and Procedures ChartTo set coater into operation: 1 2 3 4 5 6 7 Insert proper composition roller and bring it into operating position. Install correct anilox roll for film weights. Bring scraper and pans into operating position. Set feed board for proper sheet length. Bring #1 feed fingers to timing position. Set side gauges at timing position. Adjust pumps.

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Figure 7

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Figure 8

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Figure 9

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Figure 10 (refer to drawing on page 11)

Figure 11 (refer to drawing on page 13)

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Figure 12

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Anilox SystemThere are two blades incorporated in the unit, one plastic blade at the bottom of the chamber to scrape off the excess coating from the anilox roller and one plastic blade at the top of the chamber to contain the coating within the chamber.

Figure 13 Two nylon end plates are fastened at each end of the chamber and slide over the face of the revolving anilox roller to totally enclose the coating within the chamber. There are two drain holes in the anilox chamber for returning the coating back to the lacquer tank. The bottom return hole has a flow control spindle to make sure the chamber is full of coating so as to prevent starvation. The catchment tray supplied is used as a return to the lacquer tank for the coating.

Setting the Blade to the Anilox RollerRotate both of the adjusting handles (1) counterclockwise until both blades are just touching the anilox roller. Start the anilox roller rotating, and then turn on the lacquer pump to send coating into the blade chamber.Wagner Sheet Coater

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Figure 14 Set the flow into the chamber with the flow control lever (it is important that the flow is not at full pressure as this will cause flooding). The coating should return out of each end plate at the speed of a slow running tap. Make final adjustments to the pressure of the blades by turning the adjusting handles (1) by approximately half a turn counterclockwise. Do not have excessive pressure on the blade as this wears the blade prematurely. Tighten clamping screws (2). The blades are now set and do not need to be adjusted when cleaning or changing rollers.Sheet Coater Wagner

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Figure 15

Figure 16

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Setting the Anilox Roller to the Applicator Roller

Figure 17 Make sure the quick release handle (3) is locked in the UP position. Undo locknuts (4). Turn knurled handles (5) clockwise to move the anilox roller and chambered blade together onto the applicator roller. Once set at the required pressure, tighten the four locknuts (4). To remove the anilox roller from the applicator roller, place the quick release handle (3) to the DOWN position. This will separate the rollers by approximately 0.25" while keeping the gears in mesh.

Figure 18

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Replacing BladesRelease the clamping handle (6) and rotate the chamber to its horizontal position. Loosen the blade clamping screws (7) and remove the old blade (protective gloves should be worn at all times when handling blades).

Figure 19 Cut a new blade to length, ensuring the edges are as square as possible. Care should be taken to make the blade as close as possible to each nylon end plate, but not too long as to cause a ripple in the blade.Wagner Sheet Coater

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Figure 20 Position the new blade under the clamping strip; ensuring the blade is pushed back as far as possible to the step in the blade housing. Retighten the blade clamping screws. Repeat the procedure for the other blade. Rotate the chamber to its original position and retighten the clamping handle (6).

Changing the RollerRetract the anilox roller from the applicator roller and wrap around the protective blanket provided. Screw the eye bolts through the cap and into the roller at each side. Lower the hoist beam and put