novomatics AlphaTackPlus User manual
AlphaTackPlus
Precision Tack Measuring Instrument
Owners Manual
Operation Manual
Issue: 06/2018 (c) 2016 by NOVOMATICS GmbH
NOVOMATICS GmbH
Aubachstr. 1
D-56410 Montabaur
Germany
Phone: ++(49) 26 02 – 919 9622
FAX: ++(49) 26 02 – 919 8052
solutions@novomatics.com
www.novomatics.com
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Content:
1. AlphaTackPlus Highlights.................................................................. 4
2. Importance of tack measurement in the printing ink industry .................... 5
2.1. What is tack? ................................................................................... 5
2.2. How to measure ink tack?.................................................................... 5
2.3. Principle of AlphaTack measurement ...................................................... 6
2.4. Principle of temperature control ............................................................. 8
3. Getting Started.............................................................................. 10
3.1. Safety Precautions ...........................................................................10
3.2. Advanced safety function for AlphaTack HS (High Speed) ............................11
4. Installation ................................................................................... 12
4.1. Software installations.........................................................................12
4.1.1. Installation of WinAlphaTACK software from CDROM...............................12
4.1.2. Installation of WinAlphaTACK software from Internet................................12
4.1.3. Installation of AlphaTackPlus device driver............................................12
4.2. Setting up the AlphaTackPlus ..............................................................15
4.2.1. Instrument cables and connections .....................................................15
4.2.1.1. Mains cable.........................................................................15
4.2.1.2. USB cable...........................................................................15
4.2.1.3. Switching on the AlphaTackPlus, Start of WinAlphaTack...................15
5. Start of a first tack measurement....................................................... 16
5.1. Sample settings ...............................................................................16
5.2. Program settings..............................................................................17
5.2.1. General Settings ...........................................................................17
5.2.2. Basic Settings ..............................................................................18
5.2.3. Program steps ..............................................................................18
5.3. Automatic ink dispenser .....................................................................19
6. Cleaning ...................................................................................... 21
6.1. Rapid cleaning ................................................................................21
6.2. AlphaTackPlus instrument case............................................................22
6.3. Cleaning agents...............................................................................22
7. Data evaluation ............................................................................. 23
7.1. Principles of data saving.....................................................................23
7.2. Loading result into results diagraphs ......................................................23
7.3. Measuring reports ............................................................................23
8. Definition of variables..................................................................... 27
8.1. Pressure Distribution Function..............................................................27
8.2. Definition of variables ........................................................................28
8.2.1. Independent Variables ....................................................................28
8.2.2. Dependent Variables ......................................................................29
9. Data Objects and Files .................................................................... 30
9.1. Preset Files (*.set) ............................................................................30
9.2. Measurement Files (*.res)...................................................................30
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9.3. Diagram Files (*.w2d) ........................................................................30
9.4. Sample Operation Procedure Files (*.sop) ...............................................31
10. Maintenance ................................................................................. 32
10.1. Exchange of teflon piston of dispenser .................................................32
10.2. Exchange of elastomer roller.............................................................35
10.3. Approving of tack measuring sensor....................................................36
11. Technical specification ................................................................... 37
12. Contacting Novomatics................................................................... 39
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1. AlphaTackPlus Highlights
The AlphaTackPlus instrument allows quick tack determination of printing inks with a high
degree of accuracy and reproducibility. Due to its closely controlled test conditions the
AlphaTackPlus methodology offers significant advantages over the usual tack testing
methods. The AlphaTackPlus provides a problem-solving approach to measuring pure tack
(QC), ink length, tack stability vs. time, vs. temperature, vs. line force and offers a practical
and consistent solution to commonly encountered problems of splitting ink films.
The AlphaTackPlus is a new, innovative tack measuring instrument. It features a fully
automated system, providing accurate results under controlled conditions
Features
- operator independent, fully automated measuring system
- stable measurements over the lifetime of the instrument
- accurate, reliable and easy to operate
- cost savings through minimal labour time and accurate
measurements
- automated, embedded ink film dispensing unit
- internal, liquid free temperature control for high reliability and energy
saving
- temperature controlled rollers (metal and elastomer)
- provides compatible tack numbers with previous tack measuring
instruments
- automatic tack and temperature calibration
- no balance or manual dispensing tools required
- cleans in just a few seconds
- space saving, compact design
- easily transported by one person
- ideal for use outside of the laboratory
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2. Importance of tack measurement in the printing ink
industry
2.1. What is tack?
Tack is a measure of the forces required to split a single film into two. In case of ink, such
film splitting is influenced by rheological and adhesive ink properties and the internal
cohesion of the ink.
Tack depends heavily on the ink formulation. Inks must be formulated to optimize the quality
of printing and minimize undesired effects in the printing process, such as substrate rupture
or coating pick-up, web contamination, dot gain, poor setting, loss of gloss, loss of color
density etc. that can be caused by too high or too low tack.
When tack is too high it is hard to separate the paper from the printing blanket or when it is
too low the ink does not transfer properly down the inking roller chain. A major influence on
ink tack has the vehicle system used for the formulation, so that good tack properties of
vehicles are crucial for good performance of litho inks on the press.
Tack is a critical issue in the lithographic process and tack is relevant to all stages of
distribution or transfer in the printing process. Therefore, accurate tack measurements are
essential for a good performance of ink on the press.
2.2. How to measure ink tack?
Conventional instruments being developed to measure tack all rely on the same principle of
measuring the force exerted on a measuring roller that is positioned on the ink film of a
driven roller. This method suffers various disadvantages due to the fact that the result of both
compression and splitting forces are measured.
In addition to this, different manufacturers of tackmeters have established their own arbitrary
scales, so that it is difficult to compare the results of tack measurements of an instrument
from "manufacturer A" with the ones from a "manufacturer B". Even comparability of
measurement results of instruments from a single manufacturer is difficult, mainly due to the
fact that different viscoelastic properties of the measuring elastomer roller and the wear of
bearings causing differences in tack reading. The AlphaTackPlus test method is a
breakthrough in tack measuring technology by elimination of errors caused by these effects.
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2.3. Principle of AlphaTack measurement
Tack measurements usually provide a tack value which includes the film splitting force
combined with contributions from the elastomer roller elasticity, ball bearing friction and
forces for ink film formation.
Owing to its innovative technical design the AlphaTackPlus overcomes all the principle-
based difficulties of the usual tack measuring method. A solid state force sensor is
embedded seamlessly into the surface of driving metal roller. This sensor measures the
complete pressure profile in the roller nip and transfers this data to the PC after each nip
passage.
Figure 1
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The measuring software considers only the negative parts of the pressure profile, which
represent the pure splitting force in the vertical direction. The summarized parameter is
called LineTack [N/m] and expresses the pure force for film splitting based on SI units.
Consequently factors like variations of elastomer roller elasticity or ball bearing friction are
eliminated and do not influence the test results anymore. That’s why the AlphaTackPlus
provides uniquely accurate and reproducible measurements over the lifetime of the
instrument.
Figure 2
Figure 3
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2.4. Principle of temperature control
The correct and stable temperature setting is one of the key factors for reproducible and
accurate measuring results. A deviation of one degree in temperature may lead to a
deviation in tack to five percent or more.
The AlphaTackPlus controls metal and elastomer roller temperature independently of each
other but at same set temperature. Platinum temperature probes are placed inside the rollers
close to their surface. So the nip temperature is stabilized with accuracy better than 0.1 °C.
The AlphaTackPlus active heating and cooling systems are encapsulated in the rollers and
operate without liquids for high reliability. Compared to water bath only a fracture of electrical
energy is consumed, essentially lowering operational costs during the instruments lifetime.
Why does the AlphaTackPlus stabilize the elastomer roller temperature?
Controlling only the metal roller may lead to deviations of nip temperature. Measurements
have shown that the yielding nip temperature is determined approximately 70 % by metal
surface and 30 % by elastomer surface. So the temperature of elastomer roller affects
essentially the accuracy of tack measurement.
Consequently the AlphaTackPlus has no specific warming up period. For example, after
switching on the roller temperatures are stabilized exactly at 30.0 °C in less than 3 minutes.
Because of these short response times the AlphaTackPlus can vary the nip temperature
during a measurement in defined manner too. So specific measurements like tack stability
vs. temperature can be performed easily.
Figure 4
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External water baths or closed cycle cooler are thermally inert and demand extra space and
energy. Because of the integrated solution extra devices for temperature control are
eliminated.
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3. Getting Started
3.1. Safety Precautions
Read this note before the instrument will be taken into operation!
Before connecting the AlphaTackPlus instrument the power supply:
Ensure that the MAINS switch at the rear panel is in off position.
Ensure that the power voltage of your mains socket corresponds with the power
voltage of the instrument.
Ensure that the power cable plug is connected only to a power socket that has
a protective earth contact. This applies equally, if an extension cable is used:
the cable must contain an earth conductor!
To effect grounding of the instrument case, the power plug must be inserted
before connections are made to a computer and balance. The power plug must
remain connected until all other units have been connected or disconnected.
Any interruption of the ground connection (inside or outside the instrument) is
prohibited.
The instrument must be disconnected from all voltage sources before it is
opened for any adjustment, replacement or repair. The manufacturer does not
take any responsibility for any adjustments, maintenance by the user. Consult
NOVOMATICS, if repairs are necessary.
Whenever it is likely that the safety of the instrument has been impaired, it should be
made inoperative and secured against any unintended operation. Safety could be
impaired if:
Any case or cable shows visible damage.
The instrument fails to perform the intended operation.
It has been subjected to prolong under unfavorable storage conditions.
It has been subjected to severe transport stress.
When the instrument will be taken into operation or during operation:
Don't touch the rollers; touching the rollers may lead to injuries of skin or hair.
Protect your hairs by a hairnet or something similar, if your head may be
located near to the rotating rollers. Unprotected hairs or hairs may lead to
injuries of the head if the instrument is not switched off immediately.
Use glasses to protect your eyes when the sample under test will be observed,
as ink particles may lead to injuries of the eyes.
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