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
[e-mail]
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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3.2. Advanced safety function for AlphaTack HS (High Speed)
The AlphaTack HS supports roller speeds up to 450 m/min. For protecting the operators
coming in any touch with these fast turning rollers the AlphaTack HS is equipped with
ultrasonic proximity switch for instant roller stop.
A periodic peep sounds as soon as there any object closer than 40 cm in front of the rollers.
In case the distance is shorten down to 30 cm the rollers and so also the test stop within one
second.
Washing is possible without any limitation since elastomer roller is separated from metal
roller.
Figure 5 shows proximity switch on front side

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4. Installation
4.1. Software installations
There are two packages needed for instrument operation. Before starting make sure that the
instrument is off and the instrument cable is not connected to the computer.
4.1.1. Installation of WinAlphaTACK software from CDROM
1. Insert the installation CDROM WinAlphaTack
2. Start the program cdrom:\winalphatacksetup.exe manually if not started by auto
start
3. Follow the default adjustments by pressing Next
4.
4.1.2. Installation of WinAlphaTACK software from Internet
1. Visit: http://www.novomatics.de/downloads/
2. Login in with username and password
3. New users please fill out the registration request to receive login details
4. Download winalphatacksetup.exe
5. After downloading from Novomatics server start the program
winalphatacksetup.exe manually
6. Follow the default adjustments by pressing Next
7. The WinAlphaTack will be installed, USB driver is placed at {install path}\driver, for
example:
c:\program files\novomatics\winalphatack\driver
4.1.3. Installation of AlphaTackPlus device driver
1) USB Driver installation
Please note WinAlphaTack operation is fully verified for Windows 10 only.
Execute CDM21224_Setup.exe as administrator found on your WinAlphaTack
CDROM or within your WinAlphaTack installation path.

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Figure 6 Setup Executable Run as administrator

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You may see a message from ‘User Access Control’ asking ‘Do you want to allow this app to
make changes to your PC? If so, click yes to continue.
Press the Extract button. Follow all installation including license terms agreement
acceptance shown and the driver will be automatically installed. From a legal point of view,
the user must accept the license terms of the driver. Successful installation is shown in
Figure 7 wizard
Figure 7 Driver Installation Completion

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4.2. Setting up the AlphaTackPlus
Place the instrument on a heavy and stable table that is usable for weights of more than 50
kg. Furthermore the table should not be sensitive for resonance that can be affected by
vibrations of the instrument.
For reproducible tack results it is essential that the AlphaTackPlus has to be surrounded
completely with air of same temperature. Don't exposure the unit the direct influence of air
conditions and/or heating.
Don't place any electronic devices on top of the instrument. Because the top is warmed up
by inner electrical devices the self-cooling of a device placed on top is not granted, so that
malfunctions of this device are possible.
4.2.1. Instrument cables and connections
The AlphaTackPlus measuring system needs only a main cable and a USB cable. If any
damage is detected exchange the hose/cable before the instrument is taken in further
operation. In case of doubt contact your supplier or Novomatics (please refer to page
Fehler! Textmarke nicht definiert.).
4.2.1.1. Mains cable
Please only use cable from the manufacturer. These are tested and delivered in mechanical
stable version. Your socket must have a secure, electrical ground connection.
4.2.1.2. USB cable
Please only use cable from the manufacturer. These are tested and delivered in mechanical
stable version.
4.2.1.3. Switching on the AlphaTackPlus, Start of WinAlphaTack
The AlphaTackPlus can be switched on, if all connections to the instrument are made. In the
instrument display serial number, software version and operation time are shown.
Start WinAlphaTack now. The connection to the AlphaTackPlus is made automatically. You
indicate a fine connection when several instrument instructions are output within the
communication window on lower frame edge.
After installation and before a first test is started several adjustments must be proven
because they can be changed during transport.

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5. Start of a first tack measurement
The WinAlphaTack computer software supports the operator in data evaluation, curve
overlays, automatic creation of measurement reports, data transfer to other programs etc.
Open the dialog Measurement/AlphaTackPlus Sample Preparation... Enter sample
names and correct sample weight. Eventually you add a comment, which is saved for later
evaluation within the result file.
5.1. Sample settings
Figure 8
Please select program standard within the upper toolbar.

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5.2. Program settings
Open the dialog measurement\programs … for checking the program settings. The
WinAlphaTack software provides a maximum of flexibility for creating own measuring
programs.
5.2.1. General Settings
Figure 9

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5.2.2. Basic Settings
For advanced testing conditions please press Basic tab in this dialog. Define sample volume,
manner of ink film creation, temperature stabilization conditions within this dialog.
Figure 10
5.2.3. Program steps
The program run can be checked and modified at Measurement/Programs/Steps.
The program is organized in steps. For every step the parameter can be set separately.
Usually the temperature should not be changed within a measuring program, so please set
all temperature set point to the equal value.
For adding new steps at list end use the add button. For inserting steps after list selection
use the insert button. For deleting steps use the remove button. Press change for taking over
changed values into step press change button.

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Figure 11
5.3. Automatic ink dispenser
Manual ink dispensing units for tack tests based on piston-tube design are known from lab
practice. The AlphaTackPlus has been equipped with a similar but embedded, automated ink
dispensing unit. Its dispensing volume is defined indirectly via the film thickness parameter of
the selected measuring program.
The setting volume can be defined within the basic program settings. The standard volume is
100 µl.
Press the start button on upper toolbar for starting the test. After
Manual ink dispensing units for tack
tests based on piston-tube design
are known from lab practice. The
AlphaTackPlus has been equipped
with a similar but embedded,
automated ink dispensing unit. Its
dispensing volume is defined
indirectly via the film thickness
parameter of the selected
measuring program.

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Before the measurement is started
the operator fills up the ink with a
small smooth spatula to its upper
edge.
During the first seconds of test the
ink is continuously dispensed and in
cooperation with the oscillating
elastomer roller a reproducible ink
film is created.
The ink dispensing unit does not
require attention for cleaning. It is
cleaned during the roller cleaning
process.