OPERATING MANUAL

IGT ORANGE PROOFER

[ ] OP [ ] OP M [ ] OP 70 [ ] OPx3
Version: 418.000.044.H

IGT Testing Systems

P.O. Box 22022
1302 CA ALMERE
The Netherlands
Randstad 22-02
1316 BX ALMERE
The Netherlands
Telephone: +31 20 409 9300
Fax: +31 20 409 9339
E-mail: sales@igt.nl
Internet: http://www.igt.nl
IGT ORANGE PROOFER TYPES OP – OP M – OP 70 – OP X3 Page 2

1 CONTENTS
1 CONTENTS .......................................................................... 2 7.2 Printing......................................................................... 13
2 CUSTOMER REGISTRATION FORM ................................... 3 7.3 Cleaning ....................................................................... 13
3 TECHNICAL DETAILS .......................................................... 4 7.3.1 Aluminium printing discs ..................................... 13
3.1 Test certificate ................................................................4 7.3.2 Printing discs with rubber (blanket) ..................... 13
3.2 Technical specifications ..................................................5 7.3.3 Cleaning solvents ............................................... 14
3.3 Standard delivery ............................................................5 7.4 Switching off................................................................. 14
3.4 Declaration of CE conformity...........................................6 7.5 Storage of discs and top rollers .................................... 14
4 SAFETY ................................................................................ 7 8 MAINTENANCE AND REPAIR ............................................ 15
5 INSTALLATION ..................................................................... 8 8.1 Parts ............................................................................ 15
5.1 Unpacking.......................................................................8 8.2 Speed .......................................................................... 15
5.2 Mains voltage..................................................................8 8.3 Lubrication ................................................................... 15
5.3 Conditioning ....................................................................8 8.4 Printing force ................................................................ 15
5.4 Accessory holder ............................................................8 8.5 Inspection before each use .......................................... 15
5.5 Switching ON ..................................................................8 8.6 Troubleshooting ........................................................... 16
6 INTRODUCTION ................................................................... 9 9 STORAGE AND TRANSPORT ............................................ 17
6.1 Inking unit .......................................................................9 9.1 Storage ........................................................................ 17
6.2 Printing Unit ....................................................................9 9.1.1 Use of the original box ........................................ 17
6.3 Printing disc holder .........................................................9 9.1.2 No use of the original box ................................... 17
6.4 Printing discs ................................................................10 9.2 Transport...................................................................... 17
6.5 Substrate carrier ...........................................................10 9.2.1 Use of the original box ........................................ 17
6.6 Method of operation ......................................................10 9.2.2 No use of the original box ................................... 17
6.7 Standards .....................................................................10 10 OVERVIEW OF COMPONENTS .................................. 18
6.8 Materials .......................................................................10 10.1 Orange Proofer OP ...................................................... 18
6.9 Testing conditions .........................................................10 10.1.1 Inking.................................................................. 18
6.10 Preparation ...................................................................11 10.1.2 Printing ............................................................... 18
6.10.1 Set printing force ................................................ 11 10.2 Orange Proofer M, OP70, OPx3 ................................... 19
6.10.2 Mounting test strip .............................................. 11 10.2.1 Inking.................................................................. 19
6.10.3 Stopwatch .......................................................... 11 10.2.2 Printing ............................................................... 19
7 OPERATION ....................................................................... 13 11 Maintenance records .................................................... 20
7.1 Inking in ........................................................................13

This manual has been compiled with the utmost care. However, may you find any inadequacies or if there are any comments, we kindly request
you to send these to IGT Testing Systems, Sales Department.

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2 C U S T O M E R R E G I S T R AT I O N F O R M
IGT 1-year limited warranty is ONLY valid for end users if the information below is immediately returned to IGT.

Start date of warranty

□ Orange Proofer OP
□ Orange Proofer OP M
Type of tester
□ Orange Proofer OP 70
□ Orange Proofer OP x3
Serial number ….. . ….. . …..

Company Name

Contact person

Full address

City

Country

Phone

Fax

E-mail
Return to IGT Testing Systems by mail, e-mail or register at www.igt.nl

IGT Testing Systems

P.O. Box 22022
1302 CA ALMERE
The Netherlands
Randstad 22-02
1316 BX ALMERE
The Netherlands
Telephone: +31 20 409 9300
Fax: +31 20 409 9339
E-mail: sales@igt.nl
Internet: http://www.igt.nl

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3 T E C H N I C A L D E TA I L S
3.1 Test certificate

□ Orange Proofer OP
□ Orange Proofer OP M
Type of tester
□ Orange Proofer OP 70
□ Orange Proofer OP x3
Serial number ….. . ….. . …..

The unit as indicated above has been tested

according to the IGT Test Procedure Orange Proofer

Visual check □
Functional test □
Printing force □
Printing speed □
Print result □
Shifting shaft (OP x3 only) □
Test date:

Signature:

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3.2 Technical specifications

Type ► Orange Proofer Orange Proofer M Orange Proofer 70 Orange Proofer x3

Weight (kg) 25

Dimensions (h * w * d) mm 320 * 620 * 350

Printing speed (m/s) 0.3

Printing force (N)e 200 - 800 N

Printing force drive Manually Motorized

Maximum printing width 50 mm 70 mm 50 mm

Print width (mm) 35 – 50 35 – 70 3x 15 mm – 50

Printing length (mm) 200

Substrate carrier (mm) 60 * 275 80 * 275

Maximum substrate
4
thickness (mm)

Inking unit area (cm2) 720

Power supply 100 – 240 V (3.15 AT) / 50 – 60 Hz

Sound level < 70dB(A)

Working conditions

Temperature 15 – 30 C

Relative humidity 30 - 90% RH (non-condensing)

3.3 Standard delivery

Type ► Orange Proofer Orange Proofer M Orange Proofer 70 Orange Proofer x3

Article number 417.000.000 418.000.000 423.000.000 419.000.000

Top roller for

425.098.001
conventional inks

402.120 402.127 402.095

Printing disc rubber blanket, 50 mm, rubber blanket, 70 mm, rubber blanket, 15 mm,
Ø 66 mm, 350 g Ø 66 mm, 190 g Ø 66 mm, 130 g

Accessory holder 418.410.000

Substrate carrier 404.001.012 404.001.014

Adjustment key 130.319

Mains cable 150.110 or 150.220

Manual English *) 418.000.044

*) Other languages upon request.

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3.4 Declaration of CE conformity

IGT Testing Systems

Randstad 22-02
1316 BX Almere
The Netherland

herewith declares that the IGT

[ ] IGT ORANGE PROOFER

[ ] IGT ORANGE PROOFER M

[ ] IGT ORANGE PROOFER 70

[ ] IGT ORANGE PROOFER x3

Serial number ………. . ….. . ……….

is in conformity with the provisions of directive 2006/42/CE, 2014/35/EU, 2014/30/EU, as amended, and with
national implementing legislation.
There where appropriate, the machinery complies with the harmonized standard(s), other standards or technical
specifications, applicable requirements of these standards and/or specifications of ISO 14120:2015,
IEC 600204-1, IEC 60529 and ISOTR 14121-2.

Almere,

K. van Middelkoop, Managing Director

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4 SAFETY
General safety instructions:
• When installing and operating the tester, follow the instructions in the manual to the letter.
• If the tester is to be moved, have this done by specialized personnel due to the weight.
• To avoid damaging the tester and causing physical injury, the tester should only be used as described in this
instruction manual by or under the supervision of employees qualified to do so.
• Do not use the tester in (confined) spaces containing explosive vapours. It is not protected against explosion.
• Make sure the workplace is well ventilated because volatile and flammable cleaning agents are usually required to
clean the printing discs and inking unit.
• Smoking and naked flames are prohibited due to the use of cleaning agents and solvents in the inks.
• Do not allow the top rollers to rotate dry on the cylinders. This may cause a build-up of static charge.
• To prevent short-circuits, do not allow any part of the tester to become wet.
• Do not wear loose clothing, ties, and chains and avoid loose-hanging long hair. They may get caught up in the
cylinders of the inking unit.
• Make sure that the inks and solvents to be used do not come into contact with skin or eyes. Wear protective clothing
such as laboratory coats, gloves and safety glasses.
• Waste left over after using the tester should be treated as chemical waste and disposed of or destroyed accordingly.
The same applies to printing discs coated with rubber or covered with a rubber blanket and top rollers.
• The tester should only be serviced or repaired by personnel authorized by IGT Testing Systems.

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5 I N S TA L L AT I O N
WARNING: The weight of the Orange Proofer is approximately 25 kg. In case you lift the tester alone, stand BEHIND
the tester and lift it while resting to your belly. NEVER apply any force to the front cylinders, as this will incur severe
damage inside the tester.

TIP: Keep the packaging material for future transport or storage.

5.1 Unpacking
• Cut and remove the straps holding the package together.
• Open the top lid.
• Remove the accessories.
• Remove the upper part of the interior.
• Lift the tester with at least two persons and place on the workbench.
• Turn the handgrip into the threaded hole of the lifting shaft on the right hand side of the tester.
• Remove the rubber bands from the inking section cylinders.
NOTE: The arm on the right hand side of the unit is tensioned with a spring with an upward force depending on the set
printing force; do not let the arm jump free to prevent damage to the tester.

5.2 Mains voltage

The unit is equipped with a power supply that recognizes any voltage between 100Vac-240Vac / 50-60Hz. There is no
need to change the required voltage within these limits

5.3 Conditioning
Before connecting the mains power supply, allow the unit to warm up to room temperature to avoid any formation of
condensation and the risk of short-circuits.

5.4 Accessory holder

The components of the accessory holder are delivered as
parts and must be mounted on the back of the tester.
• Mount the printing disc shafts and stop watch onto the
right positions on the mounting plate as shown in the
next pictures:
• Loosen the two or three screws at top of the back of the
tester.
• Mount the accessory holder with the printing disc shafts
pointing toward the front with these two or three screws
at the back.

5.5 Switching ON
• Switch the tester on with the on/off switch at the back of
the tester.
• Flip the printing disc holder to the left.
• Move the arm on the right hand side down and backward to
lock it so that the printing disc shaft of the printing unit is lifted.
• The tester is ready to start a new test..

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6 INTRODUCTION
The IGT Orange Proofer is developed to print reproducible strips of substrate with offset inks and to determine ink
transfer in g/m2. It consists of a printing unit and an integrated inking unit.

The maximum printing width for the Orange Proofer and the Orange Proofer M is 50 mm and for the Orange Proofer 70
it is 70 mm; the printing length is about 200 mm. Also light weight versions of the printing discs are available to test the
ink transfer in g/m².
If different ink densities or different colours have to be printed on a single substrate, the Orange Proofer x3 can be used.
It can print three solids of 15 mm wide next to another.

With the unit it is possible to print on about every substrate: paper, board, plastic, tin, and so on.
The printed strips can be used for measuring colour with colour-measuring systems or spectrophotometers, making
them ideal for colour-matching systems. The colour strips can also be used effectively for visual appraisal of the printing
quality, if necessary in combination with density measurements and measurement of other characteristics such as wear
resistance, scratch resistance, fastnesses, etc.

Unless stated otherwise, this instruction manual applies to the standard versions of the printability testers for printing on
standard-width strips of substrate.

Detailed test descriptions can be found in the IGT W-leaflets. These can be ordered from IGT or downloaded from
www.igt.nl.

If tests are required in which the temperature of the ink is important, the High Speed Inking Unit 4 can be used for inking
rather than the Orange Proofer’s internal inking unit. The HSIU is also better suited for quick-drying inks.

NOTE: The tester is not suitable for continuous use! For this purpose the IGT Printability testers C1, C1-5, C1-7 or Cx3
are recommended.

6.1 Inking unit

The inking unit consists of two cylinders of different diameters, on top of which a top roller has been mounted. The
standard top roller is a roller which is resistant to conventional inks; for UV-inks another special roller is available.

The small cylinder is electrically powered, while the large cylinder is driven by the top roller and also moves axially. The
total surface area of the inking unit (small and large cylinders plus top roller) is 720 cm2.

The printing disc is inked by applying a specific quantity of ink on the inking unit, distributing the ink evenly, and
subsequently bringing the printing disc into contact with the top roller.
Inking time is short, due to the diameter of the cylinders, the axial movement of the large cylinder and the driving
method. Ink fly and increase in temperature are kept to a minimum.

6.2 Printing Unit

The printing unit consists of an impression cylinder and a printing disc, which is inked on the inking unit. The printing
disc is the actual printing form. The substrate being printed is guided between the impression cylinder and the printing
disc by means of a substrate carrier. The printing disc can be lifted up to 4 mm above the impression cylinder, so
extremely thick substrates can also be printed. In that case, use of the substrate carrier is not necessary.
The printing speed is 0.3 m/s.

On the Orange Proofer x3 the printing disc shaft can be pulled out and pushed in, creating three different printing
positions. These can be used for three different prints of 15 mm width on the same substrate or for two overlapping
prints (trapping) in case of wider printing forms.

The Orange Proofer, type OP, has a manually controlled spring to set the printing force between 200 and 800 N. This
unit is convenient if there is no need to set the printing force frequently.
The other types of Orange Proofers have a motor controlled spring which is used to set the printing force easily between
200 and 800 N.

To make a print, the operator has to create the contact between the printing form and the substrate by moving the arm
on the right hand side and consequently to push a button shortly. After that the contact must be eliminated with the arm
on the right hand side.

6.3 Printing disc holder

A swing-over guiding arm has been installed between the inking and printing unit. If the arm is turned to the right, it
functions as the printing disc holder for the inking unit.

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6.4 Printing discs

The printing discs are used as the printing form.
The standard printing disc for the Orange Proofer is 50 mm wide disc covered with rubber blanket for conventional inks.

Light weight discs with a weight < 150 g are available in case the discs must be weighed. Also discs (letterpress and
other tests) and discs with rubber (to print on very smooth papers when the print quality of the rubber blanket disc is not
good enough) are available.

The standard disc for the Orange Proofer 70 is a 70 mm wide disc, clad with rubber blanket for conventional inks. Also
the 50 mm wide discs can be used.

For the Orange Proofer x3 the standard printing form is a 15 mm wide printing disc with rubber blanket for conventional
inks.

NOTES:
For UV inks separate discs are available. Discs with a width of 50 mm can be used as well.
Never use the discs for conventional inks with UV inks or the other way around.

6.5 Substrate carrier

The substrate carrier is a glass fibre plate clad with a strip of rubber blanket .The substrate is mounted over the rubber
blanket with a piece of tape.
NOTES:
It is advised to always use the substrate carrier. Only when printing on very thick and rigid substrate, the use of
the carrier is not necessary.
It is advised to use the substrate carrier for only one width of the printing disc, as over time a “groove” may
appear in the rubber blanket. If a wider disc is used in this case, this could be seen in the print.

6.6 Method of operation

• Printing force is set.
• The paper is mounted on the substrate carrier.
• Carrier with paper is placed over the impression cylinder on the metal bars.
• The correct amount of ink is applied to the top roller.
• Inker is set into motion with controlled speed for even distribution.
• Printing disc is brought into contact with the top roller.
• After inking, the disc is lifted from the inking unit and placed on the printing shaft.
• Printing force is applied by moving the arm on the right hand side slowly.
• Print is made.

6.7 Standards
The unit can be used for drawdowns according to ISO 2846 and other standards for colorimetric measurements, gloss
measurements etc.

6.8 Materials
• [404.001.012] Substrate carrier 60*275 mm OR
• [404.001.014] Substrate carrier 80*275 mm
• [425.098.001] Top roller conventional inks
• [402.687] Printing disc 50 mm OR
• [402.625] Printing disc 70 mm OR
• [402.692] Printing disc15 mm
• [130.319] Printing force adjustment key for type Orange Proofer
• [404.001.040.000] Accessory holder
• [404.011.029] Reference paper C 2846
• [404.011.030] Reference paper CT 2846 (black band for transparency measurement)

6.9 Testing conditions

Standard test atmosphere according to ISO 187 (23,0 ± 1,0 °C and 50 ± 2% RH).
Sample conditioning:
Cut test strips size 55 x 250 mm (OP, OP M) or 75 x 250 mm (OP 70, OP x3) and mark top/bottom as well as
directionality (MD/CD) Store in test environment for a least 6 hours. Be aware of the fact that a different way of
conditioning of the samples can have influence on the results.

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6.10 Preparation
WARNING:
The arm on the right hand side of the unit is tensioned with a spring with an upward force depending on the set printing
force; do not let the arm jump free to prevent damage to the tester.

6.10.1 Set printing force

• Place the printing disc (without ink) on the printing disc shaft.
• Place the substrate carrier with the substrate between
the printing disc and the impression cylinder on the
substrate guide pins.
• Apply the printing force by moving the arm on the right
hand side of the unit slowly forward and upward. The
printing disc moves onto the substrate.
• For Orange Proofer OP only: place the adjustment key
on the nut in the hole at the left-hand side, rotate it
clockwise to increase the force or anti clock wise to
reduce the force. Read the force from the printing force
scale.
• For Orange Proofer M, 70 and x3 only: adjust the
printing force with the two knobs marked < and > at the
front of the unit. Read the printing force from the printing
force scale.
• When set, lift the printing disc by moving the arm on the right hand side down and backward.
• Remove disc and substrate carrier.

6.10.2 Mounting test strip

• Avoid touching the test strip with your hands to prevent
grease and moisture influencing the printing results.
• Place the substrate carrier on the table with the rubber
blanket facing upwards.
• Attach the test strip to the front end of the rubber blanket
cladding with adhesive tape.
• If the length of the sample is shorter than the required
length, stick it so, that the back end reaches the back of
the carrier, or stick it on a strip of another paper with the
right length.

6.10.3 Stopwatch
NOTE:
The stopwatch comes as part of the accessory holder.

6.10.3.1 Setting clock

• Set the short switch (1) at the right hand side to position
SET.
• Set the long switch (2) at the right hand side to position
CLOCK.
• The top display is activated.
• Set the desired time with the buttons HR, MIN and SEC.
• Set the short switch to position LOCK

6.10.3.2 Setting times

• Set the short switch (1) to position SET.
• Set the long switch (2) to position T1.
• The top display is activated.
• Set the desired distribution time (e.g.30 s) with the button
HR, MIN and SEC.
• Press MEMORY.
• Set the long switch at the bottom of the right hand side to position T2.
• The middle display is activated.
• Set the total time of distribution and the inking time of the printing disc (e.g. 45 s) with the buttons HR, MIN and SEC.
• Press MEMORY.
• Set the short switch to position LOCK.
• Set the long switch to position T123

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6.10.3.3 Start countdown

• Press START/STOP for countdown to start.
• After the 1st set time (time of distribution) an acoustic signal sounds.
• After the 2nd set time (inking time of printing disc) a quicker acoustic signal sounds.
• Press START/STOP two times to stop the signal and counting of both displays.
• Press CLEAR two times to zero.
• Press MEMORY.
• The stopwatch is ready to use again

6.10.3.4 Clearing or changing set times

• Set the short switch (1) to position SET.
• Set the long switch (2) to position T1
• the top display is activated.
• If stopwatch is counting down, press START/STOP.
• Press CLEAR.
• Press MEMORY.
• Press CLEAR.
• Set the long switch to position T2
• the middle display is activated.
• Press CLEAR.
• Press MEMORY.
• Press CLEAR.
• Now new times can be entered (see 6.10.3.2)

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7 O P E R AT I O N
7.1 Inking in
WARNING: Do not wear loose clothing, ties, and chains and avoid loose-hanging long hair. They may get
caught up in the cylinders of the inking unit.
Do not allow the top rollers to rotate dry on the cylinders. This may cause a build-up of static charge.

TIP: When applying ink, the use of the IGT ink pipette with resolution 0.01 or resolution 0.001 ml is
recommended.

• Place the printing disc on the printing disc shaft of the inking arm until click and swing the arm to the left, using the
handle.
• Place the top roller on the cylinders of the inking unit by hooking it into the aperture.
• Apply ink in lines of 0.03 – 0.05 cm³ as evenly as possible across the entire width and circumference of the top roller.
• Press the INKER button, which activates ink distribution and, if in use, at the same time start the stop watch.
NOTE: If the ink is not applied evenly, inking time will be prolonged. In that case, it is advisable to rotate the top roller
after 20 seconds.
• Once the ink has been fully distributed on the inking unit, swing the inking arm over to the right, so that the printing
disc rests on the top roller.
• Leave the printing disc on the top roller for at least 20 seconds.
• If the printing disc is inked well, swing the inking arm back.
NOTE: Do NOT swing the inking arm on the grip of the printing disc; this leads to streaks in the print.
• The printing disc is now ready to print.
• Stop the inker by pressing the INKER button again.

7.2 Printing
• For Orange Proofer x3 only: pull or press the printing disc shaft in the desired position.
• For all Orange Proofers: remove the inked printing disc from the inking arm.
• Place the inked printing disc on the printing disc shaft until click.
• Place the substrate carrier with the test strip facing upwards on the substrate guiding pins, as far to the right as
possible, with the front end of the substrate carrier on the left-hand pin.
• Move the arm on the right hand side carefully forward and upward to apply the set printing force.
• Push the PRINT button and hold it shortly. The tester will make a print.
NOTE: If the button is kept depressed the tester will make more than one revolution.
• Release the printing force by moving the arm at the right hand side down and backward again.
• Remove the substrate carrier with the printed strip.
• Remove the printing disc.
• Remove the test strip from the carrier.
• Appraise the required aspects of the test strip.
• Clean the printing disc as described in section 7.6.
• After having finished testing, clean all parts as described in section 7.3 and store them according to section 7.5
NOTE: Multiple prints can be made, however, It is not advised to add any ink, due to the drying time.

7.3 Cleaning
WARNING: Make sure that the inks and solvents to be used do not come into contact with skin or eyes. Wear
protective clothing such as laboratory coat, gloves and safety goggles.
• Make sure the workplace is well ventilated because volatile and flammable cleaning agents are usually required to
clean the printing discs and inking unit.
• Smoking and naked flames are prohibited due to the use of cleaning agents and solvents in the inks.
• Waste left over after using the tester should be treated as chemical waste and disposed of or destroyed accordingly

7.3.1 Aluminium printing discs

Clean aluminium discs with lint free towels, with a cleaning solvent. Before using the disc again, let the solvent
evaporate or dry it. Let the disc reach room temperature.
IMPORTANT: Never use an ultrasonic bath to clean aluminium discs; this may destroy the aluminium.

7.3.2 Printing discs with rubber (blanket)

Clean discs with rubber or rubber blanket with lint free towels wetted with a suitable cleaning solvent. Before using the
disc again, let the solvent evaporate or dry the disc. This can take a long time: up to 10 minutes or longer, depending on
the used cleaning solvent. Also let the disc reach room temperature again.

IMPORTANT: Apply only little force while cleaning, to prevent wear of the coating of the disc or the rubber. The solvent
must do the job.

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7.3.3 Cleaning solvents

The following cleaning solvents are recommended:

7.3.3.1 For conventional inks

Clean with Do not use
• White Spirit • Ester like Ethyl Acetate
• Cleaning Naphtha • Ketone like Acetone
• Lighter fluid • Aldehyde
• Turpentine • Methyl Ethyl Ketone (MEK)
• Boiling point (100 – 140 ˚C) with less than 2%
aromatic contents

7.3.3.2 For black rubber discs with art.nr. 402.6xx

Clean with Do not use
• White Spirit • Ester like Ethyl Acetate
• Cleaning Naphtha • Ketone like Acetone
• Lighter fluid • Aldehyde
• Turpentine • Methyl Ethyl Ketone (MEK)
• Alcohol like Ethanol
• Boiling point (100 – 140 ˚C) with less than 2%
aromatic contents

7.3.3.3 For other black rubber UV discs and UV rubber blanket discs
Clean with Do not use
• Ethyl Acetate • White Spirit
• Acetone • Cleaning Naphtha
• Methyl Ethyl Ketone (MEK) • Lighter fluid
• Ethanol • Turpentine
• Spiritus

The higher the boiling point, the longer it takes before the cleaning solvent has been evaporated, the longer it takes
before you can make the next print with the printing disc.

IMPORTANT: If in doubt about a cleaning agent, please contact IGT Testing Systems and/or send a recent SDS of this
cleaning agent, so that IGT can investigate the suitability.
• Never soak the printing discs in any cleaning agent.
• Never use any of the UV cleaning agents for conventional rollers.
• Never leave any rubber part of the rollers resting on another surface while not in use.
• Always store the printing discs on their core in a cool and dark place, free from heat and chemicals.
• Always store the top rollers on their core or resting only on the steel core, preferable on the special carriers.

7.4 Switching off

Proceed as follows:
• Move the arm at the right hand side downward and backward.
• Place a printing disc on the printing disc shaft of the printing unit.
• Move the arm at the right hand side forward and upward.
• For Orange Proofer OP only: place the adjustment key on the nut in the hole at the left-hand side, rotate it anti clock
wise until stop.
• For Orange Proofers M, 70 and x3 only: set the printing force to the minimum value by pressing the button > until
the motor stops.
• Move the arm at the right hand side downward an backward.
• Take the printing disc and top roller from the unit.
• Move the arm at the right hand side downward and backward.
• Now the spring of the printing force mechanism is not loaded.
• Switch the tester off using the mains switch on the back.

7.5 Storage of discs and top rollers

Keep printing discs and top rollers on a safe place in lab environment: 23ºC and 50% RH.
Preferably store them in a clean and dark place free from heat, sunlight, solvents etc, and make sure there is no contact
between the rubber and any other material to prevent damaging, indentations or flat sides; store discs on their core and
top rollers in their carrier.

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8 M A I N T E N A N C E A N D R E PA I R
The tester contains no components that can be serviced by the user. If the tester requires internal maintenance, service
personnel authorized by IGT Testing Systems need to carry this out. For maintenance other than referred to in the
following overview, consult your supplier or local agent.

8.1 Parts
When ordering replacement components always state the following:
• Type and serial number of the tester as indicated on the unit (e.g. 417.H.566)
• The article number of the component.

8.2 Speed
Deviations in the speed cannot be observed without special equipment.

8.3 Lubrication
By a certified service engineer (IGT Testing Systems):
• All ball bearings have life-long lubrication.
• Once a year internal hinges should be lubricated.
• The sliding shafts and the glide bearings should be cleaned and oiled once per year or if contaminated with ink.
• The printing shafts should be greased monthly with acid free Vaseline.

8.4 Printing force

Deviations in the printing force cannot be observed without special equipment. This may be checked using the IGT PFM
(Printing Force Meter). Checking once a year is sufficient for average use.

8.5 Inspection before each use

Check that the printing discs, top roller and substrate carrier are in a good condition.
• For rubber discs, rubber blanket discs, top roller and substrate carrier: check for swollen edges, hardness, dents.
• Aluminium discs: check for scratches, dirt.

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IGT ORANGE PROOFER TYPES OP – OP M – OP 70 – OP X3 Page 16

8.6 Troubleshooting
Problem Possible cause Solution

GENERAL

Tester does not work at all Main switch is off Turn main switch on

Mains cable is not properly connected Connect mains cable properly to tester and wall
socket

Mains cable plug defective Use different mains cable

There is no mains power Let inspect mains power

Fuse in tester defective Change fuse

Large cylinder (D) does not rotate or Contact the supplier for repair
rotates irregularly

Top roller is lifted from inker Top roller is unround Use new top roller, do not subject it to pressure
while not in use and clean it with the right
Top roller is swollen cleaning agent
Top roller is worn

Top roller core is bend

PRINTING DISC

Printing disc does not fit on printing Temperature of printing disc too low (shrunk) Allow the printing disc to warm up
disc spindle

Printing force mechanism does not Impression cylinder is not rotating with Tighten impression cylinder with Allen bolt in
work. spindle groove on spindle

Micro switch is defective

Impression cylinder keeps rotating Contact the supplier for repair
Micro switch is running next to wheel

PRINT QUALITY

Printing force is too low Increase printing force

Rubber disc: exchange for new one;

Printing disc is too hard
Rubber blanket: exchange for new one
Printing quality is poor Printing disc lining is worn Use a new printing disc

Ink has dried onto inker/printing disc Use shorter inking times

Printing disc and/or top roller selection is

Select proper printing disc and/or top roller
incorrect (conventional/UV)

Dents in printing disc

Use new printing disc/top roller/substrate carrier
Dents in top roller and do not subject them to pressure while not
in use
Streaks in print Dents in substrate carrier

Inking time too short Prolong inking time

Printing disc arm is not lifted at handle Swing arm over with handle

Fine stripe pattern in print Rectifier is defective

Contact the supplier for repair
Density left/right is not the same Bearing is defective
For other faults and repairs Consult IGT Testing Systems.

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9 STORAGE AND TRANSPORT

9.1 Storage
WARNING: the tester weighs approximately 25 kg.

9.1.1 Use of the original box

• Remove the plug from the wall socket.
• Remove the handgrip from the handle at the righthand side of the tester.
• Remove the accessory holder if present.
• Place the tester in the foam interior at the bottom of the box.
• Place top form on top of the tester with the recesses facing upwards
• Place all parts and accessories in the recesses.
• Fill voids with protective foam, wadded paper or similar.
• Cover with 6 mm thick top foam sheet.
• Close the box and store in a clean, dry and safe place, away from heat, sunlight, solvent vapours etc..

TIP: Make sure there is no pressure on the rubber of the top roller and printing discs to prevent indentations.

9.1.2 No use of the original box

• Take a box or crate that is large and strong enough to accommodate the unit including the accessories.
• Place all items inside.
• Fill voids with protective foam, wadded paper or similar.
• Cover and close the box.
• Store in a clean, dry and safe place, away from heat, sunlight, solvent vapours etc.

9.2 Transport
9.2.1 Use of the original box
• Carry out the first three steps as described in section 9.1.1.
• Place the box on a sturdy pallet.
• Place the tester in the foam interior at the bottom of the box.
• Finish the steps from section 9.1.1 until and including covering the content of the box.
• Close the box with suitable tape and/or straps.
• Secure straps around both box and pallet.

9.2.2 No use of the original box

• Take a box or crate that is large and strong enough to accommodate the unit including the accessories and protective
packing of foam or wadded paper.
• Place this box on a sturdy pallet.
• Place the unit and the accessories inside.
• Fill voids with protective foam, wadded paper or similar.
• Cover and close the box with suitable tape and/or straps.
• Secure straps around both box and pallet.
• Mark the package in such a way that the transport company can see that it must be stored dry and upright and should
not be tilted or thrown..

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10 OVERVIEW OF COMPONENTS
10.1 Orange Proofer OP
10.1.1 Inking

10.1.2 Printing

B Oscillating cylinder K Substrate guide

C Hole for top roller / Top roller L Impression cylinder
E Driven small cylinder M Printing shaft for printing
F Inking arm O 'PRINT' button
G Printing disc shaft for Inking Q Force scale
H Substrate carrier S Inker button
I Substrate T Inker button
J Safety pin U Nut for printing force

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IGT ORANGE PROOFER TYPES OP – OP M – OP 70 – OP X3 Page 19

10.2 Orange Proofer M, OP70, OPx3

10.2.1 Inking

10.2.2 Printing

B Oscillating cylinder L Impression cylinder

C Hole for top roller / Top roller M Printing shaft for printing
E Driven small cylinder O 'PRINT' button
F Inking arm P ‘Force up’ button
G Printing disc shaft for Inking Q Force scale
H Substrate carrier R ‘Force down’ button
I Substrate S Inker button
J Safety pin T Force application handle
K Substrate guide

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11 MAINTENANCE RECORDS
Date Engineer Work done/see document Initials

418.000.044.H.005