Operating Manual CX104 - Print
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HUNGOperating Manual CX104 - Print
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HUNGPreface
Preface
00.956.3001-000UTKENU_03
1.1 Notes for the Reader
Target group
This is the operating manual for the machine. Together
with the operating manual of the control station and the
maintenance and cleaning manual of the machine, it
gives you all the information you need as an operator.
Read this operating manual for the machine.
Keep this operating manual for the machine in the
vicinity of the machine, ready at hand.
Composition of User Information
The user information consists of the following manu-
als:
● Maintenance and cleaning manual of the ma-
chine
● Operating manual for the control station
○ Prinect Press Center operating manual
○ Wallscreen operating manual (optional)
● Operating manual for the machine
Note
The main chapter A Safety in the oper-
ating manual for the machine is a com-
ponent of this manual. Always read the
main chapter Safety in the operating
manual for the machine before perform-
ing the work.
Structure of the operating manual of the machine
The operating manual for the machine contains the
main chapters A and B.
Numbered tabs subdivide the main chapters into
chapters.
Each main chapter and each chapter starts with the
relevant table of contents.
The main chapter A Safety contains the basic infor-
mation you require to be able to work safely on your
machine.
The main chapter B Machine describes the control
panels and the mechanical components of the ma-
chine and their operation and adjustment.
The index helps you to find specific information.
Equipment
This manual describes the machine with its maximum
equipment. Part of the equipment described in here is
optional and it might not exist on your machine.
Abbreviations Used in This Document
D.S. = Drive side
O.S. = Operator's side
SC.999.0020/01
Preface
PU = Printing unit
CU = Coating unit
ICWD = Impression cylinder washup device
IRWD = Inking roller washup device
BWD = Blanket washup device
LED = Light-emitting diode
MID = Press display
Currency
The information provided in this user information cor-
responds to the series version of the machine at the
time of publication of this document. We reserve the
right to make changes in accordance with the progress
of modern technology.
In case of doubt, please contact your responsible
agency.
Note on Protection
Essential parts, devices and assemblies as well as
software, control and measuring devices of our ma-
chines are internationally protected by copyright,
patents and other intellectual property laws and regu-
lations. The reproduction, distribution and utilization of
this document as well as the communication of its con-
tents to others without express authorization is pro-
hibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant
of a patent, utility model or design.
Open Source Software
Some software libraries and other software programs
which are part of the scope of delivery of the Heidel-
berg software are applications from third-party
providers. They are Open Source Software, for which
the granted rights of use are subject to the regulations
pertaining to the license agreements. Upon your writ-
ten order you can obtain a free and fully machine-
readable copy of the source code of such Open
Source Software, in line with applicable provisions,
from Heidelberg. The costs for the data carrier,
postage and administration will be charged.
You can obtain a copy of the source code stating your
Heidelberg software version from:
Heidelberger Druckmaschinen AG
Service Hotline Electronics
E-Mail: [email protected]
Copyright, Address of Manufacturer
© Copyright by
Heidelberger Druckmaschinen AG
Kurfürsten-Anlage 52 - 60
69115 Heidelberg
Deutschland
SC.999.0020/01
Overall chapter overview
Table of Contents
A Safety .................................................................................................................................... A.1
Safety ...................................................................................................................................... A.1.1
1 Basic safety instructions ............................................................................................... A.1.1
2 Accessories and additional equipment .......................................................................... A.1.13
3 Specifications ................................................................................................................ A.1.20
4 Workplaces at the press ............................................................................................... A.1.24
5 Controls ......................................................................................................................... A.1.25
6 Protective devices ......................................................................................................... A.1.33
7 Checking protective devices with the control station .................................................... A.1.54
8 Bleeding the pneumatic system .................................................................................... A.1.58
9 Turning the press manually ........................................................................................... A.1.61
B Press ...................................................................................................................................... B.1
Overview of touch screen control panels ............................................................................ B.1.1
1 Touch screen overview ................................................................................................. B.1.3
Control panels on the feeder ................................................................................................ B.2.1
1 Feeder control panels ................................................................................................... B.2.3
2 Feeder touch screen, overview ..................................................................................... B.2.14
3 Job menu on the touch screen ...................................................................................... B.2.17
4 Production menu on the feeder touch screen ............................................................... B.2.23
5 Feeder menu on the feeder touch screen ..................................................................... B.2.26
6 Touch screen feeder menu - feeder pile ....................................................................... B.2.28
7 Washup menu on the touch screen .............................................................................. B.2.30
8 Consumables display menu on the touch screen ......................................................... B.2.32
9 Malfunction/Service menu on the touch screen ............................................................. B.2.35
Control panels on the printing unit/coating unit ................................................................. B.3.1
1 Intelliline operator assistance ........................................................................................ B.3.3
2 Printing unit control panels ............................................................................................ B.3.5
3 Coating unit control panels ........................................................................................... B.3.9
4 Control panels of intermediate unit ............................................................................... B.3.17
Control panels on the delivery .............................................................................................. B.4.1
1 Delivery control panel ................................................................................................... B.4.3
2 The "Production" menu .................................................................................................. B.4.8
3 Dampening menu ........................................................................................................... B.4.11
4 Delivery menu ................................................................................................................ B.4.13
5 "Additional devices" menu .............................................................................................. B.4.27
SC.999.0020/01 1
Overall chapter overview
6 Consumables menu ....................................................................................................... B.4.30
7 Malfunction/Service menu .............................................................................................. B.4.31
Feeder ..................................................................................................................................... B.5.1
1 Feeder - safety instructions ........................................................................................... B.5.7
2 Pile change .................................................................................................................... B.5.8
3 Automatic non-stop pile change (optional) .................................................................... B.5.14
4 Preloading and pile change .......................................................................................... B.5.28
5 Automatic pile alignment ............................................................................................... B.5.30
6 Automatic non-stop pile change (optional) .................................................................... B.5.33
7 Suction head .................................................................................................................. B.5.48
8 Overview table - suction head settings for different printing materials .......................... B.5.54
9 Sheet separator fingers .................................................................................................. B.5.57
10 Adjusting the blast air on the suction head ................................................................... B.5.59
11 Pile stops on the suction head ...................................................................................... B.5.62
12 StaticStar - ionizing unit (option) ................................................................................... B.5.63
13 Ionizing blowers at the suction head (optional) ............................................................. B.5.67
14 Foil printing (optional) ................................................................................................... B.5.70
15 Lateral sheet separation blowers .................................................................................. B.5.78
16 Rope guide and guide plate .......................................................................................... B.5.80
17 Sheet monitoring ........................................................................................................... B.5.85
18 Forwarding rollers .......................................................................................................... B.5.103
19 Guide rolls on the suction tape ..................................................................................... B.5.104
20 Pulling device ................................................................................................................ B.5.106
21 Separator rolls ................................................................................................................ B.5.115
22 Front lays ...................................................................................................................... B.5.118
23 Crash bar ....................................................................................................................... B.5.121
24 Adjustment information for special printing material ..................................................... B.5.122
25 CutStar (sheeter) - Preset Plus feeder .......................................................................... B.5.124
26 Troubleshooting on the feeder ...................................................................................... B.5.129
27 Emergency measures in the event of the failure of a servo-drive in the feeder ............ B.5.134
Printing unit ............................................................................................................................ B.6.1
1 Printing unit - safety instructions .................................................................................... B.6.5
2 Printing-related notes on cylinder rolling ....................................................................... B.6.9
3 Height adjustment of the gripper pads on the feed cylinder .......................................... B.6.13
4 Removing lost sheets .................................................................................................... B.6.16
5 Suction brush ................................................................................................................. B.6.21
6 Plate cylinder ................................................................................................................ B.6.28
7 Hickey catcher .............................................................................................................. B.6.29
2 SC.999.0020/01
Overall chapter overview
8 Hand-held scanner with base station (Press Center 3/XL3 code reader with Ethernet
connection, option) ........................................................................................................ B.6.30
9 Requirements for the printing plate ............................................................................... B.6.42
10 AutoPlate ....................................................................................................................... B.6.46
11 Positioning correction at the tail edge of print ................................................................ B.6.50
12 Blanket cylinder ............................................................................................................. B.6.53
13 Blanket washup device ................................................................................................. B.6.65
14 Impression cylinder washup device .............................................................................. B.6.80
15 Washing fluid container ................................................................................................. B.6.90
16 Washup ......................................................................................................................... B.6.94
17 Sheet-transferring cylinders and drums ........................................................................ B.6.97
18 Air settings in the printing unit ....................................................................................... B.6.102
19 Malfunctions on the printing unit ................................................................................... B.6.104
Plate changer .......................................................................................................................... B.7.1
1 Plate changer - safety instructions ................................................................................ B.7.3
2 AutoPlate Pro ................................................................................................................ B.7.4
3 AutoPlate Pro - manual plate change ........................................................................... B.7.12
4 Notes on troubleshooting .............................................................................................. B.7.15
5 Error message: "General malfunction: automatic plate change" or "Finger protecting bar/
protective device" or emergency stop or "DWBA movement lock main drive" .............. B.7.17
6 Error before the start of the plate change ..................................................................... B.7.20
7 Malfunctions when removing the plate .......................................................................... B.7.22
8 Malfunctions in data transmission ................................................................................. B.7.29
9 Plate loading faults ........................................................................................................ B.7.30
Inking unit ............................................................................................................................... B.8.1
1 Inking unit - safety instructions ...................................................................................... B.8.3
2 Manual adjustment of the lateral distribution ................................................................ B.8.5
3 Inking unit temperature control ..................................................................................... B.8.9
4 Removing and installing the inking rollers ..................................................................... B.8.11
5 Template for roller adjustment ...................................................................................... B.8.33
6 Removing and installing the ink vibrator ....................................................................... B.8.36
7 Selecting, servicing and storing inking rollers ................................................................ B.8.38
8 Ink fountain .................................................................................................................... B.8.41
9 Autoprotect - automatic application of roller protective agent ....................................... B.8.47
10 Ink mist suction removal ............................................................................................... B.8.52
Dampening system ................................................................................................................ B.9.1
1 Dampening system - safety instructions ........................................................................ B.9.3
2 Print-related notes ......................................................................................................... B.9.4
SC.999.0020/01 3
Overall chapter overview
3 Requirements for the dampening solution .................................................................... B.9.6
4 Removing and installing dampening rollers .................................................................. B.9.9
5 Blower bar ...................................................................................................................... B.9.23
6 Cleaning the dampening system ................................................................................... B.9.24
Delivery ................................................................................................................................... B.10.1
1 Delivery - safety instructions ......................................................................................... B.10.7
2 Operator protection through the protective device for the detection of whole body access,
DWBA ........................................................................................................................... B.10.10
3 Guide pulleys ................................................................................................................ B.10.19
4 Cover plates on the delivery ......................................................................................... B.10.27
5 Air in the sheet ascent ramp ......................................................................................... B.10.36
6 Air in the pile area ......................................................................................................... B.10.41
7 Powder spray device ..................................................................................................... B.10.44
8 Print-related notes on powdering .................................................................................. B.10.45
9 Format bridging device .................................................................................................. B.10.49
10 Sheet brake system - Overview and variants ............................................................... B.10.51
11 Modular sheet brake system - overview ....................................................................... B.10.52
12 Modular sheet brake system - handling the sheet brake modules ................................ B.10.59
13 Modular sheet brake system - configuration variants for straight printing ..................... B.10.75
14 Modular sheet brake system - Component versions for straight printing and perfecting B.10.78
15 Modular sheet brake system - Remedies in the event of problems .............................. B.10.84
16 Suction tapes ................................................................................................................ B.10.85
17 Gripper opening cam ..................................................................................................... B.10.87
18 Overrun sheet control .................................................................................................... B.10.90
19 Sheet joggers ................................................................................................................ B.10.92
20 Rear edge stop ............................................................................................................. B.10.96
21 CleanStar (option) ......................................................................................................... B.10.99
22 Removal of sample sheet .............................................................................................. B.10.103
23 Tape inserter .................................................................................................................. B.10.105
24 Tape inserter on face side ............................................................................................ B.10.106
25 Lateral tape inserter D.S. / O.S. .................................................................................... B.10.109
26 Pile change .................................................................................................................... B.10.117
27 Non-stop operation ........................................................................................................ B.10.120
28 Automatic non-stop system ........................................................................................... B.10.132
29 Print-related information on the auto-non-stop system (optional) ................................. B.10.140
30 Troubleshooting on the delivery .................................................................................... B.10.142
4 SC.999.0020/01
Overall chapter overview
Coating unit ............................................................................................................................ B.11.1
1 Coating unit - safety instructions ................................................................................... B.11.5
2 Coating unit - overview .................................................................................................. B.11.9
3 Print-related notes on coating ....................................................................................... B.11.11
4 Coating blanket cylinder with combination clamping rails ............................................. B.11.13
5 Positioning corrections on the coating blanket cylinder with combination clamping rails B.11.31
6 Pressing roller ............................................................................................................... B.11.36
7 Notes on treatment of the screen roller ......................................................................... B.11.39
8 Screen roller .................................................................................................................. B.11.40
9 Fitting/removing rolling bearings ................................................................................... B.11.51
10 Chambered blade and pressurized chambered blade .................................................. B.11.53
11 Screen rollers of spraying device (option) ..................................................................... B.11.78
12 CoatingStar varnish supply unit .................................................................................... B.11.83
13 CoatingStar Compact varnish supply unit ..................................................................... B.11.90
14 Coating unit with 2 varnish circulation systems (optional) ............................................ B.11.96
Dryer ........................................................................................................................................ B.12.1
1 Dryer - Safety Instructions ............................................................................................. B.12.3
2 Dryers in the units (optional) ......................................................................................... B.12.5
3 UV interdeck dryer (optional) ........................................................................................ B.12.11
4 Dryers in the delivery (optional) .................................................................................... B.12.13
5 Print-related notes on the dryer .................................................................................... B.12.17
Index ...................................................................................................................................... Ind.1
SC.999.0020/01 5
Overall chapter overview
6 SC.999.0020/01
Main chapter overview
A Safety
Safety ............................................................................................................................................... A.1.1
1 Basic safety instructions ...................................................................................................... A.1.1
1.1 Hints for the user and operator of the press ................................................................. A.1.1
1.2 EC declaration of conformity .......................................................................................... A.1.2
1.3 Structure of the safety instructions ................................................................................ A.1.2
1.4 Intended use .................................................................................................................. A.1.3
1.5 Your personal protection equipment ............................................................................. A.1.5
1.6 Notes for people with a pacemaker (PM) or implantable cardioverter defibrillator (ICD) A.1.5
1.7 Alcohol, cleaners, functional fluids, solvents and varnishes ......................................... A.1.6
1.8 Working on the press without risk ................................................................................. A.1.6
1.9 Explosion protection and division into zones ................................................................ A.1.10
1.10 In-plant fire protection .................................................................................................... A.1.11
2 Accessories and additional equipment ............................................................................... A.1.13
2.1 General note .................................................................................................................. A.1.13
2.2 Electrical interface .......................................................................................................... A.1.13
2.3 Powder spray device ...................................................................................................... A.1.14
2.4 Dryer .............................................................................................................................. A.1.14
2.5 Washup devices ............................................................................................................. A.1.17
2.6 Dampening system ........................................................................................................ A.1.17
2.7 Device for dampening solution treatment ...................................................................... A.1.17
2.8 Inking unit temperature control ...................................................................................... A.1.18
2.9 Suction system ............................................................................................................... A.1.18
2.10 Equipment for lifting components, e.g. hoisting devices, load suspension devices, slings,
suspension elements ..................................................................................................... A.1.18
2.11 Conveyor system ........................................................................................................... A.1.19
3 Specifications ........................................................................................................................ A.1.20
3.1 Note ............................................................................................................................... A.1.20
3.2 Printing material ............................................................................................................ A.1.20
3.3 Feeder and delivery ...................................................................................................... A.1.20
3.4 Ink/Varnish .................................................................................................................... A.1.20
3.5 Cleaners for automatic and manual washup ................................................................. A.1.21
3.6 Noise emission values .................................................................................................. A.1.21
3.7 Vibrations - effects on human beings ............................................................................. A.1.22
3.8 Factors influencing function and performance ............................................................... A.1.23
3.9 Requirements of air quality ............................................................................................ A.1.23
3.10 Electrical fusing of the presses ..................................................................................... A.1.23
SC.999.0020/01 A. 1
Main chapter overview
4 Workplaces at the press ....................................................................................................... A.1.24
4.1 Workplaces at the press ................................................................................................ A.1.24
4.2 Handling movable steps and flaps in areas that can be walked on .............................. A.1.24
4.3 Handling gallery parts on hinged platforms .................................................................... A.1.24
5 Controls ................................................................................................................................. A.1.25
5.1 Main switch ................................................................................................................... A.1.25
5.2 Emergency stop palm button ........................................................................................ A.1.26
5.3 Zone stop palm button .................................................................................................. A.1.28
5.4 Reset button .................................................................................................................. A.1.29
5.5 Setup processes with main drive ................................................................................... A.1.30
5.6 The Control panel selection push button ...................................................................... A.1.30
5.7 Inching mode ................................................................................................................ A.1.31
5.8 Crawl speed mode ........................................................................................................ A.1.32
5.9 Positioning .................................................................................................................... A.1.32
6 Protective devices ................................................................................................................. A.1.33
6.1 To be observed when performing any work ................................................................... A.1.33
6.2 Fixed guards ................................................................................................................. A.1.33
6.3 Movable guards ............................................................................................................. A.1.33
6.4 Movable guards on the feeder ...................................................................................... A.1.34
6.5 Fixed guards on the feeder ............................................................................................ A.1.35
6.6 Movable guards only on the first printing unit ............................................................... A.1.36
6.7 Movable guards on the printing unit .............................................................................. A.1.37
6.8 Fixed guards on the printing unit ................................................................................... A.1.38
6.9 Movable guards at the automatic plate changer ........................................................... A.1.39
6.10 Safety devices in the printing unit ................................................................................. A.1.40
6.11 Movable guards on the intermediate unit ...................................................................... A.1.41
6.12 Fixed guards on the intermediate unit ........................................................................... A.1.42
6.13 Movable guards on the coating unit .............................................................................. A.1.43
6.14 Fixed guards on the coating unit ................................................................................... A.1.45
6.15 Safety devices in the coating unit ................................................................................. A.1.46
6.16 Movable guards on the delivery .................................................................................... A.1.47
6.17 Fixed guards on the delivery ......................................................................................... A.1.48
6.18 Electrically monitored protective devices on the delivery with automatic non-stop function
....................................................................................................................................... A.1.49
6.19 Protective device for detecting whole body access (DWBA) ........................................ A.1.51
6.20 Other safety devices ...................................................................................................... A.1.52
7 Checking protective devices with the control station ....................................................... A.1.54
7.1 Checking protective devices (overview) ........................................................................ A.1.54
A. 2 SC.999.0020/01
Main chapter overview
7.2 Checking the individual units ......................................................................................... A.1.55
8 Bleeding the pneumatic system .......................................................................................... A.1.58
8.1 Shutoff device of the pneumatic system ........................................................................ A.1.58
8.2 Place of installation of the maintenance unit .................................................................. A.1.58
8.3 Bleeding the pneumatic system .................................................................................... A.1.59
8.4 Securing pneumatic system against start-up ................................................................ A.1.59
8.5 Aerating the pneumatic system ..................................................................................... A.1.60
9 Turning the press manually ................................................................................................. A.1.61
9.1 General notes ................................................................................................................ A.1.61
9.2 Tool and holding fixture .................................................................................................. A.1.61
9.3 Cranking the press by hand ........................................................................................... A.1.62
9.4 Special feature of CX 104-1+L ....................................................................................... A.1.63
9.5 Releasing the motor brake manually ............................................................................. A.1.65
SC.999.0020/01 A. 3
Main chapter overview
A. 4 SC.999.0020/01
Safety
1 Basic safety instructions
LS.901.0000-000UTKENU_31
Safety
1.1 Hints for the user and operator of the press
● Read the operating manual before start-up of the
press.
Note
Please ask your Heidelberg agency if
you there is anything you do not under-
stand or if you have any further ques-
tions about using your printing press
safely and in the proper manner. Please
ask about everything that seems impor-
tant to you in this connection. Your Hei-
delberg agency will be happy to provide
you with information.
● Ensure that all persons working on this machine
○ have received training and instructions,
○ have read and understood the operating
manual,
○ follow the regulations and instructions for
working without risk.
● Keep the operating manual so that it is always
available to the operators of the press.
● The operator is obliged to evaluate the risks in-
volved in using the entire system as intended in
order to define requirements for the examples
listed:
○ Type of cleaning including regular cleaning
intervals, for example of dust deposits.
○ Implementation and use of operating sup-
plies and functional fluids.
○ Creating operating instructions, e.g. using
the safety instructions in the operating man-
ual.
○ Generating explosion protection docu-
ments.
SC.999.0020/01 A.1.1
Safety
1.2 EC declaration of conformity
The following information is valid exclusively within the
LS.901.0096-000GRAUND_00
member states of the European Economic Area (EEA)
and for products that are completely manufactured by
Heidelberg.
● You have received a copy of the EC declaration
of conformity together with the invoice docu-
ments.
● Attach this copy to the operating manual.
Fig. 1 Basic principle
1.3 Structure of the safety instructions
This operating manual contains two categories of
safety instructions, which are explained below.
In order to clarify the individual safety instructions,
symbols (pictographs) with a specific meaning are as-
signed to each category. Some of the pictographs are
also attached to the press as stickers.
First-level safety instruction
These safety instructions warn you of potentially dan-
gerous situations. Non-observance of these instruc-
tions can lead to serious injury. In extreme cases, this
can result in death. In addition, machinery and acces-
sory equipment may be seriously damaged.
Relevant pictographs with signal words:
Warning - General hazards!
Description
Warning - Risk of injury from elec-
trical voltage!
Description
Warning - Risk of injury on hot sur-
faces!
Description
Warning - Risk of injury from mov-
ing parts!
Description
A.1.2 SC.999.0020/01
Safety
Warning - Risk of injury from mov-
ing parts!
Description
Warning - Risk of injury from mov-
ing chain gripper systems!
Description
Warning - Explosion hazard!
Description
Warning - Risk of cutting injury!
Description
Warning - Risk of injury from falling!
Description
Warning - Risk of injury due to cor-
rosive substances!
Description
Second-level safety instruction
This safety instruction warns you of potentially un-
wanted situations. Non-observance of these instruc-
tions may result in damage to machinery and acces-
sory equipment.
Relevant pictograph with keyword:
Caution - <Brief description of the
hazard>
Description
1.4 Intended use
The press is designed to print the intended materials.
The specifications of the intended materials can be
found in the "Specifications" section.
The press may only be run and operated by personnel
trained and instructed for this purpose. Installation,
conversion and dismounting of the press may only be
performed by your Heidelberg agency.
When installing and handling the printing press, the
user and his/her employees must observe the national
safety and accident prevention regulations.
SC.999.0020/01 A.1.3
Safety
Improper use and non-observance of the operating
manual may jeopardize
● your health
● your life
● presses and equipment
.
Safety devices on the press
● must not be removed,
● must not be manipulated,
● must not be bypassed,
● must be checked daily for presence and correct
functioning,
● must be cleaned regularly,
● must be maintained appropriately,
● must be repaired or replaced as necessary, in
order to preserve the functional properties.
Ensure that:
● safety identifications, e.g. yellow-colored marks,
● danger signs and
● safety lights,
remain easily visible and retain their effectiveness;
● the rope safety devices on the gallery are suffi-
ciently tensioned and also retain their effective-
ness.
Clean the safety identifications regularly, repair dam-
age in color and have the safety identifications re-
paired or replaced if necessary.
Heidelberg takes responsibility only for the delivery
status of the press and for any work performed by
skilled Heidelberg personnel.
Service life
Heidelberg uses various components to implement
safety functions that ensure proper use of the ma-
chine. These components are subject to a mathemat-
ical proof of their theoretical likelihood of failure in ac-
cordance with ISO 13849-1. This calculation is based
on a general maximum service life of 20 years.
Based on our knowledge and practical experience, we
highly recommend performing an expert safety check
of the machine after this maximum service life of 20
years. After the check and the implementation of any
recommended measures, the machine's service life
may be extended by a period to be determined at that
time.
A.1.4 SC.999.0020/01
Safety
1.5 Your personal protection equipment
When working, always wear
● safety shoes,
● close-fitting clothing,
● if necessary, a hairnet,
● protective gloves and safety goggles when han-
dling chemicals, e.g. when cleaning and topping
up liquids,
● no jewelry, watches, etc., which might get caught
up in grippers, moving parts or infeed nips,
● cut-resistant protective gloves when working on
blades (e.g. chambered blade in the coating unit,
ink chamber blade in the Anicolor inking unit) or
sharp components.
Suitable personal ear protection has to be chosen,
prepared and used in line with the operator's local
health and safety regulations.
1.6 Notes for people with a pacemaker (PM) or implantable cardioverter defibrillator (ICD)
Presses from Heidelberg that are operated as intend-
ed, comply with the European guideline on electro-
magnetic compatibility regarding radiated interference
in industrial areas.
Should people with a pacemaker (PM) or implantable
cardioverter defibrillator (ICD) wish to conduct activi-
ties on presses and their devices in the intended man-
ner, Heidelberg is not in a position to make any state-
ment regarding the suitability of such medial devices.
Heidelberg is not able to assess the pacemakers or
concerned implantable cardioverter defibrillators with
regard to their susceptibility to electromagnetic radia-
tion. This is something that only the manufacturers of
the pacemaker or implantable cardioverter defibrillator
can do.
The devices to be monitored include, for example,
closed control cabinets and distributors, drives and
motors as well as plasma and ionizing systems.
Heidelberg therefore recommends only allowing the
people in question to work on its installations after
consultation with the manufacturer of the pacemaker/
defibrillator and the relevant insurance company. En-
sure at all times that no health or safety risks are in-
volved.
Note
People wearing a pacemaker or defibril-
lator may not work on or stand near the
press and the above-mentioned de-
vices, e.g. to perform maintenance op-
erations or rectify any faults.
SC.999.0020/01 A.1.5
Safety
1.7 Alcohol, cleaners, functional fluids, solvents and varnishes
Alcohol, cleaners, functional fluids, solvents and var-
SF.901.0055-000GRAUND_00
nishes can be flammable, explosive, caustic, aller-
genic, toxic and volatile. You should therefore always
observe the following instructions:
General notes
● Make provision for good room ventilation.
● No naked flames, no ignition sources.
Fig. 2 Symbol for functional fluids ● Observe explosion prevention measures.
● When working with these substances, do not
smoke, drink or eat.
● Wear protective gloves and safety goggles.
● Do not heat substances above their flash point.
● Observe the relevant accident prevention regu-
lations, safety regulations and safety data sheets
of the manufacturers.
● Use only cleaners and solvents with the pre-
scribed specifications.
● Only store in suitable containers.
● Do not store on the press or close to UV dryers
and IR dryers.
● Dispose of any spilt materials immediately and
the proper manner.
● Dispose of any waste in compliance with regula-
tions.
● Any vapors generated by washing fluids and sol-
vents must be kept away from air intake open-
ings.
● Avoid any direct skin contact with functional flu-
ids, varnishes, cleaners and solvents. These
substances may be unhealthy. Should your skin
be contaminated wash the area immediately.
● UV inks and varnishes will only cure through ex-
posure to UV light. If your work clothes have been
contaminated they must be changed and thor-
oughly cleaned. Otherwise any UV ink and var-
nish residue may diffuse through the clothing and
make contact with your skin. Always wash con-
taminated clothing separately. Store your work-
ing clothes for UV inks away from the other cloth-
ing.
1.8 Working on the press without risk
Prior to switching on the press, check whether
● railings and handles are firmly fitted,
● guards, covers and moving parts are correctly fit-
ted and engaged,
● there are any trip hazards caused, e.g through
cables, hoses and pipelines.
A.1.6 SC.999.0020/01
Safety
● any foreign bodies might get into the press (e.g.
tools that are left lying around or have been
dropped).
Before press start-up and prior to moving the pile
up or down, perform a visual check to ensure that
nobody is in the danger area of movable parts (es-
pecially in the area of the chain gripper systems in
the delivery and the pile support plates).
During operation
● When working in the area of the feeder, no dot
reach beneath or around moving parts (e.g. lifting
and forwarding suckers, forwarding flap, sucker
bar and feed table height control bar) and adja-
cent components (danger of crushed fingers).
● When working near the material infeed, avoid
hazardous movements. Do not reach into the gap
between the guard and the material infeed.
● When working in areas secured by a light barrier
system (e.g. DWBA), please be aware that there
are still residual risks in this secured area. There-
fore do not take hold of or reach under the safe-
guard. Pay special attention when working in
these areas.
● Always supervise a press in operation.
● Keep unauthorized persons out of the danger
area.
● When working on the swung-down and engaged
ink fountain, pay special attention to the move-
ment of the ink fountain roller.
● When working on the delivery (pile change, re-
moval of sample sheet, working with spacer
wedges) pay particular attention to the move-
ment of the chain gripper bars.
● Never stay on or underneath the pile support
plate when the press is not secured against being
put into operation. Never stand, sit or lie on a
moving pile support plate.
Makeready, cleaning and maintenance
should be carried out as follows, due to an increased
risk of injury:
● With utmost care and attention.
● Only properly trained persons are allowed to
work in the areas with travel-limited inching
mode.
● When you clean the cylinders, make sure that the
ball of your hand points in the direction of the in-
feed nip. Your fingers must point in the direction
of the outlet nip (select the corresponding direc-
tion of rotation).
● Clean the swung-down ink fountain only when
the ink fountain roller is at standstill. Your fingers
SC.999.0020/01 A.1.7
Safety
must at all times be kept pointing away from the
infeed nip.
● Reverse-inch or position the press only when no
sheets are in the press. Print sheets can be bent
in reverse direction and can damage grippers,
blast tubes and cylinder surfaces.
● Machine parts, especially washup devices,
rollers, doctor blades and slide-in dryers, may re-
quire particular care and special measures due to
their weight or handling. That is why you should
enlist the help of another person, e.g. to assist
with removal and installation and with carrying
and transporting such machine parts.
● Observe the instructions for cleaning and main-
taining the press. Avoidable dangers may be
caused by a press that has been given inade-
quate care or insufficient maintenance.
Practical utilization of main switch and emergency
stop button
The following procedure must be used, unless it is
in contradiction to national safety and accident
prevention regulations (e.g. Lockout/Tagout
(USA)).
● Main switch
Before performing all extensive work (e.g. setup,
maintenance, cleaning and service work and trou-
bleshooting) on the press or on units that requires
more than 5 minutes, as well as prior to all work on
voltage-carrying parts:
1. Switch the main switch to 0/OFF, and lock it with
a padlock.
2. Leave a sign with the name of the person autho-
rized to switch on the press.
Result
The press is locked against being
switched on as long as the main switch is
locked.
Note
The function requires that you wait until
the press has been switched off for at
least 10 seconds, before switching the
press back on again.
● Emergency stop button
Before all work on the press and on units (e.g. setup,
maintenance and cleaning work and troubleshooting)
that requires less than 5 minutes:
A.1.8 SC.999.0020/01
Safety
1. Press the Emergency stop palm button on the
nearest control panel.
Note
If you cannot ensure that the Emergency
stop button remains pressed (for exam-
ple due to lack of visibility), you have to
secure the press against being switched
on at the main switch.
Delivery
For all deliveries with an access height of less than
800 mm (Press model QM 46, GTO, SM 52, SX 52,
PM 52, PM 74, SM 74-N, SX 74-N) the following ap-
plies:
Prior to any work in the delivery that takes less than
5 minutes to complete:
1. Press the emergency stop button on the delivery
control panel.
For all deliveries with an access height of more than
800 mm (press model SM 74, SX 74, SX 102, CD 74,
CX 75, XL 75, CS 92, SM 102, CD 102, CX 102,
XL 105, XL 106, XL 145/XL 162) the following applies:
Prior to any work in the delivery that takes less than
5 minutes to complete:
1. Press the Emergency stop button on the delivery
control panel after you have
2. also opened the front guard on the delivery.
After the press has been switched off, keep in
mind that
● The module blowers and the ventilators in the
delivery continue to run-on for about one minute.
● Dryers, supply devices and additional devices
may still be hot. Allow the dryers, supply devices
and additional devices to cool down before work-
ing on them.
● The pneumatic system of the press is still under
pressure even after the press is switched off.
Parts of the system (e.g. the pressure tank of the
compressor) may maintain this pressure for
weeks. Bleed the pneumatic system before car-
rying out any work on it.
In the case of a malfunction or failure of a safety
device
● Stop the press immediately.
● Notify the service department of your Heidelberg
agency immediately.
SC.999.0020/01 A.1.9
Safety
Electrical devices
● Any work on the electrical equipment may only be
carried out by authorized skilled personnel.
● Keep control cabinets and housings closed at all
times.
● Do not connect any additional electrical equip-
ment in the control cabinet.
1.9 Explosion protection and division into zones
Dust (powder and paper dust), alcohol, washing fluids
and solvents may be combustible and explosive. Only
functional fluids and varnishes that cannot form an ex-
plosive atmosphere may be used.
You must therefore observe the following notes on
the substances mentioned above:
● Do not store on the press or close to UV and IR
dryers.
● Only use suitable containers. The containers
need to be sufficiently stable. Gases must be
safely prevented from escaping to form an ex-
plosive atmosphere (impermeability).
● Only use powders, washing fluids and solvents
specified by Heidelberg.
● Do not heat substances above their flash point.
● Dispose of any spilt materials immediately and
the proper manner.
● Make provision for good room ventilation.
● Fire, smoking and open light on the system and
when working with these substances are prohib-
ited.
● Formation of fire loads, for example by storing
combustible waste at the machine, must be pre-
vented.
● Operating instructions are to be drawn up and the
employees instructed every year.
● Areas soiled with powder have to be cleaned with
a suitable and approved industrial vacuum clean-
er according to the degree of soiling (maximum
permitted height of dust: 1 mm). The areas
should be cleaned at least once a week.
● Ensure that no dust is swirled up, for example
never use compressed air to clean out areas
soiled with powder.
● Clean dust filters, for example on powder extrac-
tion devices, at regular intervals and check them
for damage. Observe the information on the fil-
ters given by the manufacturer.
● Draw up a cleaning plan.
● Define and comply with company-specific explo-
sion prevention measures.
A.1.10 SC.999.0020/01
Safety
● Have ground connections (equipotential bond-
ing) checked for damage and function by an au-
thorized person at regular intervals (at least once
a year).
● Comply with IP54 as the minimum level of pro-
tection for electrical equipment.
● Observe the relevant accident prevention regu-
lations and safety data sheets of the manufac-
turers.
Division into zones (in accordance with EN 1127-1)
When drawing up the explosion protection documents,
the operator should also refer to the following zones:
Location Zone
Delivery, not cleaned Zone 22
Interior of suction tubes and systems Zone 22
Washing fluid container, interior and filler opening (for T > 30°C) Zone 0
Washing fluid container, exterior (if undamaged and watertight) No zone
Central dampening solution supply - the specifications given by the manufacturer have to be Zone 0
observed!
Assumption: If no specifications are given - in particular in the alcohol supply reservoir and at a
distance of 30 cm around the filler opening.
Powder exhaust air cabinet, interior during jogging Zone 21
Powder exhaust air cabinet, exterior (if undamaged and airtight) No zone
Further possible zones have to be determined in the course of the risk evaluation to be performed by the operator.
Tab. 1 Zone classes
Note
In this context, observe all measures list-
ed with regard to explosion protection in
order to operate the entire system safely
and in line with regulations.
1.10 In-plant fire protection
● Please ensure that the required steps are taken
to detect and assess possible fire risks, e.g.
through the printing materials or operating sup-
plies used, such as powder. If necessary, consult
a local fire protection expert.
● In order to minimize the risk of fire, only use op-
erating supplies which correspond to the specifi-
cations in the operating manual. Please observe
the safety data sheets of these operating sup-
plies. For example, do not use ignitable powder,
but e.g. mineral-based powder, as far as possi-
ble, especially when using a dryer. If this is not
possible, due to production-related reasons, op-
erating instructions and cleaning schedule must
be modified accordingly. In this case, Heidelberg
recommends daily cleaning and an appropriate
SC.999.0020/01 A.1.11
Safety
visual inspection for undue, severe soiling before
start-up of the press.
● Check the selection of any necessary fire pre-
vention measures and discuss them with your in-
surance company in order to prevent any dam-
age to property and/or the environment.
● Required and helpful fire prevention measures
could be, for example, a manually operated fire
extinguishing system, an additional fire alarm
system or an automatic fire extinguishing system.
At this point please also note the safety data
sheets of the operating supplies used.
A.1.12 SC.999.0020/01
Safety
2 Accessories and additional equipment
LS.901.0001-000UTKENU_14
2.1 General note
Heidelberg printing presses can be equipped with var-
ious accessories in order to adapt them to special re-
quirements in the production process.
Your press can - depending on press model and equip-
ment - be equipped with all or some of the following
accessories:
● Powder spray device
● Dryer
● Automatic washup devices
● Device for dampening solution treatment
● Inking unit temperature control
● Suction system
● Hoisting gear
● Conveyor system.
Your press may also be delivered without any of these
accessories.
Safe handling of accessories and additional equip-
ment
● Please observe the special safety rules for the
accessories and additional equipment on your
press.
● Always follow the corresponding instructions
when operating and maintaining the accessories
and additional equipment.
● When integrating or attaching accessories and
additional equipment, the user must ensure that
○ such accessories and additional equip-
ment,
○ the resulting interface between press and
accessory/additional piece of equipment,
and
○ the thus modified and/or completed overall
press
complies with the applicable and valid safety-re-
lated requirements.
2.2 Electrical interface
Additional devices and equipment may only be inte-
grated or installed for the intended use and in confor-
mity with the pertinent and valid safety requirements.
To this end, HEIDELBERG provides a defined inter-
face if necessary. The relevant instructions, which
must be obtained via your HEIDELBERG agency,
must be observed.
SC.999.0020/01 A.1.13
Safety
2.3 Powder spray device
Powder application
The following notes should be observed with regard to
the intended use of anti set-off powder. This mainly
applies to combustible powder on the basis of starch or
sugar.
● Never use any ignitable powder, in particular
when you use a dryer (risk of deflagration). Read
and comply with the safety data sheet of the pow-
der manufacturer.
● Usage of powder can cause dust of varying den-
sity in the delivery. This can result in powder de-
posits which may produce an explosive atmo-
sphere locally when swirled up. This generates a
risk of explosion and fire.
● You must therefore remove any dust that has
settled in and on the press with a vacuum clean-
er. Establish adequate cleaning intervals and
clean the areas soiled with dust regularly, at least
once a week, particularly in the delivery.
● Only use suitable and approved industrial vacu-
um cleaners and avoid swirling up the dust, for
example by removing dust deposits with com-
pressed air.
● Only powder which does not represent a health
hazard based on the latest findings in industrial
medicine may be used.
2.4 Dryer
Notes on the dryer
● When working with dryers, use only inks and var-
nishes that do not create any explosive atmo-
sphere through heating up in the dryer. This is
indicated as not useable under the explosive limit
entry in the safety data sheet.
● After having used a dryer you must ensure that
the cylinders and press components that are to
be cleaned manually have cooled down and are
merely warm to the touch (approximately 40 °C).
● When using solvents on the press (e. g. for man-
ual cleaning work), no solvents must enter the
dryer area or be used and stored in the dryer
area. Failure to comply with this results in an in-
creased risk of explosion due to the heating of
solvents.
● When using automatic washup devices, set the
wash program in such a way that blankets and
impression cylinders are dry before renewed pro-
duction so that no washing fluid enters the dryer
area.
A.1.14 SC.999.0020/01
Safety
● Parts of the dryer can reach high temperatures
during operation. Allow the dryer to cool down
before you carry out any work on it.
● Never use any ignitable powder when you use a
dryer (risk of deflagration).
Notes on using UV dryers
● If you are working in mixed operation (UV inks
and conventional inks), observe the following
points prior to each changeover:
Only use washing fluids that are suitable for the
respective operating mode (UV or conventional).
Before changing the cleaner, the washing fluid
container and supply pipes to the washup de-
vices must have been completely drained.
Failure to do this may result in damage to the
press. The cleaners react on each other and can
clog up the supply pipes, valves and filters.
For each operating mode or for mixed mode op-
eration, use only suitable
○ inking rollers and dampening rollers
○ washup devices for blanket and inking
rollers
○ washup blades, and
○ cleaners.
Integrating a dryer from a third-party supplier
The user must perform the following actions and/or
observe the following topics, and interpret them in a
safety-related manner:
● Scattered radiation measurement
● Measurement of the surface temperatures
● Noise measurement
● Ozone measurement
● Measurement of the concentration of solvents in
the air inside the press
● Measurement of the concentration of com-
bustible material (e.g. dust, powder) in the air in-
side the press
● Electroconductive and grounded suction sys-
tems (leakage resistance less than 1 megohm)
● Interaction of the main switches of printing press
and dryer
● Input of all relevant signals of the interface
adapter (e.g. emergency stop, washup, dryer op-
eration)
● Installation of hoses and lines
● Electrical equipment according to the national
regulations.
If you have questions regarding the safe integration of
your dryer, please ask your Heidelberg agency.
SC.999.0020/01 A.1.15
Safety
Additional notes on UV dryer preparation with
CoolCure system (nitrogen system)
Upon user request, Heidelberg supplies the press to-
gether with a preparation for UV dryers with CoolCure
system. The following aspects must be taken into con-
sideration when planning and using the press:
● The CoolCure system only works with nitrogen.
Using any other gas is not permitted.
● The dryer manufacturer supplies a UV system
that is prepared for nitrogen operation, including
the nitrogen distribution in the press. The scope
of delivery of the dryer manufacturer ends at the
transition valve to the nitrogen supply system.
● Procurement, installation, operation and mainte-
nance of the nitrogen supply system are within
the responsibility of the user.
● The user must perform the following actions and/
or observe the following topics, and interpret
them in a safety-related manner:
○ Quality of the air: Adequate ventilation and
air removal must be ensured in the press
area.
○ If necessary, observe building license and
approval of liquid gas storage.
○ Specify rules of conduct for the operators in
the event of uncontrolled gas leakage.
○ Plan the gas supply shutoff system in a
safety-related way.
Notes on machines with reduced waiting times for
automatic washup
If requested by the customer, Heidelberg can release
the press with an option aimed at reducing the waiting
times before and after the washup procedure. This
option is only valid for the version and owner of the
press at the time of release of this option. The following
points have to be complied with to be able to operate
the press safely:
● The dryers and washup devices used must be
classified and released by Heidelberger Druck-
maschinen AG.
● Your Heidelberg agency has to be informed
about any addition of dryers and washup devices
to the overall press not taken account in the re-
lease, since the requirements for the use of the
option for reduced waiting times have to be
checked again.
● Your Heidelberg agency has to be informed
about any change to the dryer-washup devices
system, as the requirements for the using the op-
tion for reduced waiting times have to be checked
again.
A.1.16 SC.999.0020/01
Safety
● Your Heidelberg agency has to be informed if you
are planning to sell on the press, since the option
for reduced waiting times has to be withdrawn.
● Only use recommended and approved washing
fluids.
● After using a dryer you must ensure that the hot
surfaces on the cylinders and press components
that are to be cleaned manually have cooled
down and are merely warm to the touch (approx-
imately 40°C).
2.5 Washup devices
Notes on the washing fluid container
● For washing fluid containers with compressed-air
supply: Prior to opening the closures, close the
compressed-air supply hose and bleed the con-
tainer.
● Only use washing fluids that satisfy the required
specifications.
● Keep sources of heat away from the washing flu-
id container.
2.6 Dampening system
Integrating a dampening system from a third-party
supplier
The user must perform the following actions and/or
observe the following topics, and interpret them in a
safety-related manner:
● Observe the relevant safety standard relating to
"safety distances to prevent upper extremities
reaching hazardous areas"
● Installation of hoses and lines
● Storing all removed original parts of the machine
in order to be able to restore the machine to its
delivery state.
If you have questions regarding the safe connection of
your dampening system, please ask your Heidelberg
agency.
2.7 Device for dampening solution treatment
Proper use
● Take care when working with alcohol and damp-
ening solution additives. Remove leaking sub-
stances immediately and correctly. Use in the
manner intended by the manufacturer and in ac-
cordance with its safety instructions regarding
combustible liquids.
● The unit cools the dampening solution, and
keeps the alcohol percentage of alcoholic addi-
tives at a constant level. It must not be used for
cooling bottles, food or similar items.
SC.999.0020/01 A.1.17
Safety
● The unit works with refrigerants. Installation and
maintenance work, as well as servicing and plac-
ing out of operation, may only be carried out by
trained personnel.
● Do not operate the device without water.
● Do not place any objects on or in front of the ven-
tilation slots, otherwise the air circulation is inter-
rupted.
● Only allow repairs to the press, additional devices
and electrical devices to be performed by trained
service staff authorized by Heidelberg.
2.8 Inking unit temperature control
● The unit works with refrigerants. Installation and
maintenance work, as well as servicing and plac-
ing out of operation, may only be carried out by
trained personnel.
● Do not place any objects on or in front of the ven-
tilation slots, otherwise the air circulation is inter-
rupted.
2.9 Suction system
● Do not remove any hoses on suction systems for
powder, ozone, paper cuttings, etc. If you notice
any damage to hoses, notify the Heidelberg ser-
vice department. Have damaged hoses repaired
or replaced by trained service staff authorized by
Heidelberg. Otherwise the equipotential bonding
is no longer guaranteed. There is a risk of defla-
gration as a result of electrostatic discharge.
2.10 Equipment for lifting components, e.g. hoisting devices, load suspension devices, slings,
suspension elements
If you are working with equipment for lifting and han-
dling components such as ink screen rollers or varnish
screen rollers, you have to observe the following
points:
● The equipment must be checked with all accom-
panying parts in line with the local national safety
regulations. This check for function and possible
damage must be performed by a trained and
competent specialist.
● We recommend performing this check at least
once a year.
● Use the checklist provided and the operating
manual of the equipment manufacturer for the
check.
A.1.18 SC.999.0020/01
Safety
● As operator of the equipment, ensure that there
are no persons standing or walking in the trans-
port route or underneath suspended loads.
● Please watch out for transport work being carried
out by crane. Standing or walking under a sus-
pended load is strictly forbidden.
2.11 Conveyor system
Integration of a conveyor system, e.g, roller or
plate conveyor system, from a third party
The user must perform the following actions and/or
observe the following topics, and interpret them in a
safety-related manner:
● Do not step on the conveying elements during
operation and do not ride on the pallets.
● Pay attention to the movement of moving pallets
and piles. You must stay away from this area.
● Observe the relevant safety standard relating to
the "minimum distances to prevent crushing of
parts of the body", e.g., 0.5 m safety distance.
● Observe the relevant safety standard relating to
"safety distances to prevent upper and lower ex-
tremities reaching hazardous areas".
● Use the intended electrotechnical interface on
the printing press.
● The safety devices and safety functions, espe-
cially those of the feeder and the delivery, must
never be changed or overridden; for example ac-
cess protection or safeguarding of an area (DW-
BA).
● Safeguard and mark accessways.
Note: The integration of a conveyor system does not
result in an interlinked plant within the meaning of the
EC Machinery Directive. Both installations, the printing
press and the conveyor system, remain independent
with regard to safety.
SC.999.0020/01 A.1.19
Safety
3 Specifications
SC.B01.0100-000UTKENU_02
3.1 Note
A detailed overview of the press specifications can be
found in the "Specifications" manual.
3.2 Printing material
Maximum sheet size: 720 x 1040 mm
Minimum sheet size (without tape inserter):
340 x 480 mm
Maximum thickness: 1.0 mm
Note
For a printing material thickness exceed-
ing 0.8 mm the gripper bite is limited to a
minimum of 11 mm.
3.3 Feeder and delivery
Maximum weight of the pile
XG.901.1031-000GRAUND_00
● Feeder: 2000 kg
● Delivery: 2000 kg
Fig. 3 Basic principle of the feeder
Checking the load capacity
XG.901.1032-000GRAUND_00
The following checks have been performed in line with
the EC Machinery Directive:
● The static check with 1.25 times the maximum
weight of the pile has been carried out.
● The dynamic check has been carried out with
1.1 times the maximum weight of the pile.
Both checks have been completed successfully, i.e.
no lack of stability was apparent.
Fig. 4 Basic principle of the delivery
3.4 Ink/Varnish
● Use only commercially available inks and var-
nishes intended for use in sheet-fed offset press-
es.
● In the coating unit only water-based aqueous
varnishes may be used. A special press config-
A.1.20 SC.999.0020/01
Safety
uration is required in order to process UV var-
nishes.
3.5 Cleaners for automatic and manual washup
Use only cleaners with the following properties (unless
otherwise specified in this manual):
● Flash point > 55 °C
● pH between 5 and 9 for aqueous products,
● Benzene content < 0.1 %
● Toluene and xylene content < 1 %
● Aromatic compounds (> C9) < 1 %
● Washing fluid free of chlorinated hydrocarbons,
fluorinated hydrocarbons, terpenes, n-hexane,
secondary amines and amides , 2 butoxy ethanol
and N-methyl-2-pyrrolidone (NMP),
● Cleaners free of other hazardous substances.
For more information on cleaners see the mainte-
nance manual.
3.6 Noise emission values
The noise emission refers to the airborne noise emit-
ted by a machine. The noise emission - in contrast to
the noise reception - is calculated for standardized
installation conditions and conditions for operation.
Noise emitted by other sources and reflected noise is
not taken into account. Therefore, noise emission is a
characteristic that relates only to the source.
Parameters for the noise emission are as follows:
● Emission sound pressure level at the workplace
● Sound power level
What is the emitted sound pressure level at the
workplace?
The emission sound pressure level at the workplace
indicates how loud it would be at the workplace directly
assigned to the press if it were only affected by the
noise from this one press without any further back-
ground noise or reflected sound from the surrounding
walls and ceilings. This noise emission value is need-
ed as it is not possible to assess how noisy it will be
directly at the workplace if only the sound power level
is taken into account.
Emitted sound pressure level according to EN
13023
Measuring location Sound pressure level
(LpA) in dB(A)
Feeder control console 79
Delivery 78
SC.999.0020/01 A.1.21
Safety
Measuring location Sound pressure level
(LpA) in dB(A)
Additional measured value
Center of feeder (front 83
side)
Tab. 2 Emission sound pressure level
What is the sound power level?
The sound power level indicates how much noise is
emitted in total (in all directions). The sound power
level is suited for comparing several presses; howev-
er, it is not suited for deriving safety precautions, such
as the selection, provision and use of suitable personal
hearing protection.
Sound power level according to EN 13023
Machine Sound power level (LWA)
in dB(A)
CX 104-2+L 101.3
CX 104-4 101.9
CX 104-4+L 102.3
CX 104-5 102.3
CX 104-5+L 102.7
CX 104-6 102.7
CX 104-6+L 103
CX 104-7 103
CX 104-7+L 103.3
CX 104-8 103.3
CX 104-8+L 103.6
Tab. 3 Sound power level according to EN 13023
3.7 Vibrations - effects on human beings
The daily limit values for whole-body vibrations and
vibrations in hands and arms are not exceeded. There-
fore no technical and/or organizational measures are
required to reduce this exposure.
Statement in line with:
● ISO 2631 Whole-body vibrations,
● EN ISO 5349-2 Hand-arm vibrations
● EC directive 2002/44/EC.
A.1.22 SC.999.0020/01
Safety
3.8 Factors influencing function and performance
The function and performance of the press depends
on various factors, including:
● the specific properties and quality of the products
to be processed (e.g. processing aids and print-
ing materials, diecut sheets or folding carton in-
serts
● the specific properties and quality of the consum-
ables used (e.g. inks, varnishes, glues, printing
plates, die-cutting plates)
● the tools used (e.g. die-cutting, stripping and
blank separation tools or folding elements)
● the setting of the press or tools
● the environmental conditions (e.g. temperature
and air humidity)
● the maintenance condition of the press
These factors, which lie outside the scope of respon-
sibility of Heidelberg, can result in functional and per-
formance-related limitations of the press compared to
operation under ideal conditions. In particular, Heidel-
berg accepts no liability for the compatibility of the
press with specific tools or consumables, if these are
not expressly qualified by Heidelberg for a certain pur-
pose.
3.9 Requirements of air quality
Ensure that the air quality meets the following criteria.
● Solids: filtration range < 5 µm
● Moisture: residual moisture ≤ 6 g/m3 or pressure
condensation point ≤ +3 °C
● Total oil content ≤ 1 mg/m3
If your press was delivered with a compressor and
maintenance unit, no further actions are necessary.
3.10 Electrical fusing of the presses
The values for the electrical fusing of the press are in-
dicated on the name plate on the exterior of the control
cabinet.
SC.999.0020/01 A.1.23
Safety
4 Workplaces at the press
SC.B01.0107-000UTKENU_00
4.1 Workplaces at the press
● Control panels on the feeder (Fig. 5/1)
SC.B01.0107-000GRAUND_00
● Footboards and platforms with a bulb plate sur-
3 2 1 face (Fig. 5/2)
● Control panel on the delivery (Fig. 5/3)
● Press control system control station
● Area to supply and remove the feeder and deliv-
ery piles.
Fig. 5 Workplaces at the press
The following points must be observed when
working on the press:
● You may step only on those parts of the press
designed as footboards with bulb plate surfaces.
● Do not use the areas at the workplaces as places
to deposit tools or cleaning agents, etc.
● Avoid the risk of slipping. Keep workplaces free
from oil, grease, or other liquids.
● Avoid heat accumulation. Do not obstruct the
space in front of the exhaust air openings of the
press.
Do not put down any spray cans or containers
with volatile or combustible cleaning solutions in
this area.
4.2 Handling movable steps and flaps in areas that can be walked on
● Avoid falling and stumbling hazards. Close all
steps that can be walked on (e.g. between the
printing units) and flaps (e.g. along the walkways
and platforms) once you have completed the nec-
essary work or when leaving this workplace.
4.3 Handling gallery parts on hinged platforms
● Avoid falling and stumbling hazards. For presses
equipped with movable gallery parts, for exam-
ple, in order to enable the removal and loading of
piles, you need to make sure that when handling
movable parts (e.g. folding them down or remov-
ing them), they are put back into their guard po-
sition (e.g. folding them up or mounting them).
A.1.24 SC.999.0020/01
Safety
5 Controls
SF.901.0065-000UTKENU_08
5.1 Main switch
LS.901.0035-004GRAUND_00
1 Warning - Danger of death from
electrical voltage!
Only qualified staff may work on elec-
2 tric devices. The control cabinet may
only be opened by qualified personnel.
3 Even when the main switch is switched
off, some components in the control
cabinet still carry a voltage.
4
Note
Due to its limited service life, the main
switch must be replaced after 15 years to
preserve the power cut-off function.
Place of installation
The main switch (Fig. 6/2) of the printing press is on the
control cabinet. It is marked with a press-specific sym-
Fig. 6 Main switch / example bol (Fig. 6/1). Additional devices (e. g. dryers, additive
metering unit ...) may have separate control cabinets
and separate main switches.
Function
The main switch is a device for disconnecting the ma-
chine from the electrical supply voltage. This is for
rendering the machine/units, for example, voltage-
free.
Using the main switch
Note
Pay attention to the section "Basic safety
instructions, practice-oriented use of
main switch and Emergency stop palm
button".
Switching off at the main switch
1. To switch off the machine/units etc. at the main
switch, turn the control lever to the position
0/OFF (Fig. 6/4).
Result
The machine/unit is now voltage-free.
Switching off at the control station
1. To switch off the machine at the control station,
select the Switch off machine button. This en-
ables the control station computer to shut down
SC.999.0020/01 A.1.25
Safety
the software in a controlled way so that the soft-
ware is not damaged.
Result
The control system will run down the ma-
chine (shutdown function). The control
lever of the main switch moves to the
position "+" (Fig. 6/3). The machine/unit
is now voltage-free.
Securing the machine/units against being
switched on
1. Turn the control lever to the position 0/OFF
(Fig. 6/4).
2. Lock the main switch with a padlock.
3. Leave a sign with the name of the person autho-
rized to switch on the machine/unit.
Result
The machine/unit is secured against be-
ing switched on as long as the main
switch is locked.
5.2 Emergency stop palm button
SG.901.0108-002GRAUND_00
1 Warning - Danger of death from
electrical voltage!
Emergency stop does not make the
machine voltage-free, but secures the
machine against being put into opera-
tion. To render the machine voltage-
free, switch it off at the main switch.
Emergency stop (Fig. 7/1) is a red palm button on a
Fig. 7 Emergency stop button yellow background.
Place of installation
There is an Emergency stop palm button on each of
the following control panels/control consoles:
● Feeder control console
● Control panels on the printing units
● Delivery control console
● Control station of the machine control system.
Function
When the palm button is pressed, the machine stops
as quickly as possible. Except:
1. Rollers
● water pan and metering rollers of the dampening
systems (when the dampening system guard is
closed),
A.1.26 SC.999.0020/01
Safety
● coating pan roller and varnish metering roller/
screen roller (if the corresponding protective de-
vices are closed).
These rollers can be stopped by:
● Switching off the main switch,
● Switching off the corresponding functions at the
control station or at the appurtenant control pan-
el,
● Water pan rollers and metering rollers of the
dampening system: Opening the corresponding
protective devices,
● Coating pan roller and varnish metering roller/
screen roller: Opening the corresponding protec-
tive devices.
2. Print heads
● Print heads in the digital printing unit:
To stop the print heads, open the upstream protective
devices on the drive side.
Handling the Emergency stop palm button
Note
Pay attention to the section "Basic safety
instructions, practice-oriented use of
main switch and Emergency stop palm
button".
Press shutdown in an emergency
1. Press an Emergency stop palm button. The
Emergency stop palm button locks automatically.
Result
The machine stops as quickly as possi-
ble.
Note
To stop the machine in regular opera-
tion, press the Stop button.
Securing the machine against being put into op-
eration
Secure the machine against being put into operation
with the Emergency stop palm button:
1. Press the Emergency stop palm button on the
nearest control panel.
2. For work at the delivery:
● Press the emergency stop button on the de-
livery control panel.
● Deliveries with an access height of more
than 800 mm (e.g. machine models SX 74,
SM 74, SM 74 DI, CD 74, XL 75, CX 75,
CS 92, CX 92, SM 102, SX 102, CD 102,
CX 102, CX 104, XL 105, XL 106, XL 145,
SC.999.0020/01 A.1.27
Safety
XL 162): Also open the front guard on the
delivery.
Result
The machine cannot be put into opera-
tion as long as the emergency stop but-
ton is pressed.
Release the Emergency stop palm button
1. Turn the Emergency stop palm button in clock-
wise direction.
Result
The Emergency stop palm button is re-
leased.
5.3 Zone stop palm button JB.901.0005-000GRAUND_00
Warning - Danger of death from
electrical voltage!
Zone stop does not render the print
heads voltage-free, but secures them
against being put into operation. To
render the print heads voltage-free,
switch off the main switch.
Zone stop (Fig. 8/1) is a red palm button on a gray
background.
Places of installation
● Inside the digital printing unit at the side on O.S.
or on D.S.
● Inside the digital printing unit in the middle on
O.S. or on D.S.
Function
Fig. 8 Zone stop palm button
After the palm button has been pressed, the print
heads stop as quickly as possible.
Stopping the print head movement in an emergen-
cy
1. Press the Zone stop palm button. The Zone stop
palm button remains locked in this position.
Result
The print heads stop as quickly as pos-
sible.
Securing the print head against being moved
Use the Zone stop palm button to secure the print
heads against being moved:
A.1.28 SC.999.0020/01
Safety
1. Press the Zone stop palm button.
Result
The print head cannot be moved as long
as the Zone stop palm button is pressed.
Unlocking the Zone stop palm button
1. Turn the Zone stop palm button in the clockwise
direction.
5.4 Reset button
Using the Reset button (Fig. 9/1) you can release the
FS.901.2061-001GRAUND_00
protective devices for an accessible area.
1 Before pressing the Reset button, you need to perform
a visual check to ensure that no one is in one of the
following danger zones:
● the feeder pile, in particular the pile support plate
and the non-stop device.
● the delivery waste deflector, in particular the
Fig. 9 Reset key compressor rods.
● the delivery pile, in particular the pile support
plate and the gripper systems,
● the workpiece removal mechanism, in particular
the robot arm.
Places of installation
● On the feeder on the control panel for auto non-
stop or on the front side. On elevated presses
there may also be additional foot switches with
the reset function.
● On the delivery on the operator's side in the area
of the waste deflector.
● On the delivery on the front side or on the oper-
ator's side and drive side. On elevated presses
there may also be additional foot switches with
the reset function.
● On the loading unit on the top of the frame and at
the front.
Warning - Risk of injury due to re-
volving machine parts!
Using the Reset button you can re-
lease the protective devices for an ac-
cessible area. Before pressing the Re-
set button, you need to perform a vi-
sual check to ensure that no one is in
the danger zone.
SC.999.0020/01 A.1.29
Safety
5.5 Setup processes with main drive
The Setup processes with main drive (Fig. 10) button
LS.901.9726-001GRAUND_00
enables setup processes to be initiated which induce
the main drive to rotate (e.g. washup, perfector
changeover, fully automatic plate change). A differen-
tiation is made between the following two cases.
● When the machine is at a standstill:
Press the Setup processes with main drive but-
Fig. 10 Setup processes with main drive button ton. The startup warning signal sounds.
Press the Setup processes with main drive button
again. The machine starts up. The main drive ro-
tates and the machine performs the setup pro-
cesses.
● When the machine is rotating:
Press the Setup processes with main drive but-
ton. The setup process is conducted as soon as
all the processes that have to be executed first
are finished. The machine conducts the setup
processes without any pauses.
5.6 The Control panel selection push button
MS.901.9724-003GRAUND_00
Warning - Risk of injury due to re-
volving machine parts!
1 Use the Control panel selection push
button to assign the desired control
panel to your working position.
Prior to unlocking the machine, you
Fig. 11 Control panel selection push button must ensure, by means of a visual
check, that no one is in the danger
zone of moving parts, in particular of
the chain gripper systems in the deliv-
ery.
This push button cannot be used to
secure the machine against being put
into operation. Secure the machine
against being put into operation with
the Emergency stop palm button.
Place of installation
The Control panel selection button (Fig. 11/1) is locat-
ed at the following control panels / control consoles:
● Feeder control console
● Control panels on the printing units
● Delivery control console.
Function
This push button enables you to assign the required
control panels to your workplace. At this control panel
you can inch and position the machine or start crawl
speed mode, even when the guard in the area of this
A.1.30 SC.999.0020/01
Safety
control panel is open. The machine can then be oper-
ated only from this control panel.
Using the push button Control panel selection
Control panel selection
1. Press the Control panel selection push button at
the desired control panel twice (with a maximum
interval of 0.5 seconds). The LED (Fig. 11/1)
lights up.
Note
You can only move the machine in inch-
ing mode, crawl mode or positioning
mode from the selected control panel
when no other control panel is selected
and no other protective device (such as
finger protecting bars) is blocking the
movement.
Cancel selection
1. Press the Control panel selection push button
again twice (with a maximum interval of 0.5 sec-
onds). The LED goes out.
5.7 Inching mode
Caution - Risk of damage to the ma-
FS.901.1012-000GRAUND_01
chine when inching backward!
1 2 If there are sheets in the machine when it
. is inched backward, there is a risk of
damaging sheet-transferring cylinders
and grippers. Ensure that there are no
sheets in the machine before inching
backward.
Requirement
The control panel is selected.
Fig. 12 The Inching mode - forward, backward but-
ton If you press the Inch forward (Fig. 12/1) or Inch back-
ward (Fig. 12/2) button, a start-up warning initially
sounds for 3 seconds on the selected control panel
following an enable time of 6 seconds. You cannot
move the machine during this time.
You can start inching mode with or without travel lim-
itation within 6 seconds after the start-up warning has
stopped sounding.
Inching mode with travel limitation
If you press the Inch forward or Inch backward button
repeatedly, the cylinders are enabled for a distance of
max. 2.5 cm with each push of the button.
SC.999.0020/01 A.1.31
Safety
Inching mode without travel limitation
When the Inch forward or Inch backward button is
pressed, the machine rotates slowly at a reduced
speed.
5.8 Crawl speed mode
Requirement
FS.901.1014-000GRAUND_01
The control panel is selected.
1
If you press the Crawl speed button (Fig. 13/1) on the
selected control panel, a start-up warning initially
sounds for 3 seconds following an enable time of 6
seconds. You cannot move the machine during this
time.
The machine rotates slowly at a reduced speed if you
press the Crawl speed button again within 6 seconds
after the start-up warning signal has stopped sound-
Fig. 13 The Crawl speed button
ing.
Press the Emergency stop or Stop button to stop the
machine.
5.9 Positioning
Caution - Risk of damage to the ma-
FS.901.1015-000GRAUND_01
chine when positioning!
1 If there are sheets in the machine when it
is positioned, there is a risk of damaging
sheet-transferring cylinders and grip-
pers. Ensure that there are no sheets in
the machine before positioning.
Requirement
The control panel is selected.
Fig. 14 Positioning button If you press the Positioning button (Fig. 14/1) on the
selected control panel, a start-up warning initially
sounds for 3 seconds following an enable time of 6
seconds. You cannot move the machine during this
time.
If you press the Positioning button again within 6 sec-
onds after the start-up warning has stopped sounding,
the machine moves into the position for removing or
mounting the printing plate.
A.1.32 SC.999.0020/01
Safety
6 Protective devices
SC.B01.0110-000UTKENU_00
6.1 To be observed when performing any work
Warning - Risk of injury!
Only start up the press when all fixed
and movable safety devices are fitted
on the press and operational.
6.2 Fixed guards
Some of the screwed connections of the coverings of
the side frames on D.S. and on O.S. of feeder, delivery
and printing units are fixed. Fixed guards can only be
released and opened using a tool. Fixed guards are
not monitored electrically.
6.3 Movable guards
The movable guards are secured electrically and can
be opened manually or via a button for makeready and
maintenance. Open the guards only during press
standstill. Makeready and maintenance tasks may be
performed only once the press / moving press parts
have come to a standstill.
If a guard is opened while the press is running at pro-
duction speed, the press is stopped as quickly as pos-
sible. The following components may keep on moving:
● Ink fountain roller, when the inking unit guard is
not opened.
● Water pan roller and metering roller in the damp-
ening system, when the dampening system
guard is not opened.
● Roller drive in the coating unit,
○ when the guard in front of the coating pan
roller and the varnish metering roller is not
opened,
○ when the guard above the transfer drum in
front of the coating unit is not opened.
Activated movable guards have different effects on the
press.
SC.999.0020/01 A.1.33
Safety
6.4 Movable guards on the feeder
Feeder without automatic non-stop device
FS.901.1986-000GRAUND_00
Item Guards
1 Trip bar
1 Tab. 4 Movable guards
The trip bar secures the preset movement of the suc-
tion head.
When the trip bar is activated, no preset movements of
the suction head are possible.
Fig. 15 Movable guards
Feeder with automatic non-stop device
FS.901.5532-002GRAUND_00
Item Guards
4 1 Trip bar
1
2 Glass guard O.S.
2
3 Protective roller blind, end face
3 4 Protective flap
5 Safety shutter D.S.
Tab. 5 Movable guards (automatic non-stop de-
vice)
The trip bar secures the preset movement of the suc-
tion head. When the trip bar is activated, no preset
Fig. 16 Movable guards (automatic non-stop de- movements of the suction head are possible.
vice)
A.1.34 SC.999.0020/01
Safety
Use of the feeder is restricted when guards are open:
FS.901.1985-001GRAUND_00
● The auxiliary and main pile can only be moved in
inching mode.
● The non-stop rods cannot be moved.
Fig. 17 Movable guards (automatic non-stop de-
vice)
6.5 Fixed guards on the feeder
Feeder with automatic non-stop device
FS.901.1987-000GRAUND_00
Item Guards
1 Cover O.S.
1 2 3 2 Cover plate D.S.
3 Cover plate O.S.
4 Complete guard
5 Hinged footstep
Tab. 6 Fixed guards (automatic non-stop device)
4 5
Fig. 18 Fixed guards (automatic non-stop device)
SC.999.0020/01 A.1.35
Safety
6.6 Movable guards only on the first printing unit
SC.901.0217-001GRAUND_00
2
Fig. 19 Movable guard only on the first printing unit
Fig. 19 shows:
● First printing unit with interface to the Preset Plus
feeder.
Item Guards Inching mode with travel Inching mode without Crawl speed
limitation travel limitation
1 Front lay guard, bottom
x
(Preset Plus feeder)
2 Guard in front of washup
device x
(Preset Plus feeder)
Tab. 7 Movable guard only on the first printing unit
A.1.36 SC.999.0020/01
Safety
6.7 Movable guards on the printing unit
CX.901.0005-001GRAUND_00
10
11 9 3 2
8 4 1
12
7 5
Fig. 20 Movable guards on the printing unit
Fig. 20 shows from right to left:
● First printing unit without blanket washup device
with AutoPlate, CPC ink fountain and interface to
Preset Plus feeder.
● Subsequent unit with AutoPlate and interdeck
drying.
● Final printing unit with AutoPlate Pro
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
1 Printing unit guard at
x
feeder side
2 Inking unit guard, top x
3 Printing unit guard at de-
x
livery side, top
4 Guard at delivery side,
bottom x x
(AutoPlate)
5 Hinged footstep above
impression cylinder be-
tween printing unit/print- x
ing unit and printing unit/
final coating unit
6 Dryer guard on D.S. x
SC.999.0020/01 A.1.37
Safety
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
7 Hinged footstep above
impression cylinder with x
interdeck dryer
8 Hinged footstep above
transfer cylinder with in- x
terdeck dryer
9 Guard at delivery side,
bottom
x x
(conventional plate cylin-
der)
10 Hinged footstep above
transfer cylinder between x
printing unit/printing unit
11 Inking roller guard (Auto-
x
Plate Pro)
12 Cylinder guard (AutoPlate
x
Pro)
13 Guard of the impression
cylinder washup device
opening
Tab. 8 Movable guards on the printing unit
6.8 Fixed guards on the printing unit
CX.901.0003-000GRAUND_00
6
9 4 3
8 5 2
10 7 6 1
Fig. 21 Fixed guards on the printing unit
A.1.38 SC.999.0020/01
Safety
Item Guards
1 Dampening solution pan
2 Guide plate
3 Guard above the inking unit
4 Ink fountain with ink fountain roller guard (ink collecting pan)
5 Guards underneath ink fountain (2 guard plates)
6 Guard in front of the blanket washup device
7 Dryer guard on O.S. (screen)
8 Distance plate
(final printing unit)
9 Roller guard
10 Guard plate (D.S./O.S.)
Tab. 9 Fixed guards on the printing unit
6.9 Movable guards at the automatic plate changer
1 Inking roller guard
CX.901.0000-000GRAUND_00
2 Cylinder guard
Fig. 22 Movable guard on the fully automatic plate
changer
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
1 Inking roller guard x
SC.999.0020/01 A.1.39
Safety
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
(AutoPlate Pro)
2 Cylinder guard
x x
(AutoPlate Pro)
Tab. 10 Movable guards on the plate changer
6.10 Safety devices in the printing unit
CX.901.0004-000GRAUND_00
1
Fig. 23 Safety devices in the printing unit
In addition to the protection grids, finger protecting
bars are fitted in the printing units. Finger protecting
bars are installed between the following components:
● Inking unit and plate cylinder (Fig. 23/1),
● Plate cylinder and blanket cylinder (Fig. 23/3),
and
● Blanket cylinder and hinged footstep (Fig. 23/4).
The safety devices also include the pressing roll with
finger protection function (Fig. 23/2).
The gap cover of the blanket cylinder (Fig. 23/5) is also
a part of the protective devices.
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
1 Finger protecting bar 1
2 Pressing roller with finger
protecting switch
(AutoPlate and AutoPlate
Pro)
3 Finger protecting bar 2
A.1.40 SC.999.0020/01
Safety
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
4 Finger protecting bar 3
5 Gap cover
Tab. 11 Safety devices in the printing unit
6.11 Movable guards on the intermediate unit
SC.901.0221-001GRAUND_00
3
7 4 1
8 5 2
9 6 3
Fig. 24 Movable guards on the intermediate unit
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
1 Hinged guard
2 Hinged guard
3 Dryer guard on D.S. x
4 Protection grid on delivery x
side
(without dryer prepara-
tion)
5 Hinged footstep
(without hot air slide-in x
unit)
6 Hinged footstep x
7 Protection grid, top x
SC.999.0020/01 A.1.41
Safety
Item Guards Inching mode with Inching mode without Crawl speed
travel limitation travel limitation
8 Protection grid on delivery
side x
(with dryer preparation)
9 Hinged footstep
x
(with hot air slide-in unit)
Tab. 12 Movable guards on the intermediate unit
6.12 Fixed guards on the intermediate unit
SC.901.0222-001GRAUND_00
3 1
4 2
Fig. 25 Fixed guards on the intermediate unit
Item Guards
1 Tool deposit
(without dryer preparation)
2 Guard on the feeder side
3 Protection grid
(with dryer preparation)
4 Cover plate
5 Dryer guard (screen) on O.S.
Tab. 13 Fixed guards on the intermediate unit
A.1.42 SC.999.0020/01
Safety
6.13 Movable guards on the coating unit
6.13.1 Coating unit without interdeck drying
SC.B01.0223-000GRAUND_00
3
4
2
5
1
6
Fig. 26 Movable guards on the coating unit
Item Guards Inching mode with travel Inching mode without Crawl speed
limitation travel limitation
1 Hinged footstep x
2 Hinged guard
3 Hinged guard
4 Coating unit guard, deliv-
x x
ery side
5 Hinged guard in front of
the pressing roller
6 Hinged footstep
(variants with Pre- x
set Plus delivery and Pre-
set delivery)
Tab. 14 Movable guards on the coating unit
SC.999.0020/01 A.1.43
Safety
6.13.2 Coating unit with interdeck drying
SC.B01.0224-000GRAUND_00
3
4
2
5 1
Fig. 27 Movable guards on the coating unit
Item Guards Inching mode with travel Inching mode without Crawl speed
limitation travel limitation
1 Hinged footstep x
2 Hinged guard
3 Hinged guard
4 Coating unit guard, deliv-
x x
ery side
5 Hinged guard in front of
the pressing roller
6 Hinged footstep
(variants with Pre- x
set Plus delivery and Pre-
set delivery)
Tab. 15 Movable guards on the coating unit
A.1.44 SC.999.0020/01
Safety
6.14 Fixed guards on the coating unit
6.14.1 Coating unit without interdeck drying
SC.B01.0226-000GRAUND_00
Item Guards
1 Blower bar with splash protection plate
2
2 Guard above the screen roller
Tab. 16 Fixed guards on the coating unit
1
Fig. 28 Fixed guards on the coating unit
6.14.2 Coating unit with interdeck drying
SC.B01.0227-000GRAUND_00
Item Guards
1 Blower bar with splash protection plate
2
2 Guard above the screen roller
Tab. 17 Fixed guards on the coating unit
1
Fig. 29 Fixed guards on the coating unit
SC.999.0020/01 A.1.45
Safety
6.15 Safety devices in the coating unit
In addition to the protection grids, finger protecting
SC.B01.0229-000GRAUND_00
bars are fitted in the coating unit.
Fig. 30 Safety devices in the coating unit
Item Guards Inching mode with travel Inching mode without Crawl speed
limitation travel limitation
1 Finger protecting bars
Tab. 18 Safety devices in the coating unit
A.1.46 SC.999.0020/01
Safety
6.16 Movable guards on the delivery
SC.901.0213-001GRAUND_00
6 5 4 3 2 1
7 8
Fig. 31 Movable guards on the delivery
Note
Figure 31 shows a Preset Plus delivery
of the maximum configuration. The de-
livery of your press may deviate from
this.
Guards in front of the slide-in dryers
The guards in front of the slide-in dryer (Fig. 31/7) are
only installed when the press is prepared for the in-
stallation of dryers, and if slide-in dryers have not been
installed.
Item Guards Inching mode with travel Inching mode without Crawl speed
limitation travel limitation
1 Transfer guard on the de-
livery
x
(hinged footstep of print-
ing unit)
2 Transfer guard on the de-
livery
x
(hinged footstep of deliv-
ery)
3 Intermediate guard x
4 Intermediate guard x
5 Intermediate guard x
6 Delivery glass guard
SC.999.0020/01 A.1.47
Safety
Item Guards Inching mode with travel Inching mode without Crawl speed
limitation travel limitation
7 Guard at slide-in dryer
opening O.S.
(with installed dryer
preparation)
8 Guard upstream of side
frame recess. The guard
is locked indirectly via an x
electronic link to the trans-
fer guard.
Tab. 19 Movable guards on the delivery
6.17 Fixed guards on the delivery
SC.901.0214-001GRAUND_00
1 2 3 4 5
8 7 6
Fig. 32 Fixed guards on the delivery
Note
Figure 32 shows a delivery with maxi-
mum configuration. The delivery of your
press may deviate from this.
Item Guards
1 Guard at delivery control console (screen)
2 Intermediate guard (guard above the pile)
3 Intermediate guard (guard above the gripper
bar)
4 Screen O.S.
(identical at each extension)
A.1.48 SC.999.0020/01
Safety
Item Guards
5 Intermediate guard (guard sheet ascent
ramp, top)
6 Guard gripper bar sheet ascent ramp
(variants with UV dryer and IR drying)
7 Guard in front of the slide-in dryer
(hard glass pane, with printing press without
dryer preparation and adjacent IR drying or
UV drying)
8 Guard O.S. (delivery pile)
Tab. 20 Fixed guards on the delivery
6.18 Electrically monitored protective devices on the delivery with automatic non-stop function
FS.901.1071-001GRAUND_00
1 2 3
7
4
8
7 4
7 4
6 5
Fig. 33 Guards/light barriers
Fig. 33 Guard / monitoring light Effects
barrier
1 Delivery glass guard When the guard is open, inching mode is not possible.
SC.999.0020/01 A.1.49
Safety
Fig. 33 Guard / monitoring light Effects
barrier
When the guard is open, it is not possible to remove or insert the auxiliary pile
support.
2 Light curtain, front side The light curtain deactivates: the automatic pile movement if the distance be-
tween the auxiliary pile system and the main pile support system is less than
300 mm and the automatic movement to insert and remove the auxiliary pile
support.
3 Light curtain D.S. and The light curtains deactivate: If there is an automatic pile movement due to a
O.S. distance of less than 300 mm between the auxiliary pile system and the main
pile support system and during the automatic insertion and removal movement
of the auxiliary pile support.
4 3-beam safety system Main drive of the press:
(DWBA), D.S. and O.S. In non-stop operation:
Motion not inhibited as long as the sheets are laid out on the auxiliary pile, and
the pile support plate rests on the floor.
In normal operation:
Motion inhibited as soon as one of the light barriers is triggered.
Deactivation for a limited period of time is possible if certain criteria are fulfilled
(see operating information for DWBA in the Delivery chapter).
Drives of the auxiliary pile support, auxiliary pile and main pile:
Motion inhibited as soon as one of the light barriers is triggered.
5 Foot safeguards, D.S.
When a foot safeguard is triggered, the downward movement of the pile stops.
and O.S.
6 Foot safeguards, front
When a foot safeguard is triggered, the downward movement of the pile stops.
side
7 6-beam safety system Main drive of the press:
(DWBA), front side In non-stop operation:
Motion not inhibited as long as the sheets are laid out on the auxiliary pile, and
the pile support plate rests on the floor.
In normal operation:
Motion inhibited as soon as one of the light barriers is triggered.
Deactivation for a limited period of time is possible if certain criteria are fulfilled
(see operating information for DWBA in the Delivery chapter).
Drives of the auxiliary pile support, auxiliary pile and main pile:
Motion inhibited as soon as one of the light barriers is triggered.
8 Diagonal light barrier The diagonal light barrier activates the light curtain evaluation at a distance of
less than 300 mm during the automatic upward movement of the main pile and
the downward movement of the auxiliary pile.
Tab. 21 Movable delivery guards
A.1.50 SC.999.0020/01
Safety
6.19 Protective device for detecting whole body access (DWBA)
FS.901.1029-002GRAUND_00
1
4
2 5
3 6
Fig. 34 Monitoring area of the light barriers
Fig. 34 Monitoring light barrier Drives for the sheet size adjustment Main drive of the press
of the sheet slow-down device and
the lateral sheet joggers, for the
main pile and the auxiliary pile
1 Front side, top Motion inhibited as soon as one of the In non-stop operation:
light barriers is triggered. Motion not inhibited as long as the
2 Front side, middle
sheets are laid out on the auxiliary pile,
3 Front side, bottom and the pile support plate rests on the
4 O.S. top floor.
correspondingly In normal operation:
D.S. top Motion inhibited as soon as one of the
light barriers is triggered.
5 O.S. middle
correspondingly
D.S. middle
6 O.S. bottom
correspondingly
D.S. bottom
The protective device for the detection of whole body
access consists of several light barriers that monitor
the front access and the lateral access of the delivery.
SC.999.0020/01 A.1.51
Safety
Note
The light barriers belong to laser class 1
(max. 0.0001 W; 650 nm) as defined by
DIN EN 60825-1. Lasers in class 1 can
be considered safe under sensibly fore-
seeable operating conditions. Additional
safety measures are thus not necessary.
The light barriers monitor the access to the delivery.
The drives are stopped according to the table when a
light barrier is interrupted (by the operator, for exam-
ple).
Note
With all interventions in the delivery
zone, always observe the safety-rele-
vant instructions in this operating manu-
al. This protective device does not pro-
tect the access to the delivery zone.
Once the protective device has been triggered, the in-
hibited drives can no longer be moved. Releasing is
only possible by pressing the DWBA Reset button.
Inching or crawl speed mode of the press is not pos-
sible when the protective device inhibits the main
drive.
Normal operation
● Never lean between or over the light barriers.
● Never crawl below a safety device or light barri-
ers.
● Beware of moving parts of the press during the
manual or automatic extraction processes.
● While the press is running, ensure that nobody
walks into the hazardous zone of the delivery as
long as the pile removal process is in progress.
● Ensure, by a visual check, that there is nobody in
the hazardous zone of the delivery before you
press the DWBA Reset button to unlock the pro-
tective device.
6.20 Other safety devices
Start-up warning signal
When you press a button to put the press into opera-
tion (for example Operation, Production, Inching mode
Forward, Backward or Crawl speed), the start-up
warning signal sounds (for 3 seconds) with the first
push of the button. After the start-up warning signal,
press the button again to put the press into operation.
Note
See the Service menu for the adjust-
ment of the start-up signal.
A.1.52 SC.999.0020/01
Safety
Limitation of the descending distance of the feeder
pile board
The pile stops 12 cm above the floor when the Lower
main pile push button is pressed. You can then lower
the pile fully in inching mode.
Form guard in front of the delivery pile
The form guard ensures a safety distance of 300 mm
to the pile support plate.
Sound insulation gate for raised presses
Raised presses are equipped with a sound insulation
gate at the feeder. The sound insulation gate must al-
ways be closed during operation. Open the sound in-
sulation gate only for the necessary makeready work
and for troubleshooting.
SC.999.0020/01 A.1.53
Safety
7 Checking protective devices with the control station
SC.901.0108-000UTKENU_03
7.1 Checking protective devices (overview)
On the control station you can check the function of
electrically monitored protective devices. The protec-
tive devices are displayed as symbols. After a protec-
tive device is actuated, its symbol on the control station
goes out.
SC.901.0170-002GRAENU_00
Safety
2
1
3
7 8 9
Safety 4 5 6 Pressing roller D.S. actuated
Guard above pressing roller open Coating unit
xxxxxx xxxxxxxxxxxx xxxxxx
Metering roller guard open Coating unit
Pressing roller D.S. actuated Printing unit
10 11
Pressing roller D.S. actuated Printing unit
Pressing roller D.S. actuated Printing unit
12
Pressing roller D.S. actuated Printing unit
Pressing roller D.S. actuated Printing unit
Fig. 35 Example: Safety tab
1. Press the Heidelberg button.
A selection menu opens below the Heidelberg
button.
2. Press the Settings menu. Select the Machine
tab.
The press is displayed schematically.
3. Press the Safety button. The Safety tab
(Fig. 35/1) opens.
The overall image (Fig. 35/2) of your machine appears
on the monitor. The safety devices are shown in color
and in the form of a list (Fig. 35/3). You can move the
displayed section of the list using the scroll bar
(Fig. 35/10).
What does the list contain?
● Details on the designation of the protective de-
vice (Fig. 35/4)
● Details on the unit in which the protective device
is located (Fig. 35/5)
● Details on the location ID (Fig. 35/6)
● The selected row is highlighted in yellow. The
designation of the protective device is displayed
A.1.54 SC.999.0020/01
Safety
in the field (Fig. 35/8) together with the error num-
ber (Fig. 35/9).
● If the selected row contains an information mes-
sage, this appears in the display panel
(Fig. 35/11).
Requirement
The check can only be performed if the number next to
the symbol (Fig. 35/12) is zero. This means that none
of the protective devices may be actuated.
Is the number something other than zero?
Check whether, for example:
● a guard is open.
● a pile support plate is in the end position.
● a light barrier is interrupted.
7.2 Checking the individual units
The displays shown on the control station are decisive
for performing the check. On the control station, the
protective devices are shown according to the config-
uration of your machine. The display shown is only an
example.
Perform the check for all units as described below for
printing unit 1 (Fig. 36) by way of an example. After the
check is complete, all protective devices must have
disappeared from the display on the control station.
The blue dot above the relevant unit then also disap-
pears. Only then does the protective device function
correctly.
SC.901.0172-002GRAENU_00
Safety unit 1
1 2
Safety
Guard above transfer gripper open Printing unit
<Emergency stop> button D.S. actuated Printing unit
Transfer guard open Printing unit
The finger protection bar has been triggered Printing unit
The finger protection bar has been triggered Printing unit
3
Guard above transfer gripper open
xxxxxx xxxxxxxxxxx xxxxxx
4 5 6
Fig. 36 Example: Checking the protective devices on printing unit 1
SC.999.0020/01 A.1.55
Safety
1. Select Printing unit 1 (Fig. 35/7). A detailed view
(Fig. 36/1) of the respective protective devices
opens.
The respective protective devices (Fig. 36/3) are
shown in blue. The list (Fig. 36/2) only shows the
protective devices on printing unit 1.
2. Press the Emergency stop buttons one after the
other and then release them again.
When the palm button is pressed, the number
(Fig. 36/4) changes from 0 to 1. When the palm
button is released, the number changes from 1 to
0.
If it is functioning correctly, the symbol on the dis-
play disappears.
3. Open one by one in succession each guard, and
close it again.
When the guard is opened, the number
(Fig. 36/4) changes from 0 to 1. When the guard
is closed, the number changes from 1 to 0.
If it is functioning correctly, the symbol on the dis-
play disappears.
Checking the finger protecting bars
In order to check the finger protecting bars, the plate
cylinder guard must first be opened, for example.
4. Open the plate cylinder guard.
When the guard is opened, the number
(Fig. 36/4) changes from 0 to 1.
5. Release the finger protecting bars.
When the finger protecting bars are actuated, the
number (Fig. 36/4) changes from 1 to 2.
When you release the finger protecting bars
again, the number (Fig. 36/4) changes from 2 to
1. If they are functioning correctly, the symbol for
the finger protecting bars disappears from the
display.
6. Close the plate cylinder guard again.
When the guard is closed, the number (Fig. 36/4)
changes from 1 to 0.
If another symbol is also present on the display:
1. Locate the displayed protective device and check
it once again.
2. Contact the service department of your Heidel-
berg agency if the protective device is defective.
A.1.56 SC.999.0020/01
Safety
Reinitialize the test:
1. Press the Reset button (Fig. 36/4). The test is
reinitialized, enabling you to repeat it completely
(after an interruption, for example).
Note
The Reset button affects all protective
devices to be checked, not just the indi-
vidual unit.
Exiting the screen
1. Press the Back button (Fig. 36/5). The display
goes back to the previously selected view.
SC.999.0020/01 A.1.57
Safety
8 Bleeding the pneumatic system
SF.901.1002-000UTKENU_01
8.1 Shutoff device of the pneumatic system
The shutoff device of the pneumatic system is at the
LS.901.1995-000GRAUND_00
compressed-air control unit (Fig. 38/2) and designated
by a symbol (Fig. 37).
Cut off the compressed air supply to the press for
maintenance, repairs and troubleshooting. Secure the
shutoff device to prevent unauthorized activation.
Fig. 37 Symbol for the shutoff device of the pneu- 1. Secure the shutoff device in venting position with
matic system a padlock.
2. Leave a sign with the name of the person autho-
rized to re-open the shutoff device.
8.2 Place of installation of the maintenance unit
The maintenance unit (Fig. 38/2) is easily accessible
SF.901.1010-002GRAUND_00
1 on the feeder behind the guard on O.S. (Fig. 38/1).
The compressed air is routed to the pneumatic com-
ponents via compressed-air control units and solenoid
valves.
The following mechanisms are pneumatically con-
trolled, for example:
● impression on and impression off movements,
● throwing on/off the rollers of inking unit and
2 dampening system,
● throwing on/off the chambered blade to/from the
varnish metering roller,
● Washup devices.
Accrued condensation is automatically drained away
at this compressed-air control unit.
Fig. 38 Place of installation of the maintenance unit
A.1.58 SC.999.0020/01
Safety
8.3 Bleeding the pneumatic system
The pneumatic system can be disconnected from the
SF.901.5644-000GRAUND_00
air supply and bled by means of the control knob of the
1 mechanical shut-off valve.
Requirement
The press is switched off at the main
switch.
1. In case of central compressed-air supply, close
the compressed-air supply hose.
or
2. Ensure that the compressor is switched off.
3. Open the guard on the feeder on O.S.
4. Turn the control knob (Fig. 39/1) clockwise direc-
tion through 90°.
This disconnects the press from the air supply
and bleeds the pneumatic system. The air es-
capes audibly through the sound absorber at the
Fig. 39 Bleeding the pneumatic system underside of the shut-off valve.
Depending on the press configuration, it may take a
few seconds to bleed the pneumatic system complete-
ly.
8.4 Securing pneumatic system against start-up
You can lock the control knob in the bleeding position
DX.901.5643-000GRAUND_00
with the aid of a padlock.
1
1. Slide the latch (Fig. 40/1) forwards in the direction
of the arrow.
You can now see the opening for the padlock.
2. Secure the control knob in the bleeding position
using a padlock (Fig. 40/2).
3. Attach a sign bearing the name of the person au-
thorized to switch on the pneumatic system
again.
Fig. 40 Control knob secured - View from above
SC.999.0020/01 A.1.59
Safety
8.5 Aerating the pneumatic system
Before you can put the press into operation, the pneu-
SF.901.5645-000GRAUND_00
1 matic system must be supplied with compressed air.
The press cannot be put into operation when the op-
erating pressure is not reached. The error message
"Insufficient pressure in the pneumatic compressor"
appears.
Proceed as follows:
Requirement
The press is switched off at the main
switch.
1. Open the guard on the feeder on O.S.
2. Remove the padlock from the control knob.
3. Turn the control knob (Fig. 41/1) counterclock-
wise into operating position.
4. Close the guard on the feeder on O.S.
5. Switch on the press at the main switch.
Fig. 41 Operating position 6. In case of central compressed-air supply, open
the compressed-air supply hose.
or
7. Put the compressor into operation.
Wait until the press has reached its operating pressure
DX.901.5646-000GRAUND_00
1 and the pointer on the manometer is in the green re-
gion (Fig. 42/1).
Operating pressure: approx. 6.8 bars
Depending on the given press configuration, several
minutes may elapse before there is sufficient pressure
in the pneumatic system.
Fig. 42 Manometer (exemplary)
A.1.60 SC.999.0020/01
Safety
9 Turning the press manually
SC.B01.0106-000UTKENU_00
9.1 General notes
You can crank the press manually in an emergency or
when performing adjustment or maintenance work.
Warning - Risk of injury!
Prior to starting any of the following
operations, press the Emergency-stop
palm button on the nearest control
panel in order to secure the press
against being put back into operation.
Note
Inform all persons near the press that
you intend to crank the press manually.
Caution - Risk of press damage!
If there are still print sheets in the press,
you may only crank the press backwards
in emergencies. The print sheets may
damage sheet-transferring cylinders
and grippers when the press is cranked
backward.
9.2 Tool and holding fixture
Crank handle
FS.901.9007-000GRAUND_00
1 Depending on the configuration, your press is supplied
with a
2
● crank handle with ratchet (Fig. 43/1)
or
● crank handle with T-handle (Fig. 43/2).
The press can be turned manually using this crank
handle.
Fig. 43 Crank handle with reversible ratchet or T-
handle
Supporting device
The crank handle is inserted into the adjusting shaft
(Fig. 44/1) / (Fig. 462) on D.S.
Note
In presses with perfector, there is an ad-
justing shaft in each printing unit with
perfector.
SC.999.0020/01 A.1.61
Safety
Note
SC.B01.0105-000GRAUND_00
In presses without interdeck dryer there
is an opening (Fig. 46/3) in the guard of
2 the appropriate printing unit. In presses
with an interdeck dryer, the connector for
the crank handle is located to the right of
1
the hinged footstep at the appropriate
printing unit.
Fig. 44 Connector for the crank handle in presses
with an interdeck dryer
9.3 Cranking the press by hand
Remove the D.S. guard from the appropriate printing
SC.B01.0104-000GRAUND_00
unit as indicated by the arrows (Fig. 45/1,2).
Fig. 45 Removing the guard
A.1.62 SC.999.0020/01
Safety
Note
SC.B01.0103-000GRAUND_00
When the press is switched off, you must
1 release the motor brake manually (see
4
section "Releasing the motor brake
manually").
1. Insert the crank handle (Fig. 46/3) into the con-
nector.
3
Fig. 46 Crank and adjusting shaft
2. Lift or push down the ratchet pawl (Fig. 46/1).
3. Push or pull the adjusting shaft (Fig. 46/2) until
you hit the stop.
Result
This way the motor brake is released
when the press is activated.
4. Now crank the press.
Turning direction of the tool
● Turning the crank handle clockwise will turn the
press backwards.
● Turn the press forwards in a counterclockwise
direction (same direction of rotation as in produc-
tion mode).
Removing the tool
5. Remove the crank handle from the adjusting
shaft.
6. Lift or push down the ratchet pawl (Fig. 46/1).
7. Push or pull the adjusting shaft (Fig. 46/2) until
you hit the stop.
8. Mount the D.S. guard.
9.4 Special feature of CX 104-1+L
Note
The CD/CX 104-1+L model series differs
from the longer presses in terms of
where the crank handle is inserted and in
the corresponding direction of rotation.
Therefore, note the following procedure.
SC.999.0020/01 A.1.63
Safety
Detach protective cover
SG.901.0115-000GRAUND_00
1. The drive motor is located on the D.S. under the
gallery. The belt pulley is covered up by a cover
(Fig. 47/1). To insert the crank handle, you need
to remove the guard cover (Fig. 47/2).
2. To do so, undo the screws (Fig. 47/3).
3 Insert the tool
2 3. Insert the crank handle into the opening
(Fig. 48/1). You must press the crank handle into
the opening against the spring force.
1 4. Turn the press.
Turning direction of the tool
● In clockwise direction, the press turns forward
(same direction of rotation as in production
Fig. 47 Remove protective cover mode).
● In counterclockwise direction, the press turns
SG.901.0116-000GRAUND_00
backward.
Removing the tool
5. Remove the crank handle from the opening.
1 6. Seal the opening (Fig. 48/1) again using the pro-
tective cover (Fig. 47/2).
Fig. 48 Opening for the crank handle
A.1.64 SC.999.0020/01
Safety
9.5 Releasing the motor brake manually
Note
LS.901.0001-003GRAUND_00
If the press is deactivated, you must re-
lease the motor brake manually. If the
2 press is activated, the motor brake is re-
1
leased automatically.
1. Pull the strap (Fig. 49/1) in direction of the arrow.
This releases the motor brake.
2. Turn in the hexagon-head screw (Fig. 49/2). This
way the strap remains in the released position.
Result
This releases the motor brake. Now you
can crank the press (see section "Man-
ual cranking of the press").
3. Upon completion of this task, you must reactivate
the motor brake: Undo the hexagon-head screw
(Fig. 49/2).
Fig. 49 Main drive
Note
Ensure that the strap (Fig. 49/1) is pulled
back into the initial position.
SC.999.0020/01 A.1.65
Safety
A.1.66 SC.999.0020/01
Main chapter overview
B Press
Overview of touch screen control panels ........................................................................ B.1.1
1 Touch screen overview ........................................................................................................ B.1.3
1.1 Basic information ........................................................................................................... B.1.3
1.2 Place of installation ........................................................................................................ B.1.3
1.3 Function/Task ................................................................................................................ B.1.3
1.4 Feeder touch screen, header ........................................................................................ B.1.4
1.5 Printing unit/coating unit touch screen, header ............................................................. B.1.4
1.6 Delivery touch screen, header ...................................................................................... B.1.5
1.7 Heidelberg button .......................................................................................................... B.1.5
1.8 Main field ....................................................................................................................... B.1.6
1.9 Footer/status display ..................................................................................................... B.1.6
Control panels on the feeder ................................................................................................. B.2.1
1 Feeder control panels ........................................................................................................... B.2.3
1.1 Control panels on the feeder .......................................................................................... B.2.3
1.2 Pile control control panel ............................................................................................... B.2.4
1.3 Control panel for Auto Non-Stop and Autopile (optional) pile control ........................... B.2.6
1.4 Control panel for Start control ....................................................................................... B.2.8
1.5 Air control control panel above the feeder touch screen ............................................... B.2.12
1.6 Touch screen and intercom ........................................................................................... B.2.12
1.7 Suction head control panel ........................................................................................... B.2.13
2 Feeder touch screen, overview ............................................................................................ B.2.14
2.1 Basic information ........................................................................................................... B.2.14
2.2 Place of installation ........................................................................................................ B.2.14
2.3 Function/task ................................................................................................................. B.2.15
3 Job menu on the touch screen ............................................................................................ B.2.17
3.1 Function ......................................................................................................................... B.2.17
3.2 Job tab .......................................................................................................................... B.2.17
3.3 Automatic job change tab ............................................................................................. B.2.18
3.4 Job queue tab ................................................................................................................ B.2.19
4 Production menu on the feeder touch screen .................................................................... B.2.23
4.1 Function ......................................................................................................................... B.2.23
4.2 The "Production" menu .................................................................................................. B.2.23
5 Feeder menu on the feeder touch screen ........................................................................... B.2.26
5.1 Function ......................................................................................................................... B.2.26
5.2 Feeder menu ................................................................................................................. B.2.26
SC.999.0020/01 B. 1
Main chapter overview
6 Touch screen feeder menu - feeder pile ............................................................................. B.2.28
6.1 Function ......................................................................................................................... B.2.28
6.2 Feeder pile menu .......................................................................................................... B.2.28
7 Washup menu on the touch screen .................................................................................... B.2.30
7.1 Function ......................................................................................................................... B.2.30
7.2 Washup menu ................................................................................................................ B.2.30
8 Consumables display menu on the touch screen ............................................................. B.2.32
8.1 Function ......................................................................................................................... B.2.32
8.2 Consumables display menu ........................................................................................... B.2.32
8.3 Consumables information menu .................................................................................... B.2.33
9 Malfunction/Service menu on the touch screen ................................................................. B.2.35
9.1 Function ......................................................................................................................... B.2.35
9.2 Malfunction menu .......................................................................................................... B.2.35
9.3 Malfunction information menu ....................................................................................... B.2.36
9.4 Service menu ................................................................................................................ B.2.37
9.5 Paper run menu ............................................................................................................ B.2.38
Control panels on the printing unit/coating unit ........................................................... B.3.1
1 Intelliline operator assistance .............................................................................................. B.3.3
1.1 Function/Task ................................................................................................................ B.3.3
1.2 Cleaning the LED bar and LED element ....................................................................... B.3.4
2 Printing unit control panels ................................................................................................. B.3.5
2.1 Control panel on first printing unit ................................................................................. B.3.5
2.2 Printing unit O.S. ........................................................................................................... B.3.6
2.3 Printing unit D.S. ........................................................................................................... B.3.8
2.4 Dampening system O.S. ............................................................................................... B.3.8
3 Coating unit control panels .................................................................................................. B.3.9
3.1 Coating unit O.S., delivery side ...................................................................................... B.3.9
3.2 Coating unit O.S., feeder side ........................................................................................ B.3.12
3.3 Coating unit D.S. ............................................................................................................ B.3.14
3.4 Coating unit, manual control panel ................................................................................ B.3.15
4 Control panels of intermediate unit ..................................................................................... B.3.17
4.1 Intermediate unit on O.S. on delivery side ..................................................................... B.3.17
4.2 Intermediate station on D.S. on delivery side ................................................................ B.3.18
B. 2 SC.999.0020/01
Main chapter overview
Control panels on the delivery .............................................................................................. B.4.1
1 Delivery control panel ........................................................................................................... B.4.3
1.1 Overview of controls ...................................................................................................... B.4.3
1.2 Buttons on the delivery control panel ............................................................................. B.4.4
1.3 Header of the user interface .......................................................................................... B.4.6
1.4 Menus and symbols ....................................................................................................... B.4.7
2 The "Production" menu ......................................................................................................... B.4.8
2.1 Settings in the "Production" menu .................................................................................. B.4.8
2.2 Calling up the "Production" menu .................................................................................. B.4.8
2.3 Buttons, functions and symbols in the "Production" menu ............................................. B.4.9
3 Dampening menu ................................................................................................................... B.4.11
3.1 Settings in the "Dampening" menu ................................................................................ B.4.11
3.2 Calling up Dampening menu .......................................................................................... B.4.11
3.3 Buttons, functions and symbols in the "Dampening" menu ........................................... B.4.11
4 Delivery menu ......................................................................................................................... B.4.13
4.1 Submenus of the delivery menu .................................................................................... B.4.13
4.2 Calling up the delivery/paper run menu ......................................................................... B.4.14
4.3 Buttons, functions and symbols in the "Delivery/paper run" menu ................................ B.4.14
4.4 Calling up Delivery/sheet brake menu ........................................................................... B.4.15
4.5 Buttons, functions and symbols in the "Delivery/sheet brake" menu ............................. B.4.15
4.6 Calling up the Delivery/pile stops menu ......................................................................... B.4.16
4.7 Buttons, functions and symbols in the "Delivery/pile stops" menu ................................. B.4.17
4.8 Calling up the Delivery/suction disc, sprocket wheel shaft menu .................................. B.4.18
4.9 Buttons, functions and symbols in the Delivery/suction disc, sprocket wheel shaft menu B.4.18
4.10 Calling up the Delivery/non-stop functions menu ........................................................... B.4.19
4.11 Buttons, functions and symbols in the "Delivery/non-stop functions" menu .................. B.4.19
4.12 Additional menu on presses with automatic non-stop .................................................... B.4.21
4.13 Calling up Delivery/Autopile menu ................................................................................. B.4.23
4.14 Buttons, functions and symbols in the "Autopile" menu ................................................. B.4.23
4.15 Calling up Delivery/feeder menu .................................................................................... B.4.24
4.16 Buttons, functions and symbols in the "Delivery/feeder" menu ...................................... B.4.24
4.17 Calling up the tape inserter menu ................................................................................. B.4.25
4.18 Buttons, functions and symbols in the tape inserter menu ............................................ B.4.25
5 "Additional devices" menu ................................................................................................... B.4.27
5.1 Settings in the "Additional devices" menu ...................................................................... B.4.27
5.2 Calling up the "Additional devices" menu ...................................................................... B.4.27
5.3 Buttons, functions and symbols in the "Additional devices" menu ................................. B.4.28
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Main chapter overview
6 Consumables menu ............................................................................................................... B.4.30
6.1 Displays in Consumables menu ..................................................................................... B.4.30
6.2 Calling up Consumables menu ...................................................................................... B.4.30
7 Malfunction/Service menu ..................................................................................................... B.4.31
7.1 Settings in the Malfunctions menu ................................................................................. B.4.31
7.2 Calling up the Malfunctions menu .................................................................................. B.4.31
7.3 Calling up the Service menu .......................................................................................... B.4.32
7.4 Entering the configuration of the sheet brake modules .................................................. B.4.33
Feeder ............................................................................................................................................. B.5.1
1 Feeder - safety instructions ................................................................................................. B.5.7
1.1 To be observed when performing work .......................................................................... B.5.7
2 Pile change ............................................................................................................................. B.5.8
2.1 Determining the actual sheet size ................................................................................. B.5.8
2.2 Normal pile change ....................................................................................................... B.5.8
2.3 Non-stop pile change (optional) .................................................................................... B.5.10
3 Automatic non-stop pile change (optional) ........................................................................ B.5.14
3.1 Function ......................................................................................................................... B.5.14
3.2 Performing a non-stop pile change ............................................................................... B.5.15
3.3 Deflecting marked sheets .............................................................................................. B.5.19
3.4 Malfunctions during automatic pile change ................................................................... B.5.20
3.5 Interrupting automatic sequences in the pile change .................................................... B.5.23
3.6 Maintenance work ......................................................................................................... B.5.25
3.7 Pile heights ................................................................................................................... B.5.26
4 Preloading and pile change ................................................................................................. B.5.28
4.1 Determining the actual sheet size ................................................................................. B.5.28
4.2 Preloading device (option) ............................................................................................. B.5.28
4.3 Pile change .................................................................................................................... B.5.29
5 Automatic pile alignment ..................................................................................................... B.5.30
5.1 Determining the actual sheet size ................................................................................. B.5.30
5.2 Function ......................................................................................................................... B.5.30
5.3 Function of the buttons .................................................................................................. B.5.31
5.4 Method of operation in "Automatic pile alignment" mode ............................................. B.5.32
6 Automatic non-stop pile change (optional) ........................................................................ B.5.33
6.1 Function ......................................................................................................................... B.5.33
6.2 Determining the actual sheet size ................................................................................. B.5.34
6.3 Performing a non-stop pile change ............................................................................... B.5.34
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6.4 Deflecting marked sheets .............................................................................................. B.5.38
6.5 Malfunctions during automatic pile change ................................................................... B.5.40
6.6 Interrupting automatic sequences in the pile change .................................................... B.5.43
6.7 Maintenance work ......................................................................................................... B.5.45
6.8 Pile heights ................................................................................................................... B.5.46
7 Suction head ........................................................................................................................... B.5.48
7.1 Overview of the suction head ........................................................................................ B.5.48
7.2 Adjusting the sheet size ................................................................................................ B.5.49
7.3 Setting the height .......................................................................................................... B.5.50
7.4 Lifting suckers ............................................................................................................... B.5.50
7.5 Forwarding suckers ....................................................................................................... B.5.52
7.6 Reducing the suction air of the forwarding suckers and lifting suckers ........................ B.5.53
8 Overview table - suction head settings for different printing materials .......................... B.5.54
8.1 Lifting suckers and forwarding suckers ......................................................................... B.5.54
8.2 Sheet separator fingers ................................................................................................. B.5.54
8.3 Sheet separation blowers ............................................................................................. B.5.55
8.4 Sheet stops and forwarding flap ................................................................................... B.5.55
9 Sheet separator fingers ......................................................................................................... B.5.57
9.1 Function ........................................................................................................................ B.5.57
9.2 Adjusting sheet separator fingers .................................................................................. B.5.57
10 Adjusting the blast air on the suction head ....................................................................... B.5.59
10.1 Overview ........................................................................................................................ B.5.59
10.2 Sheet separation blower ............................................................................................... B.5.59
10.3 Outer carrier air blowers ............................................................................................... B.5.60
10.4 Inner carrier air blowers ................................................................................................ B.5.60
10.5 Rear edge blowers ........................................................................................................ B.5.60
10.6 Pre-separation air ......................................................................................................... B.5.61
11 Pile stops on the suction head ............................................................................................ B.5.62
11.1 Design ............................................................................................................................ B.5.62
11.2 Adapting the pile weight to the printing material ........................................................... B.5.62
12 StaticStar - ionizing unit (option) ......................................................................................... B.5.63
12.1 Overview ........................................................................................................................ B.5.63
12.2 Locations of StaticStar Compact components .............................................................. B.5.63
13 Ionizing blowers at the suction head (optional) ................................................................. B.5.67
13.1 Function/design .............................................................................................................. B.5.67
13.2 Activation/deactivation .................................................................................................. B.5.67
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Main chapter overview
13.3 Positioning the ionizing blowers .................................................................................... B.5.68
14 Foil printing (optional) .......................................................................................................... B.5.70
14.1 General .......................................................................................................................... B.5.70
14.2 Special air-blast nozzles for suction head and ionizing unit .......................................... B.5.70
14.3 Lifting and forwarding suckers ...................................................................................... B.5.72
14.4 Rear edge blowing unit ................................................................................................. B.5.73
15 Lateral sheet separation blowers ........................................................................................ B.5.78
15.1 Function ......................................................................................................................... B.5.78
15.2 Automatic adjustment of the lateral sheet separation blowers ...................................... B.5.78
15.3 Manual adjustment of the lateral sheet separation blowers .......................................... B.5.78
15.4 Setting the blast air volume ........................................................................................... B.5.79
16 Rope guide and guide plate ................................................................................................. B.5.80
16.1 Function ......................................................................................................................... B.5.80
16.2 Adjusting the guide plate ............................................................................................... B.5.80
16.3 Changing the rope ........................................................................................................ B.5.81
17 Sheet monitoring ................................................................................................................... B.5.85
17.1 Overview ........................................................................................................................ B.5.85
17.2 Measuring range of the double/multiple-sheet detector ................................................. B.5.86
17.3 Ultrasonic double sheet detector .................................................................................. B.5.86
17.4 Double sheet detector in the pull lay (option) ................................................................ B.5.88
17.5 Multiple sheet detector .................................................................................................. B.5.88
17.6 Sheet stream / multiple-sheet detector optional ............................................................. B.5.91
17.7 Switching the feeder back on after double sheet detection .......................................... B.5.93
17.8 Switching the feeder back on after multiple sheet recognition ...................................... B.5.94
17.9 Clearing the feeder ....................................................................................................... B.5.95
17.10 Sheet alignment monitor ............................................................................................... B.5.96
17.11 Possible causes of early, late and misaligned sheets .................................................... B.5.100
17.12 Ultrasonic sheet drag monitor ....................................................................................... B.5.102
18 Forwarding rollers .................................................................................................................. B.5.103
18.1 Adjusting to sheet format .............................................................................................. B.5.103
19 Guide rolls on the suction tape ........................................................................................... B.5.104
19.1 General .......................................................................................................................... B.5.104
19.2 Mounting position ........................................................................................................... B.5.104
19.3 Guide rolls ...................................................................................................................... B.5.104
20 Pulling device ........................................................................................................................ B.5.106
20.1 Function ......................................................................................................................... B.5.106
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20.2 Function elements .......................................................................................................... B.5.106
20.3 Setting the format .......................................................................................................... B.5.106
20.4 Adjusting the suction air ................................................................................................ B.5.107
20.5 Adjusting the pull stop to the stock ............................................................................... B.5.108
20.6 Pull lay monitor ............................................................................................................. B.5.109
20.7 Adjusting the pull lay monitor ........................................................................................ B.5.109
20.8 Adjusting the pull distance ............................................................................................ B.5.112
20.9 Retainer ........................................................................................................................ B.5.112
20.10 Cleaning the pull lay ...................................................................................................... B.5.114
21 Separator rolls ........................................................................................................................ B.5.115
21.1 Function ........................................................................................................................ B.5.115
21.2 Adjusting the height of the separator rolls ..................................................................... B.5.115
21.3 Changing the separator roll position ............................................................................. B.5.116
21.4 Throwing on/off individual separator rolls ..................................................................... B.5.116
21.5 Cleaning the separator rolls .......................................................................................... B.5.116
21.6 Cleaning the sheet guide plate ..................................................................................... B.5.117
22 Front lays ............................................................................................................................... B.5.118
22.1 Function ......................................................................................................................... B.5.118
22.2 Throwing the front lays on/off ........................................................................................ B.5.118
22.3 Adjusting the gripper bite .............................................................................................. B.5.119
22.4 Cleaning the front lays .................................................................................................. B.5.119
22.5 Blowing/suction nozzles ................................................................................................ B.5.120
22.6 Raising the sheet stop fingers ....................................................................................... B.5.120
23 Crash bar ................................................................................................................................ B.5.121
23.1 Function ........................................................................................................................ B.5.121
23.2 Adjusting the crash bar ................................................................................................. B.5.121
24 Adjustment information for special printing material ....................................................... B.5.122
24.1 Special printing materials ............................................................................................... B.5.122
24.2 Book paper ..................................................................................................................... B.5.122
25 CutStar (sheeter) - Preset Plus feeder ................................................................................ B.5.124
25.1 Function/Task ................................................................................................................ B.5.124
25.2 Conversion to operation with CutStar ........................................................................... B.5.124
25.3 Conversion to operation without CutStar ...................................................................... B.5.127
26 Troubleshooting on the feeder ............................................................................................ B.5.129
26.1 Overview ........................................................................................................................ B.5.129
26.2 Pile ................................................................................................................................. B.5.129
26.3 Sheet separation ............................................................................................................ B.5.129
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Main chapter overview
26.4 Double sheet detectors .................................................................................................. B.5.130
26.5 Suction tape feed table sheet transport ......................................................................... B.5.131
26.6 Sheet alignment system ................................................................................................. B.5.131
27 Emergency measures in the event of the failure of a servo-drive in the feeder ............. B.5.134
27.1 What is the purpose of these emergency measures? ................................................... B.5.134
27.2 Manually setting suction head to sheet size ................................................................. B.5.135
27.3 Manual suction head height adjustment ....................................................................... B.5.136
27.4 Manually setting the side stops to sheet size ................................................................ B.5.137
27.5 Manually setting cover guide height .............................................................................. B.5.138
27.6 Manually setting separator rolls .................................................................................... B.5.140
27.7 Manually setting air volume controller for the blowing/suction nozzle .......................... B.5.141
27.8 Manually setting pull lays to sheet width ....................................................................... B.5.142
Printing unit .................................................................................................................................. B.6.1
1 Printing unit - safety instructions ......................................................................................... B.6.5
1.1 To be observed when performing work .......................................................................... B.6.5
2 Printing-related notes on cylinder rolling ........................................................................... B.6.9
2.1 Bearer-to-bearer presses ............................................................................................... B.6.9
2.2 Cylinder undercut .......................................................................................................... B.6.9
2.3 Cylinder rolling .............................................................................................................. B.6.10
2.4 Packing, packing thickness ........................................................................................... B.6.10
2.5 Consequences of incorrect packing height .................................................................... B.6.10
2.6 Printing pressure ........................................................................................................... B.6.10
2.7 Influence of cylinder rolling ........................................................................................... B.6.11
2.8 Measuring the packing thickness .................................................................................. B.6.11
2.9 Packing thickness of the cylinders ................................................................................ B.6.12
3 Height adjustment of the gripper pads on the feed cylinder ............................................ B.6.13
3.1 Feed cylinder ................................................................................................................ B.6.13
3.2 Gripper pad height ......................................................................................................... B.6.13
3.3 Setting ranges ................................................................................................................ B.6.14
3.4 Adjusting the height of the gripper pads on the feed cylinder ........................................ B.6.14
4 Removing lost sheets ........................................................................................................... B.6.16
4.1 Sheet travel monitor ....................................................................................................... B.6.16
4.2 Sheet loss in the printing unit/coating unit .................................................................... B.6.16
4.3 Sheet loss in the perfector ............................................................................................ B.6.18
4.4 Sheet loss in sheet ascent of delivery ........................................................................... B.6.20
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5 Suction brush ......................................................................................................................... B.6.21
5.1 Utilization note ............................................................................................................... B.6.21
5.2 Design and function ....................................................................................................... B.6.21
5.3 Removing the suction brush .......................................................................................... B.6.22
5.4 Fitting the suction brush ................................................................................................. B.6.25
5.5 Adjusting the suction brush with respect to the impression cylinder .............................. B.6.25
5.6 Adjusting operating position or home position ............................................................... B.6.26
5.7 Cleaning the dust filters in the vacuum pump ................................................................ B.6.27
6 Plate cylinder ......................................................................................................................... B.6.28
6.1 Gluing on the polyester underlay foil ............................................................................. B.6.28
7 Hickey catcher ....................................................................................................................... B.6.29
7.1 Removing hickeys .......................................................................................................... B.6.29
8 Hand-held scanner with base station (Press Center 3/XL3 code reader with Ethernet
connection, option) ............................................................................................................... B.6.30
8.1 General .......................................................................................................................... B.6.30
8.2 Function/Task ................................................................................................................ B.6.30
8.3 Configuration on the machine ........................................................................................ B.6.31
8.4 Operation ....................................................................................................................... B.6.32
8.5 Faults ............................................................................................................................. B.6.38
8.6 Re-connecting hand-held scanner and base station ...................................................... B.6.40
8.7 Replacing the base station ............................................................................................. B.6.40
9 Requirements for the printing plate .................................................................................... B.6.42
9.1 Required size for edge-bent printing plates .................................................................. B.6.42
9.2 Technical printing plate requirements ........................................................................... B.6.43
10 AutoPlate ................................................................................................................................ B.6.46
10.1 Preparatory work for changing plates ............................................................................ B.6.46
10.2 Function of the printing unit guard on the delivery side ................................................. B.6.46
10.3 Removing the plate ........................................................................................................ B.6.47
10.4 Plate change .................................................................................................................. B.6.48
10.5 Mounting the plate ......................................................................................................... B.6.49
11 Positioning correction at the tail edge of print ................................................................... B.6.50
11.1 Overview and basic adjustment ..................................................................................... B.6.50
11.2 Positioning correction at the tail edge ............................................................................ B.6.50
12 Blanket cylinder .................................................................................................................... B.6.53
12.1 Coating the cylinder with a new chrome alloy ................................................................ B.6.53
12.2 Requirements on the cleaner ........................................................................................ B.6.53
SC.999.0020/01 B. 9
Main chapter overview
12.3 Torque when tensioning the blankets ............................................................................ B.6.53
12.4 Preparing blanket .......................................................................................................... B.6.53
12.5 Gap cover ...................................................................................................................... B.6.54
12.6 Removing the blanket ................................................................................................... B.6.55
12.7 Preparing packing sheets ............................................................................................. B.6.57
12.8 Mounting the blanket ..................................................................................................... B.6.57
12.9 Measuring the packing thickness of the blanket ............................................................ B.6.64
13 Blanket washup device ......................................................................................................... B.6.65
13.1 Function and structure .................................................................................................. B.6.65
13.2 Removing the blanket washup unit (all PU except for PU 1) ......................................... B.6.66
13.3 Removing the blanket washup unit (PU 1) ..................................................................... B.6.67
13.4 Preparations for removing the blanket washup unit from a PU with interdeck dryer ..... B.6.68
13.5 Removing the used washup cloth ................................................................................. B.6.69
13.6 Preparing the cloth supply roll ....................................................................................... B.6.69
13.7 Mounting a new washup cloth ....................................................................................... B.6.71
13.8 Fitting the blanket washup unit (all PUs, except for PU 1) ............................................ B.6.75
13.9 Fitting the blanket washup unit (PU 1) .......................................................................... B.6.76
13.10 Fitting the blanket washup unit on a PU with interdeck dryer ........................................ B.6.77
14 Impression cylinder washup device .................................................................................... B.6.80
14.1 Function and design ...................................................................................................... B.6.80
14.2 Removing the washup unit ............................................................................................ B.6.81
14.3 Removing the used-up washup cloth ............................................................................ B.6.82
14.4 Preparing the cloth supply roll ....................................................................................... B.6.83
14.5 Mounting a new washup cloth ....................................................................................... B.6.86
14.6 Installing the washup unit .............................................................................................. B.6.88
15 Washing fluid container ....................................................................................................... B.6.90
15.1 Equipment and function ................................................................................................. B.6.90
15.2 Requirements on water / washing fluid ......................................................................... B.6.90
15.3 Bleeding the washing fluid container ............................................................................ B.6.90
15.4 Filling the washing fluid container ................................................................................. B.6.91
15.5 Draining and disposing cleaner / water .......................................................................... B.6.92
15.6 Water container cell accidentally filled with cleaner? ..................................................... B.6.93
15.7 Cleaning the entire washing system .............................................................................. B.6.93
16 Washup .................................................................................................................................. B.6.94
16.1 Manual washup/automated washup .............................................................................. B.6.94
16.2 Washup devices, general information ............................................................................ B.6.94
16.3 Washup devices, detailed information ........................................................................... B.6.95
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16.4 Error messages during washing .................................................................................... B.6.96
17 Sheet-transferring cylinders and drums ............................................................................. B.6.97
17.1 Equipment ...................................................................................................................... B.6.97
17.2 Replacement of cylinder jackets ................................................................................... B.6.97
17.3 Automatically cleaning surfaces of impression cylinder with PerfectJacket/PerfectJacket
Blue ............................................................................................................................... B.6.97
17.4 Manual washup ............................................................................................................. B.6.99
17.5 Care instructions for all surfaces .................................................................................... B.6.99
17.6 Notes on PerfectJacket/PerfectJacket Blue/TransferJacket Blue ................................. B.6.99
17.7 Print-related notes .......................................................................................................... B.6.100
17.8 Super Blue system ......................................................................................................... B.6.101
17.9 General notes on straight printing and perfecting .......................................................... B.6.101
18 Air settings in the printing unit ............................................................................................ B.6.102
18.1 Air settings on the impression cylinder .......................................................................... B.6.102
18.2 Air-supported sheet guiding .......................................................................................... B.6.102
19 Malfunctions on the printing unit ........................................................................................ B.6.104
19.1 Error message: Drain oil from residual-oil reservoir ....................................................... B.6.104
Plate changer ............................................................................................................................... B.7.1
1 Plate changer - safety instructions ..................................................................................... B.7.3
1.1 Safety instruction for the plate changer ......................................................................... B.7.3
2 AutoPlate Pro ........................................................................................................................ B.7.4
2.1 Overview ....................................................................................................................... B.7.4
2.2 Usable printing plates ................................................................................................... B.7.4
2.3 Special features of presses with AutoPlate Pro ............................................................ B.7.4
2.4 Positions of the plate changer ....................................................................................... B.7.6
2.5 Method of functioning .................................................................................................... B.7.8
2.6 Plate change ................................................................................................................. B.7.10
3 AutoPlate Pro - manual plate change .................................................................................. B.7.12
3.1 Overview ........................................................................................................................ B.7.12
3.2 Removing the plate ....................................................................................................... B.7.12
3.3 Mounting the plate ........................................................................................................ B.7.13
4 Notes on troubleshooting .................................................................................................... B.7.15
4.1 Basic knowledge and conduct of operator ..................................................................... B.7.15
4.2 10 Troubleshooting rules ............................................................................................... B.7.15
SC.999.0020/01 B. 11
Main chapter overview
5 Error message: "General malfunction: automatic plate change" or "Finger protecting
bar/protective device" or emergency stop or "DWBA movement lock main drive" ....... B.7.17
5.1 Error message: "General malfunction: automatic plate change" .................................. B.7.17
5.2 Malfunctions from power failure during the plate change .............................................. B.7.18
5.3 Momentary triggering of the finger protecting bar .......................................................... B.7.18
5.4 Interruption of the automatic plate change due to a time-out ........................................ B.7.19
5.5 Brief lifting of the deflector plate on the delivery ............................................................ B.7.19
6 Error before the start of the plate change .......................................................................... B.7.20
6.1 Error: Plate change cannot be started .......................................................................... B.7.20
7 Malfunctions when removing the plate ............................................................................... B.7.22
7.1 Error message: "Malfunction: Plate rear edge sensor, PU x" ....................................... B.7.22
7.2 The error message "Malfunction: Plate ejection, printing plate end position" ............... B.7.23
7.3 Error message "Malfunction: Printing plate ejection in PU x" ....................................... B.7.24
7.4 Aborting the automatic plate changing procedure ........................................................ B.7.25
8 Malfunctions in data transmission ...................................................................................... B.7.29
8.1 Error message: "Fault on data transmission sensor - Remove plate in PU x" .............. B.7.29
9 Plate loading faults ............................................................................................................... B.7.30
9.1 Error message: "Malfunction: Front edge sensor D.S./O.S. - Remove plate PU x" ...... B.7.30
Inking unit ...................................................................................................................................... B.8.1
1 Inking unit - safety instructions ........................................................................................... B.8.3
1.1 To be observed when performing work .......................................................................... B.8.3
2 Manual adjustment of the lateral distribution .................................................................... B.8.5
2.1 General notes ................................................................................................................ B.8.5
2.2 Changing the distribution travel .................................................................................... B.8.5
2.3 Changing the start of distribution .................................................................................. B.8.6
2.4 Lateral clearance of the inking form rollers ................................................................... B.8.8
3 Inking unit temperature control ........................................................................................... B.8.9
3.1 Method of functioning ..................................................................................................... B.8.9
3.2 Regulating the flow rate at the ink fountain roller .......................................................... B.8.9
4 Removing and installing the inking rollers ......................................................................... B.8.11
4.1 Roller diagram ............................................................................................................... B.8.11
4.2 Overview and concise instructions ................................................................................ B.8.12
4.3 Preparations for the removal of the inking rollers ......................................................... B.8.16
4.4 Removing the inking rollers ........................................................................................... B.8.18
4.5 Installing and adjusting the inking rollers ...................................................................... B.8.22
4.6 Adjusting the inking form roller relative to the plate ....................................................... B.8.30
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4.7 Final steps of inking roller installation ............................................................................ B.8.30
5 Template for roller adjustment ............................................................................................ B.8.33
5.1 Template - overview ....................................................................................................... B.8.33
5.2 How do you correct the contact area? ........................................................................... B.8.35
6 Removing and installing the ink vibrator ............................................................................ B.8.36
6.1 Removing the ink vibrator ............................................................................................. B.8.36
6.2 Installing and adjusting the ink vibrator ......................................................................... B.8.36
7 Selecting, servicing and storing inking rollers ................................................................... B.8.38
7.1 Selecting correct inking rollers ....................................................................................... B.8.38
7.2 Servicing and storing inking rollers ................................................................................ B.8.38
7.3 Detaching ball bearings from roller cores ...................................................................... B.8.39
7.4 Mounting ball bearings onto roller cores ........................................................................ B.8.40
8 Ink fountain ............................................................................................................................. B.8.41
8.1 Retightening and replacing the ink fountain liner .......................................................... B.8.41
8.2 Replacing the protective film over the metering elements ............................................. B.8.43
8.3 Cleaning the drip pan ..................................................................................................... B.8.45
8.4 Removing the drip pan for cleaning purposes ............................................................... B.8.45
8.5 Ink agitation system ....................................................................................................... B.8.45
9 Autoprotect - automatic application of roller protective agent ........................................ B.8.47
9.1 General .......................................................................................................................... B.8.47
9.2 System components ...................................................................................................... B.8.48
9.3 Changing canister ......................................................................................................... B.8.49
9.4 Commissioning ............................................................................................................. B.8.51
9.5 Preselecting the "Apply roller protective agent" operating mode .................................. B.8.51
9.6 Cleaning the inking rollers ............................................................................................. B.8.51
10 Ink mist suction removal ...................................................................................................... B.8.52
10.1 General .......................................................................................................................... B.8.52
10.2 Replacing the filtering mat ............................................................................................. B.8.53
Dampening system .................................................................................................................... B.9.1
1 Dampening system - safety instructions ............................................................................. B.9.3
1.1 To be observed when performing work .......................................................................... B.9.3
2 Print-related notes ................................................................................................................ B.9.4
2.1 Settings .......................................................................................................................... B.9.4
3 Requirements for the dampening solution ......................................................................... B.9.6
3.1 Approved dampening solution additives ........................................................................ B.9.6
SC.999.0020/01 B. 13
Main chapter overview
3.2 Preventing press damage .............................................................................................. B.9.6
3.3 High printing quality ....................................................................................................... B.9.6
3.4 Additive metering unit .................................................................................................... B.9.7
3.5 Metering of alcohol and dampening solution additives .................................................. B.9.7
3.6 Changing the dampening solution ................................................................................. B.9.7
3.7 Special requirements ..................................................................................................... B.9.8
4 Removing and installing dampening rollers ...................................................................... B.9.9
4.1 Overview ....................................................................................................................... B.9.9
4.2 Cleaning the dampening solution pan ........................................................................... B.9.10
4.3 Removing dampening rollers ........................................................................................ B.9.11
4.4 Installing and adjusting the dampening rollers .............................................................. B.9.13
5 Blower bar ............................................................................................................................... B.9.23
5.1 Setting the blower bar .................................................................................................... B.9.23
6 Cleaning the dampening system ......................................................................................... B.9.24
6.1 Manually cleaning water pan roller and metering roller ................................................ B.9.24
6.2 Notes on maintaining the dampening distributor ........................................................... B.9.24
Delivery ........................................................................................................................................... B.10.1
1 Delivery - safety instructions ............................................................................................... B.10.7
1.1 To be observed when performing work .......................................................................... B.10.7
2 Operator protection through the protective device for the detection of whole body
access, DWBA ....................................................................................................................... B.10.10
2.1 What is the protective device for? .................................................................................. B.10.10
2.2 Arrangement of the light barriers ................................................................................... B.10.10
2.3 Control panels ................................................................................................................ B.10.11
2.4 Fault displays ................................................................................................................. B.10.13
2.5 Unlocking the DWBA when starting up the press .......................................................... B.10.14
2.6 Inserting strips and setting wedges with the DWBA ...................................................... B.10.14
2.7 Removing sample sheets with the DWBA ..................................................................... B.10.15
2.8 Pile change with the DWBA ........................................................................................... B.10.16
3 Guide pulleys ......................................................................................................................... B.10.19
3.1 Guide pulleys on the delivery ........................................................................................ B.10.19
3.2 Fields of application ....................................................................................................... B.10.20
3.3 Functioning principle of the locking device ................................................................... B.10.21
3.4 Fitting the guide pulley .................................................................................................. B.10.22
3.5 Positioning the guide pulleys ........................................................................................ B.10.24
3.6 Guide pulley with sheet supports .................................................................................. B.10.25
3.7 Removing a guide pulley ............................................................................................... B.10.26
B. 14 SC.999.0020/01
Main chapter overview
4 Cover plates on the delivery ................................................................................................ B.10.27
4.1 Function/Task ................................................................................................................ B.10.27
4.2 Cover plates on the sheet ascent ramp ........................................................................ B.10.27
4.3 Cover plates in the horizontal area ............................................................................... B.10.30
4.4 Cover plates behind CleanStar ..................................................................................... B.10.31
4.5 Cover plate before rows of fans ..................................................................................... B.10.34
4.6 Cleaning the sheet guide plate under the CleanStar .................................................... B.10.35
5 Air in the sheet ascent ramp ................................................................................................ B.10.36
5.1 Suction and blast air on the delivery .............................................................................. B.10.36
5.2 Control panels for the air settings ................................................................................. B.10.36
5.3 Mask on the Prinect Press Center ................................................................................. B.10.37
5.4 Recommended setting - transfer zone .......................................................................... B.10.38
5.5 Recommended setting - sheet ascent ramp area ......................................................... B.10.39
5.6 Recommended setting - extension area ....................................................................... B.10.39
5.7 Sheet decurler ............................................................................................................... B.10.40
6 Air in the pile area ................................................................................................................. B.10.41
6.1 General notes ................................................................................................................ B.10.41
6.2 Switching fans ON/OFF ................................................................................................ B.10.41
6.3 Adjusting the fans ......................................................................................................... B.10.42
6.4 Positioning the fans ....................................................................................................... B.10.43
6.5 Longitudinal blast tubes ................................................................................................ B.10.43
7 Powder spray device ............................................................................................................ B.10.44
7.1 Maintenance work .......................................................................................................... B.10.44
7.2 Powdering from below (optional) .................................................................................. B.10.44
8 Print-related notes on powdering ........................................................................................ B.10.45
8.1 Powder application - why is powdering necessary? ..................................................... B.10.45
8.2 Choosing the powder grain size and required powder .................................................. B.10.45
8.3 Disadvantages of powdering ......................................................................................... B.10.45
8.4 Required powder quality ............................................................................................... B.10.45
8.5 Factors that determine the powder volume ................................................................... B.10.46
8.6 To be observed during production ................................................................................ B.10.46
8.7 Powdering from below (optional) .................................................................................. B.10.46
8.8 Adjusting the stabilizing nozzles (optional) ................................................................... B.10.47
8.9 Checking the powder application .................................................................................. B.10.47
9 Format bridging device ......................................................................................................... B.10.49
9.1 Method of functioning and equipment ........................................................................... B.10.49
9.2 Setting the blast air ....................................................................................................... B.10.49
SC.999.0020/01 B. 15
Main chapter overview
9.3 Cleaning ........................................................................................................................ B.10.49
10 Sheet brake system - Overview and variants ..................................................................... B.10.51
10.1 Types ............................................................................................................................. B.10.51
10.2 Chapter overview ........................................................................................................... B.10.51
11 Modular sheet brake system - overview ............................................................................. B.10.52
11.1 Design and components ................................................................................................ B.10.52
11.2 Component overview ..................................................................................................... B.10.53
11.3 Overview of adjustments ................................................................................................ B.10.56
11.4 Recommended settings for air and speed ..................................................................... B.10.58
12 Modular sheet brake system - handling the sheet brake modules .................................. B.10.59
12.1 Module support .............................................................................................................. B.10.59
12.2 Entering the component setup on the control system .................................................... B.10.59
12.3 Setting the valve on the module support ........................................................................ B.10.61
12.4 Setting the sheet brakes at an angle ............................................................................. B.10.62
12.5 Inclining the brake modules ........................................................................................... B.10.63
12.6 Adjusting the friction wheel at the sheet brake module (tandem component setup) ...... B.10.64
12.7 Manually adjusting the position of the sheet brake module supports ............................ B.10.65
12.8 Removing/fitting a sheet brake module .......................................................................... B.10.66
12.9 Removing/fitting a starwheel module ............................................................................ B.10.68
12.10 Replacing starwheels ..................................................................................................... B.10.69
12.11 Replacing a sheet brake tape ........................................................................................ B.10.71
12.12 Maintenance / Cleaning ................................................................................................. B.10.71
12.13 Removing and fitting the sheet stop ............................................................................... B.10.72
12.14 Removing/fitting magnetic starwheel holders ................................................................ B.10.73
13 Modular sheet brake system - configuration variants for straight printing .................... B.10.75
13.1 General .......................................................................................................................... B.10.75
13.2 Standard component setup ............................................................................................ B.10.75
13.3 Maximum component setup for straight printing ............................................................ B.10.76
14 Modular sheet brake system - Component versions for straight printing and perfecting B.10.78
14.1 Component setup of the sheet brakes ........................................................................... B.10.78
14.2 Standard component setup ............................................................................................ B.10.79
14.3 Outer module supports in park position ......................................................................... B.10.80
14.4 Alternative component setup with 2 starwheel modules ................................................ B.10.81
14.5 Alternative population for small image-free area or small sheet size ............................. B.10.82
15 Modular sheet brake system - Remedies in the event of problems ................................. B.10.84
15.1 Remedies in the event of problems ............................................................................... B.10.84
B. 16 SC.999.0020/01
Main chapter overview
16 Suction tapes ......................................................................................................................... B.10.85
16.1 Properties ....................................................................................................................... B.10.85
16.2 Suction tapes for sheet brake modules - tape width 10 mm .......................................... B.10.86
16.3 Suction tapes for sheet brake modules - tape width 20 mm .......................................... B.10.86
17 Gripper opening cam ............................................................................................................. B.10.87
17.1 Function ......................................................................................................................... B.10.87
17.2 Setting the gripper opening cam ................................................................................... B.10.87
17.3 Interplay between gripper opening, sheet brake and delivery air .................................. B.10.88
18 Overrun sheet control ............................................................................................................ B.10.90
18.1 Method of functioning .................................................................................................... B.10.90
18.2 Ultrasonic sensor .......................................................................................................... B.10.90
18.3 Comb ............................................................................................................................ B.10.91
19 Sheet joggers ........................................................................................................................ B.10.92
19.1 Function ........................................................................................................................ B.10.92
19.2 Setting the lateral sheet joggers automatically ............................................................. B.10.92
19.3 Setting the lateral sheet joggers manually .................................................................... B.10.92
19.4 Setting the lateral sheet joggers to the sheet length ..................................................... B.10.94
19.5 Activating/deactivating the alignment movement of the lateral sheet joggers and at the
front edge ...................................................................................................................... B.10.95
20 Rear edge stop ...................................................................................................................... B.10.96
20.1 Function ........................................................................................................................ B.10.96
20.2 Setting the rear edge stop automatically ....................................................................... B.10.96
20.3 Setting the rear edge stop manually ............................................................................. B.10.97
20.4 Rear edge suction ......................................................................................................... B.10.98
21 CleanStar (option) ................................................................................................................. B.10.99
21.1 Function ........................................................................................................................ B.10.99
21.2 Operation ....................................................................................................................... B.10.99
21.3 Cleaning ......................................................................................................................... B.10.101
22 Removal of sample sheet ...................................................................................................... B.10.103
22.1 Function ........................................................................................................................ B.10.103
22.2 Removing sample sheets ............................................................................................... B.10.103
22.3 Removal of sample sheet with CleanStar ..................................................................... B.10.104
23 Tape inserter ........................................................................................................................... B.10.105
23.1 General information on tape inserter ............................................................................ B.10.105
23.2 Position of tape inserter ................................................................................................ B.10.105
SC.999.0020/01 B. 17
Main chapter overview
24 Tape inserter on face side .................................................................................................... B.10.106
24.1 Design and function ...................................................................................................... B.10.106
24.2 Notes on operating the tape inserter ............................................................................. B.10.106
24.3 Inserting/changing a tape roll ........................................................................................ B.10.107
24.4 Cleaning tape inserter ................................................................................................... B.10.108
25 Lateral tape inserter D.S. / O.S. ............................................................................................ B.10.109
25.1 Function and design ...................................................................................................... B.10.109
25.2 Information on operating the tape inserter .................................................................... B.10.109
25.3 Inserting/changing the tape roll ..................................................................................... B.10.110
25.4 Resetting the tape inserter ............................................................................................ B.10.112
25.5 Lifting/lowering the tape inserter ................................................................................... B.10.112
25.6 Removing the tape module and tape feeder ................................................................. B.10.113
25.7 Cleaning the tape inserter ............................................................................................. B.10.114
25.8 Malfunctions .................................................................................................................. B.10.114
26 Pile change ............................................................................................................................. B.10.117
26.1 Determining the actual size of the sheet ........................................................................ B.10.117
26.2 Function ........................................................................................................................ B.10.117
26.3 Pile control panel .......................................................................................................... B.10.118
26.4 Pile change ................................................................................................................... B.10.118
27 Non-stop operation ................................................................................................................ B.10.120
27.1 Function ........................................................................................................................ B.10.120
27.2 Equipment ...................................................................................................................... B.10.121
27.3 Sheet catcher in non-stop operation ............................................................................. B.10.122
27.4 Settings on the control station ........................................................................................ B.10.122
27.5 Recommended adjustments ......................................................................................... B.10.123
27.6 Checking the non-stop rake ........................................................................................... B.10.124
27.7 Manual non-stop operation ........................................................................................... B.10.124
27.8 Performing non-stop operation with non-stop rake ....................................................... B.10.126
27.9 Non-stop operation with rack board .............................................................................. B.10.127
27.10 Performing non-stop operation with rack board ............................................................. B.10.128
27.11 Non-stop pile changing with CleanStar .......................................................................... B.10.129
27.12 Elimination of malfunctions during non-stop pile changes ............................................ B.10.129
28 Automatic non-stop system ................................................................................................. B.10.132
28.1 Equipment ...................................................................................................................... B.10.132
28.2 Specifications ................................................................................................................. B.10.132
28.3 Determining the actual sheet size ................................................................................. B.10.133
28.4 Delivery control console ................................................................................................. B.10.133
B. 18 SC.999.0020/01
Main chapter overview
28.5 Recommended settings ................................................................................................ B.10.134
28.6 Overview of the functional sequence for an automatic pile change ............................... B.10.134
28.7 Overview of the functional sequence for a rack change ................................................ B.10.136
28.8 Troubleshooting for an automatic non-stop pile change ............................................... B.10.138
29 Print-related information on the auto-non-stop system (optional) ................................... B.10.140
29.1 Function ......................................................................................................................... B.10.140
29.2 Required checks before an automatic pile change ....................................................... B.10.140
30 Troubleshooting on the delivery ......................................................................................... B.10.142
30.1 Overview ........................................................................................................................ B.10.142
30.2 Sheet drop at front edge ................................................................................................ B.10.142
30.3 Sheet drop at rear edge ................................................................................................. B.10.142
30.4 Excessive shingling ........................................................................................................ B.10.143
30.5 Marks ............................................................................................................................. B.10.143
30.6 Pile formation ................................................................................................................. B.10.144
30.7 Sheet guide .................................................................................................................... B.10.145
Coating unit .................................................................................................................................. B.11.1
1 Coating unit - safety instructions ........................................................................................ B.11.5
1.1 To be observed when performing work .......................................................................... B.11.5
2 Coating unit - overview .......................................................................................................... B.11.9
2.1 Coating unit ................................................................................................................... B.11.9
2.2 Varnish circulation ......................................................................................................... B.11.9
3 Print-related notes on coating ............................................................................................. B.11.11
3.1 Pressure ......................................................................................................................... B.11.11
3.2 Jacket ............................................................................................................................. B.11.11
3.3 Print length adjustments ................................................................................................ B.11.11
3.4 Varnish application ......................................................................................................... B.11.11
3.5 UV varnish ..................................................................................................................... B.11.11
3.6 Powder ........................................................................................................................... B.11.12
4 Coating blanket cylinder with combination clamping rails ............................................... B.11.13
4.1 Coating blanket/coating plate and packing sheet .......................................................... B.11.13
4.2 Preparing packing sheet ............................................................................................... B.11.15
4.3 Selecting a control panel and throwing on the pressing roller ....................................... B.11.17
4.4 Mounting/demounting the coating blanket .................................................................... B.11.18
4.5 Mounting/demounting the coating plate ........................................................................ B.11.24
SC.999.0020/01 B. 19
Main chapter overview
5 Positioning corrections on the coating blanket cylinder with combination clamping rails
................................................................................................................................................. B.11.31
5.1 Print length adjustment for coating plates ...................................................................... B.11.31
5.2 Positioning corrections on the coating plate .................................................................. B.11.31
6 Pressing roller ....................................................................................................................... B.11.36
6.1 Place of installation / function ........................................................................................ B.11.36
6.2 Removing/fitting the pressing roller ................................................................................ B.11.37
6.3 Cleaning ........................................................................................................................ B.11.38
7 Notes on treatment of the screen roller .............................................................................. B.11.39
7.1 Bearing .......................................................................................................................... B.11.39
7.2 Transport ....................................................................................................................... B.11.39
7.3 Cleaning ........................................................................................................................ B.11.39
8 Screen roller .......................................................................................................................... B.11.40
8.1 Function ......................................................................................................................... B.11.40
8.2 Notes on cleaning the screen roller .............................................................................. B.11.40
8.3 Removing screen roller ................................................................................................. B.11.41
8.4 Installing screen roller ................................................................................................... B.11.46
9 Fitting/removing rolling bearings ........................................................................................ B.11.51
9.1 Changing bearings on screen rollers and metering rollers ........................................... B.11.51
9.2 Removing the rolling bearing from the trunnion ............................................................. B.11.51
9.3 Fitting the rolling bearings on the trunnion ..................................................................... B.11.52
10 Chambered blade and pressurized chambered blade ....................................................... B.11.53
10.1 Overview ........................................................................................................................ B.11.53
10.2 Function ........................................................................................................................ B.11.54
10.3 Preparing the chambered blade .................................................................................... B.11.57
10.4 Installing the coating pan .............................................................................................. B.11.61
10.5 Fitting the chambered blade ......................................................................................... B.11.63
10.6 Coating operation .......................................................................................................... B.11.63
10.7 Cleaning the chambered doctor blade and the coating unit .......................................... B.11.66
10.8 Removing the chambered blade ................................................................................... B.11.68
10.9 Cleaning the chambered blade ..................................................................................... B.11.68
10.10 Removing the coating pan ............................................................................................ B.11.69
10.11 Outlet tube on the pressurized chambered blade ......................................................... B.11.70
10.12 Adjusting the chambered blade to the screen roller ...................................................... B.11.70
11 Screen rollers of spraying device (option) ......................................................................... B.11.78
11.1 Function/Task ................................................................................................................ B.11.78
11.2 Activating/deactivating the spraying device ................................................................... B.11.78
B. 20 SC.999.0020/01
Main chapter overview
11.3 Cleaning ......................................................................................................................... B.11.79
11.4 Installation location and function .................................................................................... B.11.79
11.5 Components ................................................................................................................... B.11.80
11.6 Requirements of the water ............................................................................................. B.11.80
11.7 Replacing canister ........................................................................................................ B.11.80
11.8 Commissioning ............................................................................................................. B.11.82
12 CoatingStar varnish supply unit .......................................................................................... B.11.83
12.1 Features ........................................................................................................................ B.11.83
12.2 Varnish circulation ......................................................................................................... B.11.83
12.3 Control panels ............................................................................................................... B.11.84
12.4 Setting the pumping capacity (flow rate) ....................................................................... B.11.84
12.5 Tips on optimum cleaning results ................................................................................. B.11.84
12.6 Manual cleaning with washing fluid only ....................................................................... B.11.86
12.7 Manual cleaning with washing fluid and fresh water ..................................................... B.11.87
12.8 Automatic cleaning process with a cleaning program ................................................... B.11.88
12.9 Interrupting/aborting the cleaning process .................................................................... B.11.88
12.10 Recording a cleaning program using the recorder function .......................................... B.11.89
13 CoatingStar Compact varnish supply unit ......................................................................... B.11.90
13.1 Features ........................................................................................................................ B.11.90
13.2 Varnish circulation ......................................................................................................... B.11.90
13.3 Control panels ............................................................................................................... B.11.91
13.4 Setting the pumping capacity (flow rate) ....................................................................... B.11.92
13.5 Tips on optimum cleaning results ................................................................................. B.11.93
13.6 Manual cleaning with washing fluid ............................................................................... B.11.94
13.7 Semi-automatic cleaning with cleaning program .......................................................... B.11.94
13.8 Interrupting/aborting the cleaning process .................................................................... B.11.95
14 Coating unit with 2 varnish circulation systems (optional) .............................................. B.11.96
14.1 Varnish separation ......................................................................................................... B.11.96
Dryer ................................................................................................................................................ B.12.1
1 Dryer - Safety Instructions .................................................................................................... B.12.3
1.1 To be observed when performing work .......................................................................... B.12.3
2 Dryers in the units (optional) ............................................................................................... B.12.5
2.1 General notes ................................................................................................................ B.12.5
2.2 Overview (example) ...................................................................................................... B.12.6
2.3 Switching on the dryer .................................................................................................. B.12.6
2.4 Removing/fitting the interdeck dryer ............................................................................. B.12.7
2.5 Y dryer .......................................................................................................................... B.12.9
SC.999.0020/01 B. 21
Main chapter overview
2.6 Cleaning the interdeck dryer and the Y dryer ............................................................... B.12.9
2.7 Adjusting the sheet guide straps ................................................................................... B.12.10
3 UV interdeck dryer (optional) ............................................................................................... B.12.11
3.1 General information about UV interdeck dryers ............................................................ B.12.11
3.2 Adjusting the sheet guide straps ................................................................................... B.12.11
4 Dryers in the delivery (optional) .......................................................................................... B.12.13
4.1 Delivery versions ............................................................................................................ B.12.13
4.2 Variants and drying principle ......................................................................................... B.12.13
4.3 Switching on the dryer .................................................................................................. B.12.14
4.4 Removing and cleaning the slide-in dryer ..................................................................... B.12.14
4.5 Fitting the slide-in dryer ................................................................................................. B.12.16
4.6 Operation without slide-in dryers .................................................................................. B.12.16
5 Print-related notes on the dryer ........................................................................................... B.12.17
5.1 Pile temperature ............................................................................................................. B.12.17
5.2 Temperature measurement in the pile ........................................................................... B.12.17
5.3 Dryer output ................................................................................................................... B.12.17
5.4 Recommended settings ................................................................................................. B.12.18
5.5 Air circulation in the press room ..................................................................................... B.12.19
B. 22 SC.999.0020/01
Overview of touch screen control panels
Overview of touch screen control panels
panels
control
screen
touch
of
Overview
1 Touch screen overview ........................................................................................................ B.1.3
1.1 Basic information ........................................................................................................... B.1.3
1.2 Place of installation ........................................................................................................ B.1.3
1.3 Function/Task ................................................................................................................ B.1.3
1.4 Feeder touch screen, header ........................................................................................ B.1.4
1.5 Printing unit/coating unit touch screen, header ............................................................. B.1.4
1.6 Delivery touch screen, header ...................................................................................... B.1.5
1.7 Heidelberg button .......................................................................................................... B.1.5
1.8 Main field ....................................................................................................................... B.1.6
1.9 Footer/status display ..................................................................................................... B.1.6
SC.999.0020/01 B.1.1
Overview of touch screen control panels
B.1.2 SC.999.0020/01
Overview of touch screen control panels
1 Touch screen overview
SF.901.2009-000UTKENU_03
1.1 Basic information
Caution - Risk of damaging the touch
screen with self-adhesive protective
film
Never stick any protective film on the
touch screen. The glass surface of the
touch screen must be bare to enable the
system to sense the exact contact point
during operation. A protective film im-
pairs the function of the touch screen.
The glass surface can be damaged
when you peel off a self-adhesive pro-
tective film.
Note
The following figures show the maximum
configuration of touch screens. The rep-
resentation on the touch screens of your
press can be different. Number and lo-
cation of the buttons,and the sheet size
specifications can differ.
1.2 Place of installation
Your press is operated via various touch-sensitive ar-
eas, so-called touch screens. These are located on the
control station, feeder, delivery and on the printing unit
or coating unit, depending on the configuration of your
press. One touch screen each is located on the feeder
side and delivery side of the first printing unit and on
the coating units on D.S. The press is operated using
menus. The display is divided into 3 sections:
● Header
● Main section
● Footer, or status display
1.3 Function/Task
Feeder/delivery touch screen
FS.901.2043-002GRAUND_00
1 Header
The header always remains in the form shown,
1 regardless of the menu or window in the main
section. The button selected is highlighted.
2 Main section
2 The main section shows the selected menu.
3 Footer
The press status is indicated in the footer section.
3
Fig. 1 Delivery touch screen
SC.999.0020/01 B.1.3
Overview of touch screen control panels
Printing unit/coating unit touch screen
FS.901.1200-003GRAUND_00
1 Header
The header always remains in the form shown,
regardless of the menu or window in the main
1 section. The button selected is highlighted.
2 Main section
The main section shows the selected menu.
3 3 Status display
2
The press status is indicated in the footer section.
Fig. 2 Printing unit/coating unit touch screen
1.4 Feeder touch screen, header
FS.901.2059-011GRAENU_00
1 2
Fig. 3 Feeder touch screen, header
1 Header
2 Heidelberg button
Note
Please note that the headers on the
feeder, delivery and on the printing unit/
coating unit are different.
1.5 Printing unit/coating unit touch screen, header
FS.901.1204-011GRAENU_00
1 2
Fig. 4 PU/CU touch screen, header
1 Header
2 Heidelberg button
The header (Fig. 4) is the main navigation bar. Press-
ing one of the buttons in the header sections always
takes you to the top level of the respective menu. The
B.1.4 SC.999.0020/01
Overview of touch screen control panels
individual buttons in the header are explained in the
respective sections.
1.6 Delivery touch screen, header
FS.901.2059-001GRAENU_00
1 2
Fig. 5 Delivery touch screen, header
1 Header
2 Heidelberg button
1.7 Heidelberg button
1 Heidelberg button
FS.901.2059-021GRAENU_00
The Heidelberg button is a multifunctional button.
● press briefly
1 The background color changes from gray to
green. When you select a button, a help window
Calculator
2 opens.
● press and hold down for approx. 2 seconds
3 Screenshot A window opens in which you can start various
functions.
Note
Fig. 6 Heidelberg button The functions can vary on the different
touch screens.
2 Calculator
This Calculator button opens a calculator in the
current display. To close the calculator, press the
Back button in the calculator window.
3 Screenshot
Press this button to create a screenshot of the
current display of all screens (control station,
feeder/delivery display, ...). A Save screenshot
screen appears. When you press the OK button
in this window, all screenshots are saved on the
press computer. Heidelberg Service can view
these screenshots. This can be useful for trou-
bleshooting measures, for example. When you
press the Delete button in the Save screenshot
window, the screenshots are deleted and the
window closes.
SC.999.0020/01 B.1.5
Overview of touch screen control panels
1.8 Main field
In the main field you can operate the selected menus.
A detailed explanation of the individual menus can be
found in the respective chapters.
1.9 Footer/status display
FS.901.2046-002GRAUND_00
1 2 3 4 5 6 7
Fig. 7 Footer/status display
Footer
The status information is displayed in the footer.
1 Run length
Top: Number of sheets to be printed
Bottom: Number of sheets already printed
2 Printing speed
Top: Preset production speed
Bottom: Current press speed. At standstill or in
inching mode: Current angle position of the press
in degrees
3 Automatic procedures
Display of wash programs currently running, ink
presettings, etc.
4 Status display of the color measuring devices
Gray: The status display is inactive or there are
no measured values.
Green, yellow, red: Shows the status according
to the measured values and respective toler-
ances.
Note
You will see the display only if your press
is equipped with Inpress Control and a
Wallscreen.
5 Sheet infeed trend display
Left: monitoring of front edge
Right: monitoring of side edge
6 Service/maintenance required
7 Status of paper run, date, time.
The bars indicate the paper run from the feeder to
the delivery.
B.1.6 SC.999.0020/01
Overview of touch screen control panels
Status display
FS.901.1211-001GRAUND_00
1 The status display can be found on the printing unit/
coating unit touch screen. The following status infor-
mation is displayed there:
2 1 Printing speed status
The bars indicate the paper run from the feeder to
the delivery.
2 Sheet infeed trend display
3
Left: monitoring of front edge
Right: monitoring of side edge
3 Automatic processes with remaining time display
4 Lock/unlock control panel
4
Additional "Plate ready" display. This indicates
the correct feeding of the printing plate during an
automatic plate change.
Fig. 8 Status display
SC.999.0020/01 B.1.7
Overview of touch screen control panels
B.1.8 SC.999.0020/01
Control panels on the feeder
Control panels on the feeder
feeder
the
on
panels
Control
1 Feeder control panels ........................................................................................................... B.2.3
1.1 Control panels on the feeder .......................................................................................... B.2.3
1.2 Pile control control panel ............................................................................................... B.2.4
1.3 Control panel for Auto Non-Stop and Autopile (optional) pile control ........................... B.2.6
1.4 Control panel for Start control ....................................................................................... B.2.8
1.5 Air control control panel above the feeder touch screen ............................................... B.2.12
1.6 Touch screen and intercom ........................................................................................... B.2.12
1.7 Suction head control panel ........................................................................................... B.2.13
2 Feeder touch screen, overview ............................................................................................ B.2.14
2.1 Basic information ........................................................................................................... B.2.14
2.2 Place of installation ........................................................................................................ B.2.14
2.3 Function/task ................................................................................................................. B.2.15
3 Job menu on the touch screen ............................................................................................ B.2.17
3.1 Function ......................................................................................................................... B.2.17
3.2 Job tab .......................................................................................................................... B.2.17
3.3 Automatic job change tab ............................................................................................. B.2.18
3.4 Job queue tab ................................................................................................................ B.2.19
4 Production menu on the feeder touch screen .................................................................... B.2.23
4.1 Function ......................................................................................................................... B.2.23
4.2 The "Production" menu .................................................................................................. B.2.23
5 Feeder menu on the feeder touch screen ........................................................................... B.2.26
5.1 Function ......................................................................................................................... B.2.26
5.2 Feeder menu ................................................................................................................. B.2.26
6 Touch screen feeder menu - feeder pile ............................................................................. B.2.28
6.1 Function ......................................................................................................................... B.2.28
6.2 Feeder pile menu .......................................................................................................... B.2.28
7 Washup menu on the touch screen .................................................................................... B.2.30
7.1 Function ......................................................................................................................... B.2.30
7.2 Washup menu ................................................................................................................ B.2.30
8 Consumables display menu on the touch screen ............................................................. B.2.32
8.1 Function ......................................................................................................................... B.2.32
8.2 Consumables display menu ........................................................................................... B.2.32
8.3 Consumables information menu .................................................................................... B.2.33
SC.999.0020/01 B.2.1
Control panels on the feeder
9 Malfunction/Service menu on the touch screen ................................................................. B.2.35
9.1 Function ......................................................................................................................... B.2.35
9.2 Malfunction menu .......................................................................................................... B.2.35
9.3 Malfunction information menu ....................................................................................... B.2.36
9.4 Service menu ................................................................................................................ B.2.37
9.5 Paper run menu ............................................................................................................ B.2.38
B.2.2 SC.999.0020/01
Control panels on the feeder
1 Feeder control panels
SF.901.2000-000UTKENU_03
1.1 Control panels on the feeder
1 Auto-Non-Stop control panel
SF.901.1073-010GRAUND_00
2 Pile control panel
3 Start-up control panel
4 Touch screen
5 1 5 Air control panel
2
4
Fig. 1 Control panels on the feeder
SC.999.0020/01 B.2.3
Control panels on the feeder
1.2 Pile control control panel
SF.901.1805-010GRAUND_00
1 2 3
5 6
7 8
10
11
Fig. 2 Pile control panel
1 Suction head sheet size + (larger)
Moves the suction head away from the forward-
ing rollers.
2 Pile towards O.S.
"Manual" operating mode: Moves the active pile
towards O.S.
"Non-stop" operating mode: Moves the pile sup-
port plate towards O.S.
3 Pile towards D.S.
"Manual" operating mode: Moves the active pile
towards D.S.
"Non-stop" operating mode: Moves the pile sup-
port plate towards D.S.
4 Suction head sheet size - (smaller)
Moves the suction head towards the forwarding
rollers.
B.2.4 SC.999.0020/01
Control panels on the feeder
5 Auxiliary pile up (optional)
Moves the auxiliary pile upward as long as the
button is pressed.
6 Main pile up
Moves the main pile upward as long as the button
is pressed.
7 Auxiliary pile down (optional)
Moves the auxiliary pile downward as long as the
button is pressed.
8 Main pile down
Moves the main pile downward. The downward
movement stops approximately 12 cm above the
ground. Pressing the button again briefly moves
the pile support plate down to a distance of ap-
proximately 1 cm above the floor. Pile support
plate and pile support frame are centered and set
down to the floor.
9 Pile stop
Interrupts the movement of auxiliary pile and
main pile.
10 Malfunction
LED ON/blinks: A malfunction in the feeder pre-
vents the printing press from being put into oper-
ation.
11 Emergency stop button
Press the palm button: The printing press stops
immediately. The palm button is locked.
Twist the palm button: The locking is removed.
SC.999.0020/01 B.2.5
Control panels on the feeder
1.3 Control panel for Auto Non-Stop and Autopile (optional) pile control
SG.901.5948-010GRAUND_00
1 2 3
4 5
6 7
8 9
10 11
13
12
Fig. 3 Control panel for Auto Non-Stop and Autopile pile control
1 Autopile
Manual operation: Manual actuation of convey-
ing elements.
Only on presses with Autopile.
2 Move pallet forwards
Moves the pallet on the selected conveying ele-
ment forward.
3 Move pallet backwards
Moves the pallet on the selected conveying ele-
ment backward.
4 Selection of second axis
Selection of second moving axis (e.g. rotating
conveyor, buffer conveyor)
5 Reversal of direction of movement
B.2.6 SC.999.0020/01
Control panels on the feeder
If you push the button Reversal of direction of
movement, the residual pile will move back to the
transfer conveyor.
The LED at the button is on.
Note
The direction of movement remains this
way until you push the button again.
The LED at the button is off.
6 Preselection Automatic non-stop operation (op-
tional)
LED OFF: The "Automatic non-stop operation"
preselection is not active.
LED blinks: The preselection is active, but auto-
matic non-stop operation cannot be started. One
of the prerequisites (such as "Guards closed") is
not fulfilled.
LED ON: preselection is active. Automatic non-
stop operation starts when the residual pile
height is reached.
7 Pull rods out of the pile (optional)
The non-stop rods move to their home position.
8 Preselection Move rake manually (optional)
LED OFF: The "Move rake manually" preselec-
tion is not active.
LED blinks: The preselection is active, bus the
rods cannot be moved because one of the pre-
requisites is not fulfilled.
LED ON: The Pull rods out of the pile and Insert
rods into the pile buttons for manual rake move-
ment are enabled.
9 Insert rods into the pile (optional)
The non-stop rods move to the work position.
10 Open/close front side safety shutter
Opens/closes the safety shutter on the feeder
face side.
11 Open/close safety shutter D.S.
Opens/closes the safety shutter D.S. of the feed-
er.
12 Feeder free - reset
Pressing this push button with closed guards
confirms that there is nobody in the pile area of
the feeder. This enables automatic non-stop pile
change.
● The LED in the button shows the operating sta-
tus:
○ LED OFF: Front side safety shutter and/or
safety shutter D.S. are/is open.
○ LED blinks: The feeder guards are closed.
Pressing the pushbutton Feeder free - Re-
SC.999.0020/01 B.2.7
Control panels on the feeder
set enables you to actuate the automatic
non-stop pile change.
○ LED ON: The feeder guards are closed. The
Feeder free - reset button was pressed. The
automatic non-stop pile change is enabled.
13 Feeder pillar control panel locked
LED OFF: The safety shutters can be opened.
LED ON: Control panel disabled - the safety shut-
ters cannot be opened.
1.4 Control panel for Start control
SF.901.1094-010GRAUND_00
1 2 3 4 5 6 7 8
9 10 12 15
11 13
14
19
18
16 17
20 21 22
Fig. 4 Control panel, start-up control without Auto-Non-Stop
Start-up control panel
1 Production
● Press is not running:
○ Press once to sound the startup warning.
○ When pressed again: all selected functions
are activated.
○ Press three times to accelerate the press to
the preselected production speed.
● Press in operation:
○ Press once to activate all selected func-
tions.
○ Press twice to accelerate the press to the
preselected production speed.
Note
The compressor must be switched on.
2 Printing speed +
B.2.8 SC.999.0020/01
Control panels on the feeder
Increases the press speed continuously.
3 Run
Startup warning sounds.
When pressed again, the press starts up at min-
imum speed.
4 Feeder on
Switches the feeder automatically ON (LED is
ON) and OFF (LED is OFF).
5 Paper ON
Switches paper run ON (LED is ON) and OFF
(LED is OFF).
6 Lateral sheet separation blower sheet size +
The opposite lateral sheet separation blower
moves away from the pile. The lateral sheet sep-
aration blower on the pull side remains.
7 Pile towards D.S.
The active pile moves to D.S.
8 Suction head up
Moves the suction head outwards.
9 Stop
Stops the press.
When pressed during production: All functions for
the production run - except for the compressor -
are switched off.
Note
The compressor must be switched on.
10 Printing speed -
Reduces the press speed continuously.
11 Compressor
Switches the compressor ON (LED is ON) and
OFF (LED is OFF).
12 Dampening form roller ON/OFF
All preselected dampening form rollers are man-
ually thrown on (LED is ON) or OFF (LED is
OFF).
SC.999.0020/01 B.2.9
Control panels on the feeder
SF.901.1094-020GRAUND_00
1 2 3 4 5 6 7 8
9 10 12 15
11 13
14
24 19
18
16 17 23
20 21 25 26 22
Fig. 5 Control panel, start-up control with Auto-Non-Stop
13 Lateral sheet separation blower sheet size -
The opposite lateral sheet separation blower
moves towards the pile. The lateral sheet sepa-
ration blower on the pull side remains.
14 Pile towards O.S.
The active pile moves to O.S.
15 Suction head down
Automatic mode: Reduces the nominal value of
the height adjustment.
Manual mode: Moves the suction head down.
16 Inch forward
The startup warning signal sounds, afterwards
the press is inched forwards.
Prerequisite: The Control panel selection button
on the feeder is pressed.
17 Control panel selection
Press twice (LED ON): At this control panel, you
can move the press only in inching mode.
To cancel the selection: Press the button again
(LED is OFF).
18 Suction head sheet size - (smaller)
Moves the suction head towards the forwarding
rollers.
19 Suction head sheet size + (larger)
Moves the suction head away from the forward-
ing rollers.
20 Opening the front lay guard
Opens the front lay guard at the 1st printing unit.
B.2.10 SC.999.0020/01
Control panels on the feeder
21 Release sheet stop fingers
Raises the sheet stop fingers on the front lay
guard. Fixed sheets can now be removed from
the feed table.
22 Emergency-stop
The press stops immediately, and the palm but-
ton is locked.
Rotate the button clockwise: The lock is released.
Note
The start-up control panel with Auto
Non-Stop also contains buttons 23 to 26.
23 Preselection Automatic non-stop operation (op-
tional)
LED OFF: The "Automatic non-stop operation"
preselection is not active.
LED blinks: The preselection is active, but auto-
matic non-stop operation cannot be started. One
of the prerequisites (such as "Guards closed") is
not fulfilled.
LED ON: preselection is active. Automatic non-
stop operation starts when the residual pile
height is reached.
24 Pull rods out of the pile (optional)
The non-stop rods move to their home position.
25 Preselection Move rake manually (optional)
LED OFF: The "Move rake manually" preselec-
tion is not active.
LED blinks: The preselection is active, bus the
rods cannot be moved because one of the pre-
requisites is not fulfilled.
LED ON: The Pull rods out of the pile and Insert
rods into the pile buttons for manual rake move-
ment are enabled.
26 Insert rods into the pile (optional)
The non-stop rods move to the work position.
SC.999.0020/01 B.2.11
Control panels on the feeder
1.5 Air control control panel above the feeder touch screen
1 Lateral sheet separation blowers D.S.
SF.901.1077-000GRAUND_00
1 3 5 Adjusts the blast air volume of the lateral sheet
separation blowers D.S.
2 Lateral sheet separation blowers O.S.
Adjusts the blast air volume of the lateral sheet
separation blowers O.S.
3 Diagonal blowers D.S.
Adjusts the blast air volume of the diagonal blow-
ers D.S.
4 Diagonal blowers O.S.
Adjusts the blast air volume of diagonal blowers
O.S.
5 Guide plate
2 4 6 Adjusts the level of the guide plate.
Fig. 6 Air control panel 6 Pre-separation air
Adjusts the pre-separation air volume of the car-
rier air blowers and sheet separation blowers.
The pre-separation air is blown into the pile be-
fore sheet travel is switched on.
1.6 Touch screen and intercom
1 Touch screen
SF.901.1095-001GRAUND_00
1 2 Voice button
3 Control knob for the volume
4 Microphone
4 3 2
Fig. 7 Touch screen and intercom
B.2.12 SC.999.0020/01
Control panels on the feeder
1.7 Suction head control panel
1 Forwarding sucker O.S.
SF.901.1078-000GRAUND_00
Adjusts the height of the forwarding sucker O.S.
2 Inclination lifting sucker
Adjusts the inclination of the lifting suckers.
3 Rear edge blowers
Adjusts the blast air volume of the rear edge
blowers.
4 Inner carrier air blowers
10.109.5499/02
Adjusts the blast air volume of the inner carrier air
blowers.
1 2 3 4 5 6 7 8 5 Outer carrier air blowers
Adjusts the blast air volume of the outer carrier air
blowers.
Fig. 8 Suction head control panel
6 Sheet separation blower
Adjusts the blast air volume of the sheet separa-
tion blowers.
7 Lifting sucker displacement
Adjusts the stroke of the lifting movement.
8 Forwarding sucker D.S.
Adjusts the height of the forwarding sucker D.S.
SC.999.0020/01 B.2.13
Control panels on the feeder
2 Feeder touch screen, overview
SF.901.2004-000UTKENU_02
2.1 Basic information
Caution - Risk of damaging the touch
screen with self-adhesive protective
film
Never stick any protective film on the
touch screen. The glass surface of the
touch screen must be bare to enable the
system to sense the exact contact point
during operation. A protective film im-
pairs the function of the touch screen.
The glass surface can be damaged
when you peel off a self-adhesive pro-
tective film.
Note
The following figures show the maximum
configuration of touch screens. The rep-
resentation on the touch screens of your
press can be different. Number and lo-
cation of the buttons,and the sheet size
specifications can differ.
2.2 Place of installation
Note
The feeder touch screen control panel of
the XL 145/162 is located at PU1 (feeder
side O.S.).
The feeder touch screen control panel of
the XL 75/106 and the CX/SX 102 is lo-
cated at the feeder (O.S.).
B.2.14 SC.999.0020/01
Control panels on the feeder
2.3 Function/task
XG.901.0098-003GRAUND_00
2 3 4 5 6 7 8
10
11 12 13 14 15 16
Fig. 9 Touch screen control panel
Header
1 Header
The header remains unchanged at all times, re-
gardless of the menu selected. The button se-
lected is highlighted. The 6 icons in the header
(Fig. 9/2 ... 8) open the top level of the related
menu.
2 Job preparation menu
3 The "Production" menu
4 Feeder menu
5 Feeder pile menu
6 Washup menu
7 Consumables menu
8 Malfunction/Service menu
SC.999.0020/01 B.2.15
Control panels on the feeder
Main section
9 Main section
The main section displays the selected menu.
Footer
10 Footer
The footer displays the current status of the
press.
11 Run length
Top: Number of sheets to be printed
Bottom: Number of sheets already printed
12 Printing speed
Top: Preset production speed
Bottom: Current press speed. At standstill or in
inching mode: Current angle position of the press
in degrees
13 Automatic procedures
Display of wash programs currently running, etc.
14 Sheet infeed trend display
Left: monitoring of front edge
Right: monitoring of side edge
15 Service/maintenance required
16 Status of paper run, time, date
The bars indicate the paper run status.
B.2.16 SC.999.0020/01
Control panels on the feeder
3 Job menu on the touch screen
SF.901.2005-000UTKENU_03
3.1 Function
The Job menu contains the following tabs:
● Job menu
● Automatic job change tab
● Job queue tab
3.2 Job tab
FS.901.1101-002GRAUND_00
1
XXXXXXX
XXXXXXX
2
3
xxxx xxxxx xxxxx
4
5 6
Fig. 10 Job menu
1. Press the Job button (Fig. 10/1) in the banner
line.
2. Press the Job tab (Fig. 10/2).
The Job menu appears.
Buttons in the Job menu
Fig. 10 Designation Function
10/3 Display of job data Displays job number, job name and customer name.
10/4 Display of printing material properties Displays sheet size, paper manufacturer and straight printing
and perfecting properties of the preset paper.
10/5 Display of off-center deviation Displays the direction and extent of the off-center position.
10/6 Display of pull direction Displays the pull direction of the sheet on the feed table.
Tab. 1 Functions in the Job menu
SC.999.0020/01 B.2.17
Control panels on the feeder
3.3 Automatic job change tab
FS.901.1102-002GRAENU_00
1 3
Details
XXXXXXX
2 XXX 6
XXX
XXX
XXX 4
XXX
Confirm job
XXX
5 7
Fig. 11 Automatic job change tab
1. Press the Job button (Fig. 11/1) in the banner
line.
2. Press the Automatic job change tab (Fig. 11/2).
The Automatic job change menu appears.
Buttons in the "Automatic job change" menu
Fig. 11 Designation Function
11/3 Display of process steps Lists the current process steps.
11/4 Confirm job When selecting this process step, another Details selector
button appears (Fig. 11/6).
11/5 Optional - notes on process steps Displays optional detailed information on the corresponding
process steps.
11/6 Details When selecting this button, another window opens. This
contains information about the job that is ready to be ac-
cepted.
11/7 Setup operation with main drive The press emits a sound when this button is pressed for the
first time.
When pressed a second time, the control system carries out
the process steps shown in the Automatic job change tab in
the given order.
11/8 Delete Cancels the job change in progress.
Tab. 2 Functions in the "Automatic job change" menu
B.2.18 SC.999.0020/01
Control panels on the feeder
3.4 Job queue tab
Requirement
The Job queue tab is only displayed if
the machine is equipped with a
Wallscreen XL and Intellistart 2. The Job
queue shows up to 3 jobs. Ink changes,
stock changes and plate changes in the
upcoming jobs are displayed, allowing
you to prepare the required materials be-
fore the job change.
FS.901.1178-000GRAENU_00
1
Remaining time
2
3 6
Job number 4 5
Job name
Operation
Customer
Quantity
Planned waste
7
Format
Manufacturer
Straight printing
Perfecting
Fig. 12 Job queue tab - production
Display during production
1. Press the Job button (Fig. 12/1) in the banner
line.
2. Press the Job queue tab (Fig. 12/2).
The Job queue menu opens.
Fig. 12 Designation Function
12/3 Position number of the displayed job in the Corresponds to the numbering on the Wallscreen. The dis-
Intellistart job queue. play is limited to 3 jobs.
Yellow warning sign: Job parameters change while the job is
displayed (e.g. due to a change on the Wallscreen). The yel-
low warning sign disappears when you press the Position
number button.
Prepare: Shows that the next job requires different plates,
stock or a different color allocation. The job parameter list
shows the items you need to prepare for the next job.
SC.999.0020/01 B.2.19
Control panels on the feeder
Fig. 12 Designation Function
12/4 Use the Scroll button to go to the previous/next job. When the
first/last job is displayed, the Scroll button is gray and cannot
be selected.
Yellow warning sign: Signals that the parameters of a previ-
ous or following job have changed.
12/5 Job note Press the Job note button to display the job note.
If there is no job note, the button is gray and cannot be se-
lected.
12/6 Remaining time Production: Shows the estimated time to the end of the job
(remaining time).
12/7 List of job parameters This shows the job parameters.
Parameters are grayed out and not taken into account in a
job change if "Preserve machine settings" has been activat-
ed for them. This is possible for the following parameters:
press run, pull direction, paper, sheet size, manufacturer,
paper grade, straight printing, perfecting, grammage and
grain direction.
The displayed values are identical with the values on the
Wallscreen.
FS.901.1179-000GRAENU_00
1
2
4
Perfecting
5
3 Grammage
Direction of sheet travel
Pull direction
Unit 1
Unit 2 7
Unit 3
Unit 4
Unit 5
Unit 6 8
9
Fig. 13 Job queue tab - job change
Display during a job change
1. Press the Job button (Fig. 13/1) in the banner
line.
2. Press the Job queue tab (Fig. 13/2).
The Job queue menu opens.
B.2.20 SC.999.0020/01
Control panels on the feeder
Fig. 13 Designation Function
13/3 Position number of the displayed job in the Corresponds to the numbering on the Wallscreen. The dis-
Intellistart job queue. play is limited to 3 jobs.
Yellow warning sign: Signals that job parameters change
while the job is displayed (e.g. due to a change on the
Wallscreen). The yellow warning sign disappears when you
press the Position number button.
Prepare: The two curved arrows indicate that you must pre-
pare different plates, paper or colors for the next job. The job
parameters list shows what you have to prepare.
13/4 Use the Scroll button to go to the previous/next job. When the
first/last job is displayed, the Scroll button is gray and cannot
be selected.
Yellow warning sign: Signals that parameters of a previous or
following job have changed.
13/5 Job note Press the Job note button to display the job note.
If there is no job note, this button is gray.
13/6 Remaining time Job change: Shows the time remaining for the current oper-
ation. The displayed values are the same as the ones in the
Intelliguide widget on the Wallscreen.
13/7 List of job parameters This shows the job parameters.
Parameters are grayed out and not taken into account in a
job change if "Preserve machine settings" has been activat-
ed for them. This is possible for the following parameters:
press run, pull direction, paper, sheet size, manufacturer,
paper grade, straight printing, perfecting, grammage and
grain direction.
The displayed values are identical with the values on the
Wallscreen.
13/8 Prepare Is displayed if new paper or ink must be prepared for this job.
If Prepare is displayed in at least one line, the corresponding
symbol appears in the position number,
13/9 Plate change Is displayed if a new plate must be mounted for this job in the
corresponding unit. Plate removal is not indicated.
SC.999.0020/01 B.2.21
Control panels on the feeder
FS.901.1184-000GRAUND_00
1
Fig. 14 Display note
Display note
1. Press the Job button (Fig. 14/1) in the banner
line.
2. Press the Job queue tab (Fig. 14/2).
The Job queue menu opens.
3. Press the Note button (Fig. 14/3).
The job-specific notes are displayed.
4. Press the button (Fig. 14/4) to close the notes.
B.2.22 SC.999.0020/01
Control panels on the feeder
4 Production menu on the feeder touch screen
SF.901.2001-000UTKENU_02
4.1 Function
In the Production menu you can set all functions in the
area of the feeder and the 1st printing unit.
4.2 The "Production" menu
FS.901.1105-003GRAUND_00
1
2 3 4
5 6 7 8 10
9
19
18
11 12 13 14 15 16 17
Fig. 15 The "Production" menu
1. Press the Production button (Fig. 15/1) in the
header.
The Production menu appears.
Note
The display panels in the Production
menu show the set value in percent or
mm.
The + and - buttons, which can be found
below the values, increase or reduce the
corresponding values.
The individual buttons and menu functions are listed in
the following table.
Buttons in the Production menu
Fig. 15 Designation Function
15/2 Clear feeder Transports all sheets on the feed table forward to clear it.
15/3 Ionizing unit Switches the ionizing unit on or off.
SC.999.0020/01 B.2.23
Control panels on the feeder
Fig. 15 Designation Function
The button is highlighted when the ionizing unit is switched
on.
15/4 Print until pallet is empty The press does not stop when the specified number of
sheets has been printed. The press does not stop until the
pallet is empty.
15/5 Cardboard position Puts the separator rolls into the cardboard position.
Pressing the button again puts the separator rolls back into
the paper position.
15/6 Automatic pile alignment ON/OFF Switches the automatic pile alignment on or off.
The push button is highlighted when the automatic system is
switched on.
15/7 Suction tape bypass Opens a bypass which also reduces the set suction air vol-
ume at the suction tape.
15/8 Automatic blast air compensation Automatically adapts the blast air on the suction head to the
printing material properties defined in the control system.
15/9 Manual misalignment correction D.S. Corrects misaligned sheets in the shingle that are out of line
Manual misalignment correction O.S. on D.S. or O.S. in the direction of paper travel. The buttons
have no function if the automatic misaligned sheet correction
is active.
The degree value of the inclination appears in the display
below the buttons (control range: -10 to +10).
15/10 Automatic misalignment correction ON/OFF. Activates automatic misalignment correction.
Pressing the button again switches the automatic misalign-
ment correction off again.
15/11 Blowing/suction nozzle + Increases or reduces the blast air volume of the blowing/
Blowing/suction nozzle - suction nozzles.
15/12 Separator rolls up Increases or reduces the distance between the separator
Separator rolls down rolls and the feed table.
15/13 Suction air setting on the suction drive roller Increases or reduces the suction air on the suction drive
roller.
15/14 Pull distance correction toward D.S. Moves the active pile toward D.S. or O.S.
Pull distance correction toward O.S.
15/15 Suction air setting on the pull rail Increases or reduces the suction air on the pull rail.
15/16 Suction tape + Increases or reduces the suction air volume of the suction
Suction tape - tape.
15/17 Blast air on the suction head + The buttons work with active and inactive blast air compen-
Blast air on the suction head - sation.
Control range if blast air compensation is switched on: 20 %
to 100 %.
Control range if blast air compensation is switched off: 0 % to
100 %.
15/18 Manual sheet arrival control Corrects the sheet arrival in or against the direction of paper
travel. The buttons have no function if the automatic sheet
arrival control is active.
B.2.24 SC.999.0020/01
Control panels on the feeder
Fig. 15 Designation Function
The automatic sheet arrival control display appears in the
display below the buttons (control range: -6 to +12)
15/19 Automatic sheet arrival control Switches on the automatic sheet arrival control.
Pressing the button again switches the automatic sheet ar-
rival control off again.
Tab. 5 Functions in the Production menu
SC.999.0020/01 B.2.25
Control panels on the feeder
5 Feeder menu on the feeder touch screen
SF.901.2002-000UTKENU_01
5.1 Function
You can make the following settings in the Feeder
menu:
● Throw the suction brush on and off.
● Adjust the front lays.
● Throw the front lays on and off.
5.2 Feeder menu
FS.901.1106-001GRAUND_00
1
2 3
5 6
Fig. 16 Feeder menu
1. Press the Feeder button (Fig. 16/1) in the header.
The Feeder menu appears.
Pushbuttons in the Feeder menu
Fig. Designation Function
16
16/2 Suction brush on/off Sets the suction brush to work position (on) or home position
(off).
16/3 Front lay deflection Sets the front lay deflection in or against the direction of pa-
per travel. The value between the arrow buttons indicates the
set deflection in mm.
16/4 Adjusting the cover guide height manually Adjusts the cover guide to the desired height. The set value
is displayed above.
To increase the cover guide height: Icon button
To reduce the cover guide height: - button
B.2.26 SC.999.0020/01
Control panels on the feeder
Fig. Designation Function
16
Control range: 0.10 mm ... 1.90 mm.
16/5 Setting front lay Adjusts the front lays at an angle or parallel, in or against the
direction of sheet travel.
● Upper pair of arrows: Adjustment on D. S in/against the
direction of sheet travel.
● Middle pair of arrows: Parallel adjustment on D.S. and
O.S. in/against the direction of sheet travel.
● Lower pair of arrows: Adjustment on O.S. in/against the
direction of sheet travel.
The value between the arrow buttons indicates the set posi-
tion in mm.
16/6 Sheet trend display Displays the setting of the automatic sheet arrival control and
the automatic misalignment correction.
The sheet moves relative to the vertical line, depending on
the setting.
Tab. 6 Functions in the Feeder menu
SC.999.0020/01 B.2.27
Control panels on the feeder
6 Touch screen feeder menu - feeder pile
SF.901.2003-000UTKENU_02
6.1 Function
The Feeder pile menu permits the following settings to
be made:
● Adjusting the pile position horizontally.
● Changing the pile stroke.
● Changing the height regulation of the front edge
of the pile.
● Adjusting the blast air at the suction head.
6.2 Feeder pile menu
FS.901.1107-002GRAUND_00
1
11 10 9
2 3 4 5 6 7 8
Fig. 17 Feeder menu
1. Press the Feeder pile button (Fig. 17/1) in the
header.
The Feeder pile menu appears.
Buttons in the feeder pile menu
Fig. Designation Function
17
17/2 Pull distance correction toward D.S. Use the arrow key to adjust the position of the pile with re-
Pull distance correction toward O.S. spect to the pull lay. The reading above specifies the dis-
tance in mm. The black arrow shows the direction.
Moves the active pile toward D.S. or O.S.
17/3 Lateral sheet separation blower sheet size -/+ Only display function; the size is selected at the control sta-
tion.
B.2.28 SC.999.0020/01
Control panels on the feeder
Fig. Designation Function
17
17/4 Pile to D.S. or O.S. Only display function; the size is selected at the control
panel on the feeder.
17/5 Pile lifting increment Is adjusted automatically when you enter the thickness of
printing material. You can change the value via the buttons.
The control range is 0,5 ... 2.5 mm.
17/6 Suction head up/down Only display function; the size is selected at the control
panel on the feeder.
17/7 Suction head format -/+ Only display function; the size is selected at the control sta-
tion.
17/8 Blast air on the suction head + The buttons work with active and inactive blast air compen-
Blast air on the suction head - sation.
Control range with active blast air compensation: 20 % ...
100 %.
Control range with inactive blast air compensation: 0 % ...
100 %.
17/9 Automatic blast air compensation Automatically adapts the blast air on the suction head to the
printing material properties defined in the control system.
17/10 Automatic pile height control, front edge This button enables you to switch pile height control ON /
ON/OFF OFF.
17/11 Automatic pile alignment ON/OFF The pile is aligned with respect to the pull lay.
Tab. 7 Functions in the feeder pile menu
SC.999.0020/01 B.2.29
Control panels on the feeder
7 Washup menu on the touch screen
SF.901.2006-000UTKENU_01
7.1 Function
In the Washup menu you can select the following
functions:
● Blanket washup.
● Impression cylinder washup.
● Assign prewashup procedure with water prior to
washup procedure.
7.2 Washup menu
XG.901.0104-003GRAUND_00
1
10
9 8 7
Fig. 18 Washup menu
1. Press the Washup button (Fig. 18/1) in the head-
er.
The Washup menu appears.
Buttons in the Washup menu
Fig. 18 Designation Function
18/2 Scroll For more than 8 units or group display, you can scroll forward
using the arrow buttons.
18/3 Blanket washup sum button Selects or deselects blanket washup for all printing units.
18/4 Blanket water program sum button Selects or deselects prewashup procedure for all printing
units for removal of powder, paper dust and coating using
water.
18/5 Impression cylinder washup sum button Selects or deselects impression cylinder washup for all print-
ing units.
B.2.30 SC.999.0020/01
Control panels on the feeder
Fig. 18 Designation Function
18/6 Impression cylinder water program sum but- Selects or deselects prewashup procedure for all printing
ton units for removal of powder, paper dust and coating using
water.
18/7 Delete Cancels the wash program.
18/8 Setup operation with main drive The press emits a sound when this button is pressed for the
first time.
The second time it is pressed, the control system performs
the wash programs in the preselected printing units.
18/9 Duration of the entire washup procedure The duration is displayed in minutes. A green bar indicates
the progress of the washup procedure.
18/10 Printing unit buttons Selects or deselects individual printing units for the selected
washup procedure or water program.
Washup procedure: Selected buttons are highlighted.
Water program: Selected buttons are displayed with a white
dot in the middle.
Tab. 8 Functions in the Washup menu
SC.999.0020/01 B.2.31
Control panels on the feeder
8 Consumables display menu on the touch screen
SF.901.2007-000UTKENU_01
8.1 Function
The Consumables display menu shows consum-
ables for which the stocks are running low. All con-
sumables monitored by the control system are mea-
sured. These include, for example:
● Dampening solution
● Washing fluid
● Water
● Cleaning cloths for BWD and ICWD
● Anti set-off powder
● Inks
8.2 Consumables display menu
XG.901.0123-010GRAUND_00
1
2 3
4 5 6
Fig. 19 Consumables display menu
1. Press the Consumables display button
(Fig. 19/1) in the header.
The Consumables display menu appears.
Fig. 19 Designation Function
19/2 Display consumable - e.g. "Dampening so- Shows a list of consumables for which stocks are running
lution" low.
19/3 Display fault position Indicates the location of the consumable for which supplies
are running low, e.g. "Printing unit x".
19/4 Further information (if the Consumables dis- Opens the Consumables information menu.
play was previously activated)
B.2.32 SC.999.0020/01
Control panels on the feeder
Fig. 19 Designation Function
The display shows further information on the consumable
selected from the list.
19/5 Scroll up Scroll up through the list of consumables.
19/6 Scroll down Scroll down through the list of consumables.
Tab. 9 Functions in the Consumables display menu
8.3 Consumables information menu
XG.901.0107-010GRAUND_00
1
4 5
Fig. 20 Consumables information menu
1. Press the Consumables display button
(Fig. 20/1) in the header. The Consumables
display menu appears (Fig. 19).
2. Select the relevant line.
Note
If there is a yellow i next to the line, ad-
ditional information is available.
3. Press the Further information button (Fig. 20/2).
The Consumables information menu appears.
Fig. 20 Designation Function
20/3 Consumables display Displays the selected consumable.
20/4 Consumables information Further information on the consumable and measures for
replenishing stocks of the consumable appear in this display.
SC.999.0020/01 B.2.33
Control panels on the feeder
Fig. 20 Designation Function
20/5 Back The system returns to the Consumables display menu.
20/6 Arrow keys If more malfunctions are indicated than fit in the text box, you
need to press the arrow buttons to display them.
Tab. 10 Functions in the Consumables information menu
B.2.34 SC.999.0020/01
Control panels on the feeder
9 Malfunction/Service menu on the touch screen
SF.901.2008-000UTKENU_02
9.1 Function
● The Malfunction menu gives you an overview of
any malfunctions on the press.
● In the Service menu you can calibrate the touch
screen and lock it against being operated. Acti-
vate the training mode, activate/deactivate the
double sheet detectors at the feeder and switch
off the press.
9.2 Malfunction menu
XG.901.0105-010GRAUND_00
1
3 4 5 6 7
Fig. 21 The Malfunction menu
1. Press the Malfunction button (Fig. 21/1) in the
header.
The Malfunction menu appears.
Fig. 21 Designation Function
21/2 List of malfunctions Display range for current error messages.
21/3 History Shows the last 30 malfunctions on the press.
21/4 Malfunction information (acknowledgeable Opens the Malfunction information menu.
malfunctions)
21/5 Scroll up Scroll up through the list of malfunctions.
21/6 Scroll down Scroll down through the list of malfunctions.
21/7 Service Opens the Service menu.
Tab. 11 Functions in the Malfunction menu
SC.999.0020/01 B.2.35
Control panels on the feeder
9.3 Malfunction information menu
XG.901.0144-010GRAUND_00
1
2 3
5 6
Fig. 22 Malfunction information menu
1. Press the Malfunction button (Fig. 22/1) in the
header.
The Malfunction menu appears (Fig. 21).
2. Press the Malfunction information pushbutton
(Fig. 22/2).
The Malfunction information menu appears
(Fig. 22).
Fig. 22 Designation Function
22/3 Error message Display of marked error message.
22/4 Malfunction information This area of the display shows additional information and
possible measures for rectifying the malfunction.
22/5 Acknowledge malfunction Acknowledges the displayed malfunction. The function is on-
ly available as an option.
22/6 Back The system returns to the Malfunction menu.
Tab. 12 Functions in the Malfunction information menu
B.2.36 SC.999.0020/01
Control panels on the feeder
9.4 Service menu
XG.901.0106-010GRAENU_00
1
3 4 5
8
6 7
Switch off
press
xxxx
xxxxxxxx 9
Fig. 23 Service menu
1. Press the Malfunction button (Fig. 23/1) in the
header.
The Malfunction menu appears.
2. Press the Service button (Fig. 23/2).
The Service menu appears (Fig. 23).
Fig. 23 Designation Function
23/3 Training mode Following a confirmation prompt, the control system switch-
es to training mode. In training mode, the operator can press
all navigation buttons on the touch screen. The function but-
tons cannot be operated.
To deactivate the function, press Training mode again.
23/4 Lock control panel (Screen cleaning mode) Locks the touch screen, e.g. for cleaning of the touch screen
surface.
Lock touch screen: Press the Lock control panel pushbutton.
To release the touch screen: Press the Lock control panel
button and cancel the locking function by pressing the Lock
control panel button twice in the following submenu.
23/5 Paper run Opens the Paper run menu.
23/6 Calibrate touch screen The touch screen is calibrated when the pushbutton is
pressed.
23/7 Software version Shows the currently installed press software version.
23/8 Switch off the press Following a safety prompt, the control system switches off
the press and the control station.
23/9 Back The system returns to the Malfunction menu.
Tab. 13 Functions in the Service menu
SC.999.0020/01 B.2.37
Control panels on the feeder
9.5 Paper run menu
XG.901.0121-010GRAUND_00
1
4 5 6
Fig. 24 Service/paper run menu
1. Press the Malfunction button (Fig. 24/1) in the
header.
The Malfunction menu appears.
2. Press the Service button (Fig. 24/2).
The Service menu appears.
3. Press the Paper run button (Fig. 24/3).
The Service/paper run menu appears.
Fig. 24 Designation Function
24/4 Ultrasonic double sheet detector Switches the ultrasonic double sheet detector on or off. The
normal setting is on.
24/5 Multiple sheet detector Switches the multiple sheet detector on or off. The normal
setting is on.
24/6 Ultrasonic sheet drag monitor Switches the sheet drag monitor on or off. The normal setting
is on.
24/7 Back The system returns to the Service menu.
Tab. 14 Functions in the Service/Paper run menu
B.2.38 SC.999.0020/01
Control panels on the feeder
When a multiple sheet detector is deactivated, a warn-
XG.901.0122-010GRAENU_00
ing message (Fig. 25/1) appears. The warning mes-
sages vary according to the multiple sheet detector or
double sheet detector that has been deactivated.
! Please adhere to the corresponding warning mes-
1 Multiple sheet detector deactivated, risk of severe press sages.
damage! In case of shutdown due to malfunctions,
inform the Heidelberg Service! Insofar as possible
activate the optional tear-off detector! Please observe
Note
the operating manual!
Please note that you cannot switch off
the multiple sheet detector and ultrason-
ic double sheet detector at the same
time. One of the two detectors is always
active.
Fig. 25 Warning message, e.g. multiple sheet de-
tector
SC.999.0020/01 B.2.39
Control panels on the feeder
B.2.40 SC.999.0020/01
Control panels on the printing unit/coating unit
Control panels on the printing unit/coating unit
unit
unit/coating
printing
the
on
panels
Control
1 Intelliline operator assistance .............................................................................................. B.3.3
1.1 Function/Task ................................................................................................................ B.3.3
1.2 Cleaning the LED bar and LED element ....................................................................... B.3.4
2 Printing unit control panels ................................................................................................. B.3.5
2.1 Control panel on first printing unit ................................................................................. B.3.5
2.2 Printing unit O.S. ........................................................................................................... B.3.6
2.3 Printing unit D.S. ........................................................................................................... B.3.8
2.4 Dampening system O.S. ............................................................................................... B.3.8
3 Coating unit control panels .................................................................................................. B.3.9
3.1 Coating unit O.S., delivery side ...................................................................................... B.3.9
3.2 Coating unit O.S., feeder side ........................................................................................ B.3.12
3.3 Coating unit D.S. ............................................................................................................ B.3.14
3.4 Coating unit, manual control panel ................................................................................ B.3.15
4 Control panels of intermediate unit ..................................................................................... B.3.17
4.1 Intermediate unit on O.S. on delivery side ..................................................................... B.3.17
4.2 Intermediate station on D.S. on delivery side ................................................................ B.3.18
SC.999.0020/01 B.3.1
Control panels on the printing unit/coating unit
B.3.2 SC.999.0020/01
Control panels on the printing unit/coating unit
1 Intelliline operator assistance
SF.901.2220-000UTKENU_03
1.1 Function/Task
SF.901.2045-000GRAUND_00
1 1 1 1 1 1
Fig. 1 LED bars on O.S. (example)
Note
The LED bars on the printing unit guards
are an optional device.
The "Intelliline" operator assistance is an operating
status display that works with light-emitting diodes. An
LED bar is installed on every coating unit/printing unit
guard at O.S. (Fig. 1/1). There are LED elements on
D.S. (Fig. 2/1).
The LED bars light up in different colors, depending on
the indicated operation.
Colors of LED bars
● Gray: Machine start/start procedure
● Blue: Production
● Green: Automatic setup processes
● Yellow: Manual attention required
When the press is off, the LEDs are black.
Types of signal
The LED bars can either light up permanently (con-
stant brightness) or light up intermittently (changing
brightness).
When does the LED bar light up intermittently?
The bar lights up alternately blue and yellow if there is
an upcoming job change in production and the new
plate in the printing or coating unit is not yet ready.
SC.999.0020/01 B.3.3
Control panels on the printing unit/coating unit
The LED elements on the D.S. guards use colors to
SF.901.2046-000GRAUND_00
indicate the same procedure as is indicated on the
1 1 LED bars on the O.S.
The LED elements D.S. also light intermittently in ac-
cordance with the plate status for a new print job.
Fig. 2 LED elements on the D.S. guards (exam-
ple)
1.2 Cleaning the LED bar and LED element
Only clean the LED bars and the LED elements with
the approved cleaning agents.
Please observe the specifications on washing fluids
documented in the "Maintenance and cleaning" man-
ual.
Caution - Damage to the LED bars and
LED elements!
Only clean the LED bars and the LED
elements with a damp cloth.
Do not spray the LED bars and the LED
elements.
Do not lay cloths soaked in cleaning
agents on the LED elements.
B.3.4 SC.999.0020/01
Control panels on the printing unit/coating unit
2 Printing unit control panels
SG.901.0202-000UTKENU_10
2.1 Control panel on first printing unit
1 Inch forward
SG.901.5075-001GRAUND_00
Startup warning sounds. The press rotates for-
ward. Condition: The control panel has been se-
lected.
1 2 3 2 Control panel selection
Press 2-times. The LED is on. The press can only
be moved in inching mode with or without travel
4 5 limitation. To cancel the selection: Press the but-
ton twice again. LED off.
6 7 3 Inch backward
Startup warning sounds. The press rotates back-
8 ward. Condition: The control panel has been se-
lected.
9 4 Malfunction
LED ON: Printing unit has a malfunction.
5 Release sheet stop fingers
10
Lifts the sheet stop finger. You can pull out the
sheets at the infeed.
6 Wash dampening rollers
Fig. 3 Control panel of first printing unit
When pressed with open protection grid: Water
pan roller and metering roller rotate at washup
speed. If actuated during operation: Overdamp-
ening.
7 Engage dampening rollers
LED ON: Dampening form roller and metering
roller are thrown on. The water pan roller does
not rotate.
8 Bowing of front lay shaft
Deflects front lay shaft in the direction of paper
travel.
9 Bowing of front lay shaft
Deflects front lay shaft opposite the direction of
paper travel.
10 Emergency stop button
Press stops immediately. The palm button is
locked. To release the lock: Turn the palm button
clockwise.
SC.999.0020/01 B.3.5
Control panels on the printing unit/coating unit
2.2 Printing unit O.S.
1 Inch forward
SG.901.0266-004GRAUND_00
Startup warning sounds; printing press rotates
forward. Condition: The control panel has been
selected.
2 Control panel selection
1 3 Press the push button twice: The press can only
2 be moved in inching mode with or without travel
limitation (LED is ON). To cancel the selection:
4
Press the push button twice again (LED is OFF).
Caution - Risk of press damage!
You must only perform backwards inch-
5 7 ing or positioning when there are no print
sheets left in the press. Paper-guiding
6 cylinders and grippers could be dam-
aged when the press contains print
8 14 sheets.
3 Inch backward
Startup warning sounds; printing press rotates
9 15 backward. Condition: The control panel has been
10 selected.
4 Crawl speed
11 12 Startup warning sounds. The press rotates slowly
at reduced speed. Condition: The control panel
has been selected.
13 5 Inking form rollers on/off
Throws the inking form roller in each printing unit
on (LED ON) or off (LED OFF).
6 Faults
The signal lamp indicates that there is a malfunc-
Fig. 4 Control panel O.S. delivery side tion in the printing unit.
7 Ink vibrator on/off
Throws the ink vibrator on each printing unit on
(LED ON) or off (LED OFF).
8 Position
Startup warning sounds. Press runs at crawl
speed; the plate cylinder of the respective print-
ing unit turns to the position for plate removal.
The press stops.
Condition: The control panel has been selected.
9 Plate removal/mounting
The printing unit switches to print mode with the
arriving plate; in other words, the plate is mount-
ed into the printing unit in the "Impression on"
mode. The LED flashes when the clamping bar is
open.
10 Production
B.3.6 SC.999.0020/01
Control panels on the printing unit/coating unit
● Press is not running:
○ Press once to sound the startup warning.
○ When pressed a second time: the press
goes into operation.
● Press in operation:
○ Press once to activate all selected func-
tions.
○ Press twice to accelerate the press to the
preselected production speed.
Note
For presses with central air supply, you
must first press the Compressor button.
11 Stop
Stops the printing press. Actuation during the
production run: Switches off all functions for the
production run (except for the compressor).
Note
The Stop button does not have the same
function as the Emergency stop palm
button! Pressing this button does not
lead to an emergency stop!
12 Washup blade on/off
Throws the washup blade on or off the inking
roller.
13 Emergency stop button
The press stops immediately, and the palm but-
ton is locked.
Turn the button to release the lock.
14 Open/Close roller guard
The roller guard is the upper section of the plate
changer. This section can be separately opened
or closed by pressing the pushbutton.
15 Open/Close cylinder guard
The cylinder guard is the lower section of the
plate changer. This section can only be opened
or closed together with the roller guard by press-
ing the pushbutton.
SC.999.0020/01 B.3.7
Control panels on the printing unit/coating unit
2.3 Printing unit D.S.
1 Inch forward
SG.901.0230-004GRAUND_00
Startup warning sounds; printing press rotates
forward. Condition: The control panel has been
2
selected.
2 Control panel selection
1 Press the push button twice: The press can only
3 be moved in inching mode with or without travel
limitation (LED is ON). To cancel the selection:
Press the push button twice again (LED is OFF).
4
7 Caution - Risk of press damage!
5 You must only perform backwards inch-
ing or positioning when there are no print
6 sheets left in the press. Paper-guiding
cylinders and grippers could be dam-
aged when the press contains print
sheets.
3 Inch backward
Fig. 5 Control panel D.S., delivery side Startup warning sounds; printing press rotates
backward. Condition: The control panel has been
selected.
4 Position
Positions the press.
5 Crawl speed
Startup warning sounds. The press rotates slowly
at reduced speed. Condition: The control panel
has been selected.
6 Emergency stop button
The press stops immediately, and the palm but-
ton is locked. Turn the button to release the lock.
7 Open/Close cylinder guard
The cylinder guard is the lower section of the
plate changer. This section can only be opened
or closed together with the roller guard by press-
ing the pushbutton.
2.4 Dampening system O.S.
1 Wash dampening rollers
SG.901.0232-003GRAUND_00
When pressed with open protection grid: Water
pan roller and metering roller rotate at washup
speed. If actuated during operation: Overdamp-
ening.
2 2 Throwing on dampening rollers (LED ON)
1
Throws on dampening form roller and metering
roller. The water pan roller does not turn.
Fig. 6 Control panel O.S., feeder side
Note
Adjust the dampening rollers in this po-
sition.
B.3.8 SC.999.0020/01
Control panels on the printing unit/coating unit
3 Coating unit control panels
SC.B01.2020-000UTKENU_02
3.1 Coating unit O.S., delivery side
1 Inch forward
FS.901.0245-001GRAUND_00
1 2 3 Startup warning sounds; printing press rotates
forward.
Condition: The control panel has been selected.
2 Control panel selection
5 4 Press the push button twice: The press can only
be moved in inching mode with or without travel
limitation (LED is ON).
8 To cancel the selection: Press the push button
0,01mm 0,01mm
twice again (LED is OFF).
6 11 Caution - Risk of machine damage!
If there are print sheets in the press
9 when the press is inched backward or
positioned, there is a risk of damaging
sheet-transferring cylinders and grip-
7 12
pers. Prior to inching the press back-
wards or positioning it, you must ensure
10 that there are no print sheets in the print-
ing press.
13 14 3 Inch backward
Startup warning sounds; printing press rotates
backward.
15
Condition: The control panel has been selected.
16 17 4 Crawl speed
Startup warning sounds. Printing press runs at
approximately 5 rpm.
Condition: The control panel has been selected.
5 Display of printing pressure varnish metering
roller on D.S.
Shows the adjustment value between the screen
roller and the coating blanket cylinder on D.S.
Multiply the adjustment value with 0.01 mm.
Note
18
The displayed figure is not an absolute
10.119.9099
value. The printing pressure between
Fig. 7 Control panel O.S. delivery side the screen roller and coating blanket
cylinder depends on the thickness of the
coating blanket and the packing sheets
under the coating blanket.
6 Contact pressure on D.S. +
Increases the printing pressure between screen
roller and coating blanket cylinder on D.S.
7 Contact pressure on D.S. -
Reduces the printing pressure between screen
roller and coating blanket cylinder on D.S.
SC.999.0020/01 B.3.9
Control panels on the printing unit/coating unit
8 Display of printing pressure varnish metering
roller on O.S.
Shows the adjustment value between the screen
roller and the coating blanket cylinder on O.S.
Multiply the adjustment value with 0.01 mm.
9 Contact pressure on O.S. +
Increases the printing pressure between screen
roller and coating blanket cylinder on O.S.
10 Contact pressure on O.S. -
Reduces the printing pressure between screen
roller and coating blanket cylinder on O.S.
11 Malfunction
The signal lamp indicates that there is a malfunc-
tion in the coating unit.
12 Varnish metering roller on/off
Throws the varnish metering roller on (LED ON)
and off (LED OFF).
13 Position
Startup warning sounds. The press runs at crawl
speed. The coating blanket cylinder of the coat-
ing unit affected rotates to the plate removal or
clamping position. The press stops.
Condition: The control panel has been selected.
14 Production
● Press is not running:
○ Press once to sound the startup warning.
○ When pressed a second time: the press
goes into operation.
● Press in operation:
○ Press once to activate all selected func-
tions.
○ Press twice to accelerate the press to the
preselected production speed.
15 Stopping/starting the varnish metering roller
Rotates the screen roller (LED ON) or stops the
screen roller (LED OFF).
16 Pressing roller ON/OFF
Throws the pressing roller on the coating blanket
cylinder on (LED ON) or off (LED OFF).
Note
The pressing roller is not thrown on
when it is above the cylinder gap. How-
ever, the Pressing roller ON/OFF button
also lights up in this case. The pressing
roller is thrown on automatically when
the press is inched forward.
17 Stop
Stops the printing press.
B.3.10 SC.999.0020/01
Control panels on the printing unit/coating unit
When pressed during production: All production
functions except for the compressor are switched
off.
Note
The Stop button does not have the same
function as the Emergency stop button.
Pressing this button does not lead to an
emergency stop!
18 Emergency stop button
Press the palm button: The printing press stops
immediately; the palm button locks itself. Twist
the palm button to release the lock.
SC.999.0020/01 B.3.11
Control panels on the printing unit/coating unit
3.2 Coating unit O.S., feeder side
1 Circulate coating
FS.901.0246-000GRAUND_00
1 2 3 Circulates the varnish in the varnish supply sys-
tem (LED ON).
The varnish pump is switched off, when Empty
+ 2
coating pan is selected.
Varnish pump on/off
4 5
Switches the varnish supply pump on (LED ON)
or off (LED OFF). The pump can only be switched
on when one of the functions Circulate varnish,
Empty varnish supply system or Rinse varnish
supply system is selected and the chambered
6 8
blade is engaged.
3 Rotate the varnish metering roller
The screen roller rotates as long as the push but-
ton is pressed.
7 4 Empty varnish supply system
The varnish is pumped out of the varnish supply
system when the pump is switched on (LED ON).
The varnish is pumped out (button 1 blinks, but-
9 ton 4 is ON) if Varnish circulation was selected
beforehand.
The rinsing solution is pumped out (button 6
blinks, button 4 is ON) if Rinse varnish supply
10 system was selected beforehand.
5 Start the washing program
Starts the wash program selected at the control
station.
11
6 Rinse varnish supply system
The varnish supply unit is switched over to the
rinsing solution cycle. The push button can only
be selected if the Empty varnish supply system
push button was selected beforehand.
Provided that the CoatingStar is equipped with a
fresh water connection, the Rinse varnish supply
10.119.9299
system push button can be pressed to bring fresh
water to the varnish supply system after the rins-
Fig. 8 Control panel O.S., feeder side ing water has been pumped off.
7 Malfunction
The signal lamp indicates that there is a malfunc-
tion in the coating unit.
8 Chambered blade on/off
Press this push button twice: The chambered
blade is thrown on the screen roller.
The chambered blade can only be swung into
position when the protection grid on the delivery
side is closed.
Press push button twice again: Disengages the
chambered blade from the screen roller.
B.3.12 SC.999.0020/01
Control panels on the printing unit/coating unit
The chambered blade can only be thrown off af-
ter the varnish has been pumped out.
9 Chambered blade operation:
Delivery volume display
Shows the selected varnish delivery volume in
the range 1 ... 10.
Pressure chambered blade operation:
Pressure indication
Shows the selected pressure in the range
05 ... 30 (05 corresponds to 50 mbar, 30 corre-
sponds to 300 mbar; a zero precedes single-digit
pressure values in chambered blade mode).
The two-digit display blinks when the varnish vol-
ume flow with running machine (min. 3000 iph)
and stopped production is too high or too low.
Please refer to the "Coating unit, Chambered
blade and pressurized chambered blade" chap-
ter for information on how to adjust the reducing
valve on the chambered blade.
10 Varnish pump +
Chambered blade operation:
Increases the varnish delivery volume of the var-
nish pump.
Pressure chambered blade operation:
Increases the pressure in the chambered blade
system in steps of 0.01 bar.
11 Varnish pump -
Chambered blade operation:
Reduces the varnish delivery volume of the var-
nish pump.
Pressure chambered blade operation:
Reduces the pressure in the chambered blade
system in steps of 0.01 bar.
SC.999.0020/01 B.3.13
Control panels on the printing unit/coating unit
3.3 Coating unit D.S.
1 Inch forward
FS.901.0270-000GRAUND_00
1 2 3 Startup warning sounds; printing press rotates
forward.
Condition: The control panel has been selected.
2 Control panel selection
Press the push button twice: The press can only
4 5 be moved in inching mode with or without travel
limitation (LED is ON).
To cancel the selection: Press the push button
twice again (LED is OFF).
Caution - Risk of machine damage!
6 If there are print sheets in the press
when the press is inched backward or
positioned, there is a risk of damaging
sheet-transferring cylinders and grip-
pers. Prior to inching the press back-
wards or positioning it, you must ensure
that there are no print sheets in the print-
ing press.
Fig. 9 Control panel D.S. feeder side 3 Inch backward
Startup warning sounds; printing press rotates
backward.
Condition: The control panel has been selected.
4 Position
Startup warning sounds. The press runs at crawl
speed; the coating blanket cylinder of the respec-
tive printing unit turns to the position for plate re-
moval. The press stops.
Condition: The control panel has been selected.
5 Crawl speed
Startup warning sounds. Printing press runs at
approximately 5 rpm.
Condition: The control panel has been selected.
6 Emergency stop button
Press the palm button: The printing press stops
immediately; the palm button locks itself.
Twist the palm button to release the lock.
B.3.14 SC.999.0020/01
Control panels on the printing unit/coating unit
3.4 Coating unit, manual control panel
1 Circulate coating
FS.901.0271-000GRAUND_00
Circulates the varnish in the varnish supply sys-
1 2 tem (LED ON).
The varnish pump is switched off, when Empty
coating pan is selected.
2 Varnish pump on/off
Switches the varnish supply pump on (LED ON)
or off (LED OFF). The pump can only be switched
3 4
on when one of the functions Circulate varnish,
Empty varnish supply system or Rinse varnish
supply system is selected and the chambered
blade is engaged.
3 Empty varnish supply system
5 6 The varnish is pumped out of the varnish supply
system when the pump is switched on (LED ON).
The varnish is pumped out (button 1 blinks, but-
ton 3 is ON) if Varnish circulation was selected
beforehand.
The rinsing solution is pumped out (button 6
blinks, button 3 is ON) if Rinse varnish supply
system was selected beforehand.
4 Start the washing program
Starts the wash program selected at the control
station.
7
5 Rinse varnish supply system
The varnish supply unit is switched over to the
rinsing solution cycle. The push button can only
be selected if the Empty varnish supply system
push button was selected beforehand.
8
Provided that the CoatingStar is equipped with a
fresh water connection, the Rinse varnish supply
system push button can be pressed to bring fresh
water to the varnish supply system after the rins-
ing water has been pumped off.
9 6 Malfunction
The signal lamp indicates that there is a malfunc-
tion in the coating unit.
7 Chambered blade operation:
Delivery volume display
Shows the selected varnish delivery volume in
the range 1 ... 10.
Pressure chambered blade operation:
Pressure indication
10.118.4699 Shows the selected pressure in the range
Fig. 10 Manual control panel 05 ... 30 (a zero precedes single-digit pressure
values in chambered blade operation).
The two-digit display blinks when the varnish vol-
ume flow with running machine (min. 3000 iph)
and stopped production is too high or too low.
SC.999.0020/01 B.3.15
Control panels on the printing unit/coating unit
Please refer to the "Coating unit, Chambered
blade and pressurized chambered blade" chap-
ter for information on how to adjust the reducing
valve on the chambered blade.
8 Varnish pump +
Chambered blade operation:
Increases the varnish delivery volume of the var-
nish pump.
Pressure chambered blade operation:
Increases the pressure in the chambered blade
system in steps of 0.01 bar.
9 Varnish pump -
Chambered blade operation:
Reduces the varnish delivery volume of the var-
nish pump.
Pressure chambered blade operation:
Reduces the pressure in the chambered blade
system in steps of 0.01 bar.
B.3.16 SC.999.0020/01
Control panels on the printing unit/coating unit
4 Control panels of intermediate unit
SC.B01.2021-000UTKENU_00
4.1 Intermediate unit on O.S. on delivery side
1 Inch forward
SF.B01.0245-000GRAUND_00
1 2 3
Startup warning sounds; printing press rotates
forward.
Condition: The control panel has been selected.
2 Control panel selection
Press the push button twice: The press can only
be moved in inching mode with or without travel
limitation (LED is ON).
4
To cancel the selection: Press the push button
twice again (LED is OFF).
Caution - Risk of press damage!
If there are print sheets in the press
5
when the press is inched backward or
positioned, there is a risk of damaging
sheet-transferring cylinders and grip-
pers. Prior to inching the press back-
wards or positioning it, you must ensure
that there are no print sheets in the print-
ing press.
3 Inch backward
Startup warning sounds; printing press rotates
6
backward.
Condition: The control panel has been selected.
4 Crawl speed
7 Startup warning sounds. Printing press runs at
approximately 5 rpm.
Condition: The control panel has been selected.
5 Malfunction
The signal lamp indicates that there is a malfunc-
tion in the unit.
6 Production
● Press is not running:
8 ○ Press once to sound the startup warning.
10.119.9099 ○ When pressed a second time: the press
Fig. 11 Control panel O.S. delivery side goes into operation.
● Press in operation:
○ Press once to activate all selected func-
tions.
○ Press twice to accelerate the press to the
preselected production speed.
Note
Make sure that the compressor is
switched on.
7 Stop
SC.999.0020/01 B.3.17
Control panels on the printing unit/coating unit
Stops the printing press.
When pressed during production: All production
functions except for the compressor are switched
off.
Note
The Stop button does not have the same
function as the Emergency stop button.
Pressing this button does not lead to an
emergency stop!
8 Emergency stop button
Press the palm button: The printing press stops
immediately; the palm button locks itself. Twist
the palm button to release the lock.
4.2 Intermediate station on D.S. on delivery side
1 Inch forward
FS.901.0270-000GRAUND_00
1 2 3 Startup warning sounds; printing press rotates
forward.
Condition: The control panel has been selected.
2 Control panel selection
Press the push button twice: The press can only
4 5 be moved in inching mode with or without travel
limitation (LED is ON).
To cancel the selection: Press the push button
twice again (LED is OFF).
Caution - Risk of press damage!
6 If there are print sheets in the press
when the press is inched backward or
positioned, there is a risk of damaging
sheet-transferring cylinders and grip-
pers. Prior to inching the press back-
wards or positioning it, you must ensure
that there are no print sheets in the print-
ing press.
Fig. 12 Control panel D.S. 3 Inch backward
Startup warning sounds; printing press rotates
backward.
Condition: The control panel has been selected.
4 Position
Startup warning sounds. The machine runs at
crawl speed; the coating blanket cylinder of the
respective coating unit turns to the position for
plate removal; the machine stops.
Condition: The control panel has been selected.
5 Crawl speed
Startup warning sounds. Printing press runs at
approximately 5 rpm.
Condition: The control panel has been selected.
6 Emergency stop button
B.3.18 SC.999.0020/01
Control panels on the printing unit/coating unit
Press the palm button: The printing press stops
immediately; the palm button locks itself.
Twist the palm button to release the lock.
SC.999.0020/01 B.3.19
Control panels on the printing unit/coating unit
B.3.20 SC.999.0020/01
Control panels on the delivery
Control panels on the delivery
delivery
the
on
panels
Control
1 Delivery control panel ........................................................................................................... B.4.3
1.1 Overview of controls ...................................................................................................... B.4.3
1.2 Buttons on the delivery control panel ............................................................................. B.4.4
1.3 Header of the user interface .......................................................................................... B.4.6
1.4 Menus and symbols ....................................................................................................... B.4.7
2 The "Production" menu ......................................................................................................... B.4.8
2.1 Settings in the "Production" menu .................................................................................. B.4.8
2.2 Calling up the "Production" menu .................................................................................. B.4.8
2.3 Buttons, functions and symbols in the "Production" menu ............................................. B.4.9
3 Dampening menu ................................................................................................................... B.4.11
3.1 Settings in the "Dampening" menu ................................................................................ B.4.11
3.2 Calling up Dampening menu .......................................................................................... B.4.11
3.3 Buttons, functions and symbols in the "Dampening" menu ........................................... B.4.11
4 Delivery menu ......................................................................................................................... B.4.13
4.1 Submenus of the delivery menu .................................................................................... B.4.13
4.2 Calling up the delivery/paper run menu ......................................................................... B.4.14
4.3 Buttons, functions and symbols in the "Delivery/paper run" menu ................................ B.4.14
4.4 Calling up Delivery/sheet brake menu ........................................................................... B.4.15
4.5 Buttons, functions and symbols in the "Delivery/sheet brake" menu ............................. B.4.15
4.6 Calling up the Delivery/pile stops menu ......................................................................... B.4.16
4.7 Buttons, functions and symbols in the "Delivery/pile stops" menu ................................. B.4.17
4.8 Calling up the Delivery/suction disc, sprocket wheel shaft menu .................................. B.4.18
4.9 Buttons, functions and symbols in the Delivery/suction disc, sprocket wheel shaft menu B.4.18
4.10 Calling up the Delivery/non-stop functions menu ........................................................... B.4.19
4.11 Buttons, functions and symbols in the "Delivery/non-stop functions" menu .................. B.4.19
4.12 Additional menu on presses with automatic non-stop .................................................... B.4.21
4.13 Calling up Delivery/Autopile menu ................................................................................. B.4.23
4.14 Buttons, functions and symbols in the "Autopile" menu ................................................. B.4.23
4.15 Calling up Delivery/feeder menu .................................................................................... B.4.24
4.16 Buttons, functions and symbols in the "Delivery/feeder" menu ...................................... B.4.24
4.17 Calling up the tape inserter menu ................................................................................. B.4.25
4.18 Buttons, functions and symbols in the tape inserter menu ............................................ B.4.25
5 "Additional devices" menu ................................................................................................... B.4.27
5.1 Settings in the "Additional devices" menu ...................................................................... B.4.27
5.2 Calling up the "Additional devices" menu ...................................................................... B.4.27
5.3 Buttons, functions and symbols in the "Additional devices" menu ................................. B.4.28
SC.999.0020/01 B.4.1
Control panels on the delivery
6 Consumables menu ............................................................................................................... B.4.30
6.1 Displays in Consumables menu ..................................................................................... B.4.30
6.2 Calling up Consumables menu ...................................................................................... B.4.30
7 Malfunction/Service menu ..................................................................................................... B.4.31
7.1 Settings in the Malfunctions menu ................................................................................. B.4.31
7.2 Calling up the Malfunctions menu .................................................................................. B.4.31
7.3 Calling up the Service menu .......................................................................................... B.4.32
7.4 Entering the configuration of the sheet brake modules .................................................. B.4.33
B.4.2 SC.999.0020/01
Control panels on the delivery
1 Delivery control panel
FS.901.1505-000UTKENU_05
1.1 Overview of controls
The delivery control panel (Fig. 1) comprises the fol-
FS.901.2040-001GRAUND_00
lowing functional groups:
1 1 Touch screen (touch-sensitive screen surface)
The screen displays the setting values and func-
tion buttons. You can press the displayed func-
tion keys like normal keys. In this manual, the
function buttons are referred to as buttons.
2 Jogwheel
To activate the jogwheel: Press one of the round
buttons on the screen or press on the jogwheel
itself. The backlight behind the button indicates
that the jogwheel is active.
To deactivate the jogwheel: Press on the jog-
2 wheel itself or the active round button. The back-
light disappears.
When the jogwheel is active (backlight is on), you
4 5 can increase (turning to the right) or reduce (turn-
ing to the left) set values. The jogwheel has no
limit stop.
3 Pile control buttons
With the pile control buttons you can control the
functions of the delivery pile.
4 Press control buttons
With the press control buttons you can control the
functions of the entire press.
5 Intercom system (optional)
3 The intercom system is located on the feeder
control panel and on the delivery control panel. It
Fig. 1 Delivery control panel comprises a microphone, loudspeaker, volume
control and speaker button.
SC.999.0020/01 B.4.3
Control panels on the delivery
1.2 Buttons on the delivery control panel
FS.901.1991-000GRAUND_01
1
2 4 5 7 9 11
3 6 8 10
12 14
13 15
17 18 19
16
20
Fig. 2 Buttons on the delivery control panel
Symbol Designation Function
1 Jogwheel Use the jogwheel to change selected settings. The jogwheel has
no limit stop.
● Turning the wheel to the right increases the setting value.
● Turning the wheel to the left reduces the setting value.
2 Illuminated pushbutton Produc- Condition: The press is at standstill.
tion When pressed: The startup warning signal sounds.
When pressed again: All functions selected (such as dampening
and inking form rollers to plate, ink vibrator on, compressor on,
sheet feeding on) will be activated. The printing units start im-
pression. When pressed again, the press accelerates to the
preselected production speed.
Condition: Press is in operation.
When pressed: all selected functions are activated, e.g. damp-
ening and inking form roller to the plate, ink vibrator on, com-
pressor on, sheet feed on. The printing units start impression.
When pressed again, the press accelerates to the preselected
production speed.
3 Pushbutton Stop When pressed, the press stops.
Actuation in production: The feeder stops, all printing units go off
impression. Sheets are delivered, post dampening phase, press
stops.
B.4.4 SC.999.0020/01
Control panels on the delivery
Symbol Designation Function
When pressed during the post-dampening phase: The post-
dampening phase is immediately interrupted. The press stops.
4 Job counter on/off button Switches the job counter on (LED lights up).
When pressed again, the job counter is switched off (LED goes
out).
5 Pushbutton Fast When pressed: Increases the press speed continuously while
the button is held down.
6 Pushbutton Slow When pressed: Reduces the speed continuously while the but-
ton is held down. Interrupts the press run-up.
7 Pushbutton Run When pressed: Startup warning signal sounds.
When pressed again, the press starts up at minimum speed.
8 Illuminated pushbutton Com- Upon actuation: switches on (LED lights up) and off the com-
pressor on/off pressor.
9 Illuminated pushbutton Feeder When pressed: The feeder is switched on (LED lights up) auto-
on/off matically.
When pressed again, the feeder is switched off (LED goes out).
10 Illuminated pushbutton Dampen- Operation: Switching on (LED lights) activates the dampening
ing form roller ON/OFF form roller.
Operation again (LED goes off) switches off the dampening form
roller. The water pan roller does not rotate.
11 Illuminated pushbutton Paper When pressed: Switches paper run on (LED lights up) and off.
run on/off
12 Auxiliary pile up pushbutton The auxiliary pile moves upward.
13 Auxiliary pile down pushbutton The auxiliary pile moves downward.
14 Pushbutton Main pile up The main pile moves upward.
15 Pushbutton Main pile down The main pile moves downward.
16 Main pile stop pushbutton The main pile is stopped.
17 Forward Condition: The Control panel selection button on the delivery
has been selected. When pressed, the startup warning signal
sounds. When pressed again, the press rotates forward while
the button is held down.
18 Control panel selection Selection: Press the button twice (LED lights up). The press can
only be run in inching mode with or without travel limitation. To
cancel the selection: press button twice again (LED off).
SC.999.0020/01 B.4.5
Control panels on the delivery
Symbol Designation Function
19 Reverse Condition: The Control panel selection button on the delivery
has been selected. When pressed once, the start-up warning
signal sounds. When pressed again, the press rotates backward
while the button is held down.
20 Emergency stop button When pressed: Press stops immediately, emergency stop but-
ton locks.
Turn the button to release the lock.
Tab. 1
1.3 Header of the user interface
FS.901.2045-001GRAUND_01
1 2 3 4 5 6
Fig. 3 Header
The header (Fig. 3) is the main navigation bar. Press-
ing one of the buttons in the header sections always
takes you to the top level of the respective menu. The
header contains the keys:
1 Production
2 Dampening
3 Delivery
4 Additional equipment (e.g. dryers and powder
spray devices)
5 Consumables
6 Malfunction/Service
7 Heidelberg button
The Heidelberg button is a multifunctional button.
B.4.6 SC.999.0020/01
Control panels on the delivery
1.4 Menus and symbols
FS.901.2056-001GRAUND_00
1 2 3
Fig. 4 Overview
Selecting a menu
On the left-hand side (Fig. 4/1) you can see the button
or button sequence you need to press in order to get to
the menu depicted.
Selecting a function
The menu contains round and square buttons. By
pressing a button you select the corresponding func-
tion.
Setting a default value
● Round buttons (Fig. 4/2): Default value is set with
the jogwheel.
Turning the jogwheel to the right (clockwise) in-
creases the default value.
Turning the jogwheel to the left (counterclock-
wise) reduces the default value.
● Square buttons (Fig. 4/3): Default value is set
with the +/- buttons.
Pressing the + button increases the default value.
Pressing the - button reduces the default value.
Displaying default values
The default values are displayed in the buttons.
● Numeric value in the button (Fig. 4/4): The default
value is displayed in percent.
● Dark gray fill level (Fig. 4/5): The higher the dark
gray level, the higher the setpoint value.
SC.999.0020/01 B.4.7
Control panels on the delivery
2 The "Production" menu
FS.901.6560-000UTKENU_01
2.1 Settings in the "Production" menu
In the "Production" menu you can set:
● Speed of the fans
● Air volume of the longitudinal blast tubes
● Overdampening
● Gripper opening time
● Speed of the sheet slow-down devices
● Suction air volume of the sheet slow-down de-
vices
● Blast air volume of transport nozzles on sheet
brakes
2.2 Calling up the "Production" menu
FS.901.1992-001GRAUND_00
1
2 3 4 5 6 7 8 9
10 11 12
13 14 15 16
Fig. 5 The "Production" menu
1. Press the Production button (Fig. 5/1). The Pro-
duction menu appears.
B.4.8 SC.999.0020/01
Control panels on the delivery
2.3 Buttons, functions and symbols in the "Production" menu
No Symbol Designation Function
.
2 Fan speed in the delivery Speed adjustment of the fans upstream of and above the pile.
0
The symbols above the buttons indicate which fans are being
actuated.
3 Blast air for longitudinal blast Setting of blast air for the left, center, right longitudinal blast
0
tube tube. The symbols above the buttons indicate which blast tube is
being actuated.
4 Sum button With this button you can set the blast tubes and fans together.
Form group: If the Sum button is active, you can use the buttons
for the blast tube and the fans to form a group.
Delete group: Press the Sum button for 2 seconds. Now the
blast tubes and fans can be set individually again.
Set group: Press the Sum button. You can use the rotary switch
to alter the group's adjustment values.
5 ... Overdampening Overdampening in the selected printing unit.
24
9 1 The water pan roller turns at top speed while the button is held
down.
10 Status display of sheet decurler Indication of the operating status of the sheet decurler.
11 Dryer status Indication of the operating status of the dryer.
12 Powder spray device status Indication of the operating status of the powder spray device.
13 Gripper opening Setting the gripper opening time.
- + 0 = Grippers open at the latest possible time.
100 = Grippers open at the earliest possible time.
14 Sheet slow-down device speed Speed adjustment of the sheet brake.
0 = Lowest speed
100 = Highest speed
15 Sheet slow-down device suction Setting the suction air volume of the sheet brake.
air 0 = No suction air
100 = Maximum suction air volume
16 Transport nozzles for sheet Setting blast air volume of transport nozzles on the sheet brake.
brakes 0 = No blast air
SC.999.0020/01 B.4.9
Control panels on the delivery
No Symbol Designation Function
.
100 = Maximum blast air volume
Tab. 2 Functions in Production menu
B.4.10 SC.999.0020/01
Control panels on the delivery
3 Dampening menu
FS.901.6551-000UTKENU_01
3.1 Settings in the "Dampening" menu
You can set the following in the Dampening menu:
● Water pan roller speed for each printing unit,
● Overdampening.
3.2 Calling up Dampening menu
CD.901.2044-001GRAUND_00
1
2
Fig. 6 Dampening menu
1. Press the Dampening button (Fig. 6/1). The
Dampening menu appears.
3.3 Buttons, functions and symbols in the "Dampening" menu
Fig. Symbol Designation Function
6/2 Overdampening The current water pan roller speed is shown as a bar and in
24
1 numerical form.
SC.999.0020/01 B.4.11
Control panels on the delivery
Fig. Symbol Designation Function
The water pan roller rotates at maximum speed long as the
button is pressed.
6/3 Water pan roller speed + Press the button to increase the water pan roller speed.
6/4 Water pan roller speed - Press the button to reduce the water pan roller speed.
Tab. 3 Buttons in Dampening menu
B.4.12 SC.999.0020/01
Control panels on the delivery
4 Delivery menu
FS.901.6552-000UTKENU_06
4.1 Submenus of the delivery menu
CD.901.2047-002GRAUND_00
1 2 3 4 5 6 7 8
Fig. 7 Tab in the Delivery menu
The Delivery menu contains submenus, which you
can call up by pressing the relevant tab (Fig. 7):
1 Paper run
Gripper opening time, speed of sheet brake, rear
edge suction device.
2 Sheet brake
Positions of sheet brakes.
3 Pile stops
Positions and jogging movement of pile stops.
4 Suction disc, sprocket wheel shaft (this tab is only
displayed on presses equipped with suction discs
on the sprocket wheel shaft)
Suction disc positions
5 Non-stop functions
Descending distances, operating mode and in-
sert angle of the sheet catchers.
6 Autopile (this tab is only displayed for presses
with the Autopile function).
Manual actuation of conveying elements.
7 Feeder
Blast air of air-blast nozzle on transfer gripper.
8 Tape inserter
SC.999.0020/01 B.4.13
Control panels on the delivery
4.2 Calling up the delivery/paper run menu
CD.901.2048-001GRAUND_00
1
3 4 5 6 7 8
Fig. 8 Delivery/paper run menu
1. Press the Delivery button (Fig. 8/1).
2. Press the Delivery/paper run tab (Fig. 8/2). The
Delivery/paper run menu appears.
4.3 Buttons, functions and symbols in the "Delivery/paper run" menu
Fig. Symbol Designation Function
8/3 Gripper opening Setting the gripper opening time.
- + 0 = Grippers open at the latest possible time.
100 = Grippers open at the earliest possible time.
8/4 Sheet slow-down device speed Speed adjustment of the sheet brake.
0 = Lowest speed
100 = Highest speed
8/5 Sheet slow-down device suction Setting the suction air volume of the sheet brake.
air 0 = No suction air
100 = Maximum suction air volume
8/6 Blast air for pulse nozzles (vari- Setting blast air volume of pulse nozzles on the sheet brake.
ant specific) 0 = No blast air
100 = Maximum blast air volume
8/7 Blast air for transport nozzles Setting blast air volume of transport nozzles on the sheet
brake.
0 = No blast air
B.4.14 SC.999.0020/01
Control panels on the delivery
Fig. Symbol Designation Function
100 = Maximum blast air volume
8/8 Rear edge suction device (vari- Switches the rear edge suction device on or off.
ant specific)
Tab. 4 Symbols in the Delivery/paper run menu
4.4 Calling up Delivery/sheet brake menu
CD.901.2049-001GRAUND_00
1
2
3
4
5
8
6
7 9
Fig. 9 Delivery/Sheet brake menu
1. Press the Delivery button (Fig. 9/1).
2. Press the Sheet brake tab (Fig. 9/2). The Deliv-
ery/Sheet brake menu appears.
4.5 Buttons, functions and symbols in the "Delivery/sheet brake" menu
Fig. Symbol Designation Function
9/3 Display of the sheet size set
9/4 Brake modules Symbols for the sheet brake modules.
9/5 Direction of movement When the central brake module is moved toward D.S. or
O.S., an arrow indicating the direction of movement appears
on the corresponding side.
9/6 Position of sheet brake module Shows the distance between the corresponding sheet brake
module and the center of sheet. The settings are shown in
millimeters.
9/7 Positioning sheet brake modules These buttons can be used to set the position of the re-
spective sheet brake module.
SC.999.0020/01 B.4.15
Control panels on the delivery
Fig. Symbol Designation Function
Press a button to select the respective sheet brake module.
Enter the desired position using the jogwheel.
Once the adjusting limit has been reached, the correspond-
ing direction arrow turns gray.
In straight and perfecting mode: position the sheet brake
module in the print-free area.
9/8 Select the number of sheet brake Setting as to whether 5, 4 or 3 sheet brake modules are to be
modules used.
A menu appears in which you can select the number of sheet
brake modules.
The sheet brake modules that are not used move to the park
position.
9/9 Turn tape driving roller If the press is at a standstill: As long as this button is pressed,
the tape driving roller for the sheet brake keeps turning. This
makes it easier to clean the tape driving roller.
Tab. 5
4.6 Calling up the Delivery/pile stops menu
CD.901.2050-001GRAUND_00
1
10
7
6 8 9
Fig. 10 Delivery/pile stops menu
1. Press the Delivery button (Fig. 10/1).
2. Press the Pile stop tab (Fig. 10/2). The Delivery/
pile stops menu appears.
B.4.16 SC.999.0020/01
Control panels on the delivery
4.7 Buttons, functions and symbols in the "Delivery/pile stops" menu
Fig. Symbol Designation Function
10/3 Positioning of rear pile stop The arrow keys enable you to manually position the pile stop
(sheet jogger).
10/4 Positioning of sheet jogger on
D.S. Press this button once: The pile stop moves 1 mm in the
direction of the arrow.
10/5 Positioning of sheet jogger on
Press and hold the button: The pile stop continues to move
O.S.
towards the arrow until you release the button.
The number indicates the position. Once the adjusting limit
has been reached the corresponding arrow key turns gray.
10/6 Sheet jogger on D.S. on/off. Press button: Switch jogging movement on or off.
10/7 Pile towards D.S. Press this button once: Both sheet joggers move 1 mm to-
wards D.S.
Press button and hold: Both sheet joggers continue to move
towards D.S.
10/8 Sheet jogger front edge on/off. Press button: Switch jogging movement on or off.
10/9 Pile towards O.S. Press this button once: Both sheet joggers move 1 mm to-
wards O.S.
Press button and hold: Both sheet joggers continue to move
towards O.S.
10/10 Sheet jogger on O.S. on/off. Press button: Switch jogging movement on or off.
Tab. 6
SC.999.0020/01 B.4.17
Control panels on the delivery
4.8 Calling up the Delivery/suction disc, sprocket wheel shaft menu
XL.901.2057-001GRAUND_00
1
2
3
5
6
Fig. 11 Delivery/Autopile menu
Note
The Delivery/suction disc, sprocket
wheel shaft tab is only displayed if the
press is equipped with suction discs on
the sprocket wheel shaft.
Caution - Risk of collision with guide
pulleys!
When moving the suction discs to the
position for the smallest sheet size,
these can collide with fitted guide pul-
leys.
Before changing the sheet width, ensure
that the guide pulley has been removed.
1. Press the Delivery button (Fig. 11/1).
2. Press the Delivery/suction disc, sprocket wheel
shaft tab (Fig. 11/2). The Delivery/suction disc,
sprocket wheel shaft menu appears.
4.9 Buttons, functions and symbols in the Delivery/suction disc, sprocket wheel shaft menu
Fig. Symbol Designation Function
11/3 Position display Displays the position of the suction discs
11/4 Move suction disc outward Press the Move suction disc outward button to move the
suction disc outward.
B.4.18 SC.999.0020/01
Control panels on the delivery
Fig. Symbol Designation Function
11/5 Center suction disc Press the Center suction disc button to move the suction
disc to the center.
11/6 Move suction discs to the park If the button is selected: The suction discs move to the park
position/Move the suction discs position (20 mm outside the sheet width).
to the work position If the button is deselected: The suction discs move to the last
position set.
Tab. 7
4.10 Calling up the Delivery/non-stop functions menu
CD.901.2051-001GRAUND_00
1
5
3 4 7
8 11
12
9
13
6 6 10
Fig. 12 Delivery/non-stop functions menu
1. Press the Delivery button (Fig. 12/1).
2. Press the Delivery/non-stop functions button
(Fig. 12/2). The Delivery/non-stop functions
menu appears.
4.11 Buttons, functions and symbols in the "Delivery/non-stop functions" menu
Fig. Symbol Designation Function
12/3 Descending distance for sample Use the + and - buttons to set the descending distance of the
sheet removal main pile for inserting the sheet catcher.
12/4 Pile descent path - auxiliary pile Use the + and - buttons to set the descending distance of the
support main pile to push in the non-stop rake or the rack board.
SC.999.0020/01 B.4.19
Control panels on the delivery
Fig. Symbol Designation Function
12/5,7 Image, depending on the selec- If you selected the button Pile change with non-stop rake:
tion. You will see the delivery pile with the non-stop rake
(Fig. 12/7).
If you selected the button Pile change with pile board:
You will see the delivery with the pile board (Fig. 12/5).
12/6 Reset The sheet counter is set to the value at which a non-stop pile
change is to be executed.
12/8 Pile change with non-stop rake Pile change with non-stop rake.
The pushbutton can only be selected, if the press is
equipped with non-stop rakes.
12/9 Sheet catchers, sample sheet, Press the button to insert the sheet catchers during sample
on/off sheet removal. When the function is switched on, the push
button is highlighted.
12/10 Outer sheet catchers, sample Depending on the sheet size being processed, it may be
sheet, on/off expedient to switch the outer sheet catchers on or off.
Press the button to insert the outer sheet catchers during
sample sheet removal. When the function is switched on, the
push button is highlighted.
12/11 Rack operation Activates/deactivates non-stop operation with the rack
board
12/12 Sheet catcher non-stop ON/OFF Press the button to insert the sheet catchers in non-stop
operation. When the function is switched on, the push button
is highlighted.
12/13 Outer sheet catcher non-stop Press the button to switch the outer sheet catchers on or off
ON/OFF in non-stop operation. When the function is switched on, the
push button is highlighted.
Tab. 8
B.4.20 SC.999.0020/01
Control panels on the delivery
4.12 Additional menu on presses with automatic non-stop
CD.901.2055-003GRAUND_00
1
11 12
2
8 13
3 14
4 9
5 15
10
6 16
Fig. 13 Delivery/paper run menu
1. Press the Pile functions button (Fig. 13/1).
2. Press the Automatic non-stop tab (Fig. 13/2). The
Delivery/Automatic non-stop menu appears.
Fig. Symbol Designation Function
13/3 Pile height Displayed value of the preselected pile height
The value does not change during production.
Depending on the unit preselected at the control station, the
display shows the pile height in mm or the number of
sheets.
13/4 Pallet height Displayed value of the preselected pallet height in mm
13/5 Decrease descending distance While the button is pressed, the descending distance is de-
creased down to a factory-set minimum value.
13/6 Reset The descending distance is reset to the basic setting.
13/7 Increase descending distance While the button is pressed, the descending distance is in-
creased up to a factory-set maximum value.
13/8,1 Image, depending on the selec- If you selected the button Pile change with non-stop rake:
1 tion. You will see the delivery pile with the non-stop rake
(Fig. 13/8).
SC.999.0020/01 B.4.21
Control panels on the delivery
Fig. Symbol Designation Function
If you selected the button Pile change with pile board:
You will see the delivery with the pile board (Fig. 13/10).
13/9 Sheet counter Preselected unit: number of sheets
Non-stop operation: Counter starts with set value and counts
backward.
Preselected unit: mm
Non-stop operation: Counter starts at 0 and counts up to the
preselected pile height.
13/10 Reset The sheet counter is reset to the preselected value.
If mm is preselected as unit, the Reset button is ineffective.
13/12 Automatic non-stop pile change This button must be selected if the auxiliary pile support is to
move automatically. In addition, one of the buttons
(Fig. 13/11 or 12) must be preselected.
Standard setting: If the button is preselected, the auxiliary
pile support moves automatically to work position. The pile is
changed automatically.
If the button is not preselected: A signal sounds as soon as
the preselected pile height has been reached. You have to
start the automatic pile change by pressing the Insert auxil-
iary pile support button on the delivery console.
13/13 Rack operation Activates/deactivates non-stop operation with the rack
board
Button Rack delivery operation and Automatic non-stop pile
change preselected: The counter counts the sheets that are
deposited on the main pile. The main pile is automatically
lowered for the next rack once the preselected number of
sheets is reached.
Only button Rack delivery operation preselected: The sys-
tem gives an acoustic warning when the preselected pile
height is reached. You have to start the automatic pile
change by pressing the Insert auxiliary pile support button on
the delivery console.
13/14 Non-stop operation Button Non-stop operation and Automatic non-stop pile
change preselected: The counter counts the sheets that are
deposited on the main pile. The auxiliary pile support moves
automatically to work position. The pile is changed automat-
ically once the preselected pile height is reached.
Only button Non-stop operation preselected: The system
gives an acoustic warning when the preselected pile height
is reached. You have to start the automatic pile change by
pressing the Insert auxiliary pile support button on the de-
livery console.
13/15 Sheet catchers, sample sheet, Standard setting: If the button is preselected: Sheet catchers
on/off are inserted during sample sheet removal.
B.4.22 SC.999.0020/01
Control panels on the delivery
Fig. Symbol Designation Function
If the button is not preselected: Sheet catchers are switched
off.
13/16 Outer sheet catchers, sample Standard setting: If the button is preselected: Outer sheet
sheet, on/off catchers are inserted during sample sheet removal.
If the button is not preselected: Outer sheet catchers are
switched off.
Tab. 9 Symbols in the Delivery/paper run menu
4.13 Calling up Delivery/Autopile menu
CD.901.2053-001GRAUND_00
1
Fig. 14 Delivery/Autopile menu
Note
The Delivery/Autopile tab is only shown
when the press is equipped with Au-
topile.
1. Press the Delivery button (Fig. 14/1).
2. Press the Delivery/Autopile tab (Fig. 14/2). The
Delivery/Autopile menu appears.
4.14 Buttons, functions and symbols in the "Autopile" menu
Fig. Symbol Designation Function
14/3 Move pallet forwards Condition: A conveyor element has been selected on the
control system. In the event of a fault, the faulty conveying
element is preselected automatically.
SC.999.0020/01 B.4.23
Control panels on the delivery
Fig. Symbol Designation Function
Press the Move pallet forwards button. The pallet on the
selected conveying element moves forward.
14/4 Move pallet backwards Condition: A conveyor element has been selected on the
control system. In the event of a fault, the faulty conveying
element is preselected automatically.
Press the Move pallet backwards button. The pallet on the
selected conveying element moves backward.
14/5 Selection of second axis This function is only available for conveyors that have a
second moving axis for turning the rotating conveyor or
opening/closing the singularization rocker on the buffer con-
veyor, for example.
Tab. 10
4.15 Calling up Delivery/feeder menu
CD.901.2054-001GRAUND_00
1
Fig. 15 Delivery/feeder menu
4.16 Buttons, functions and symbols in the "Delivery/feeder" menu
Fig. Symbol Designation Function
15/3 Blast air for air-blast nozzle on Use the + and - buttons to set the blast air on the air-blast
transfer gripper nozzle on the transfer gripper. The setting value appears
above the bar chart.
Tab. 11
B.4.24 SC.999.0020/01
Control panels on the delivery
4.17 Calling up the tape inserter menu
CD.901.2052-001GRAUND_00
1
8
4 6
Fig. 16
1. Press the Pile functions button (Fig. 16/1).
2. Touch the Tape inserter tab (Fig. 16/2). The Tape
inserter menu opens.
Note
In this menu, you can also correct the
counter reading in case of a counter-
controlled tape insertion. If you are re-
moving sample sheets, for instance, you
can preselect the correction value using
the plus and minus buttons. The correc-
tion is applied once you press the Enter /
OK button (Fig. 16/8).
4.18 Buttons, functions and symbols in the tape inserter menu
Fig. Symbol Designation Function
16/3 Lift tape inserter optional With this button, you can lift the tape inserter by 20 mm.
This function is only available for laterally mounted tape in-
serters.
16/4 Insert tape When you press this button, a tape is inserted.
If the press is rotating, the tape is inserted based on the
press angle.
If the press is at standstill, the tape is inserted directly.
16/5 Manually confirmed counter cor- Counter-controlled tape insertion is active.
rection By confirming with OK, you can reduce the counter reading
by the preselected number of sheets.
SC.999.0020/01 B.4.25
Control panels on the delivery
Fig. Symbol Designation Function
The preselected number of sheets is preserved after a
restart of the press.
16/6 Plus / minus button Use these buttons to enter the correction value.
16/7 Display panel Shows the correction value.
16/8 Enter / OK Every time you press this button, the counter reading is re-
duced by the correction value.
Tab. 12
B.4.26 SC.999.0020/01
Control panels on the delivery
5 "Additional devices" menu
FS.901.6553-000UTKENU_02
5.1 Settings in the "Additional devices" menu
In the Additional devices menu you can set:
● Automatic delivery cleaning
● Powder spray device
● Sheet decurler
● Ionizing unit
● Dryer
5.2 Calling up the "Additional devices" menu
FS.901.2052-001GRAUND_00
1
2 3 4 5 6 7 8 9 10 11
Fig. 17 Additional devices menu
1. Press the Additional devices button (Fig. 17/1).
The Additional devices menu is shown.
Note
Figure 17 shows a press with maximum
equipment. In your press only the exist-
ing additional devices or their setting op-
tions are shown.
SC.999.0020/01 B.4.27
Control panels on the delivery
5.3 Buttons, functions and symbols in the "Additional devices" menu
Fig. Symbol Designation Function
17/2 Automatic delivery cleaning Press this button to select/deselect automatic delivery clean-
ing.
17/3 Powder spray device Press this button to select/deselect the powder spray device.
The powder spray device is switched on automatically as
soon as printed sheets are delivered in the delivery.
Use the + and - buttons to set the powder volume. The pow-
der volume set is displayed in percent.
17/4 Powder volume balance Use the + and - buttons to set the powder volume balance.
The values displayed indicate the ratio of how the powder is
20 / 80 applied to the sheet from above or below.
17/5 Sheet decurler Display of the operating status and the suction air volume of
the sheet decurler.
24 0 % = Sheet decurler switched off.
1 % = Sheet decurler switched on, minimum suction air vol-
ume.
100 % = Sheet decurler switched on, maximum suction air
volume.
17/6 Ionizing unit Press this button to select/deselect the ionizing unit.
The ionizing unit switches on automatically together with the
paper run.
17/7 Pile surface temperature control This function is only available if you have the an automatic-
capable dryer. If the button is selected the dryer regulates
the pile surface temperature through the heat output to the
set value.
Use the + and - buttons to set the desired pile surface tem-
perature.
Number over the pile symbol: Actual value of pile surface
temperature.
Number below the pile symbol: Set value of pile surface
temperature.
17/8 Hot-air dryer output If temperature is not regulated through the pile temperature:
Use the + and - buttons to set the dryer output for the dryer.
17/9 IR dryer output
B.4.28 SC.999.0020/01
Control panels on the delivery
Fig. Symbol Designation Function
17/10 UV dryer output
17/11 Dryer Press this button to select/deselect the dryer(s).
The dryer switches on automatically together with the paper
run.
Tab. 13 Symbols in Additional devices menu
SC.999.0020/01 B.4.29
Control panels on the delivery
6 Consumables menu
FS.901.6571-000UTKENU_01
6.1 Displays in Consumables menu
The Consumables menu shows when consumables
such as, e.g. water, washing fluid, washup cloth etc.
are almost used up. All consumables monitored by the
control system are measured. If the supply of a con-
sumable is running low, then the header highlights the
Consumables button.
6.2 Calling up Consumables menu
CD.901.2056-001GRAUND_00
2
1
Fig. 18 Consumables menu
1. Press the Consumables button (Fig. 18/1). The
Consumables menu appears.
The display area (Fig. 18/2) shows all the consum-
ables that are running low.
2. Replenish the consumables listed (e.g. change
washup cloth, fill up washing fluid, etc.).
3. To exit the menu: Press a different button in the
header.
B.4.30 SC.999.0020/01
Control panels on the delivery
7 Malfunction/Service menu
FS.901.6565-000UTKENU_03
7.1 Settings in the Malfunctions menu
In the Malfunctions menu you can:
● obtain an overview of the press malfunctions.
● call up the Service menu to lock the delivery
control panel.
7.2 Calling up the Malfunctions menu
XL.901.2053-001GRAUND_00
1
xxxxxxxx xxxxxxx
2
3 4 5 6 7
Fig. 19 Malfunctions menu
1. Press the Malfunction push button (Fig. 19/1).
The Malfunction menu appears.
If malfunctions are present, a corresponding message
appears in the info box (Fig. 19/2).
2. Press the Log push button (Fig. 19/3). A fault log
appears.
3. Select an item in the info box (Fig. 19/2). Press
the Details/acknowledge button (Fig. 19/4). A
menu appears displaying further information on
the entry. If the malfunction has to be acknowl-
edged, the acknowledgment button also appears
in this menu.
4. Press the Up (Fig. 19/5) or Down button
(Fig. 19/6) to select an entry.
5. Press the Service button (Fig. 19/7) to call up the
Service menu.
SC.999.0020/01 B.4.31
Control panels on the delivery
7.3 Calling up the Service menu
XL.901.2054-001GRAUND_00
1
3 5
6 7
xxxxxxxxxxx
xxxxx xxxx xxxx
Fig. 20 Malfunctions menu
1. Press the Malfunction push button (Fig. 20/1).
The Malfunction menu appears.
2. Press the Service button (Fig. 20/2). The Service
menu appears.
3. Press the Lock control panel button (Fig. 20/3). A
confirmation dialog appears. You must confirm it
to lock the delivery control panel for cleaning, for
example. To cancel the lock, you must press the
button again and then confirm the subsequent
confirmation dialog by pressing twice.
4. Press the Training mode button (Fig. 20/4). You
will see a safety query which you must confirm to
switch the delivery control panel to training mode.
You can then switch over in the header, but can-
not change any settings. To cancel the lock, you
must press the button again and confirm the sub-
sequent confirmation dialog.
5. Press the Configuration of sheet brake modules
button (Fig. 20/5) to open the Configuration of
sheet brake modules menu. You can enter the
configuration of the sheet brake modules here.
6. Press the Screen calibration button (Fig. 20/6).
The menu for calibrating the screen appears.
7. Press the button (Fig. 20/7) to exit the Service
menu.
B.4.32 SC.999.0020/01
Control panels on the delivery
7.4 Entering the configuration of the sheet brake modules
XL.901.2056-001GRAUND_00
1
2
5
6
3
8 9
7
Fig. 21 Configuration of the sheet brake
The module supports can be equipped with 0, 1 or 2
sheet brake modules. In this menu you have to specify
the equipment of the module supports. If the equip-
ment is not entered correctly, the module supports do
not move to the correct lateral position.
1. Press the Malfunction push button (Fig. 21/1).
The Malfunction menu appears.
2. Press the Service button (Fig. 21/2). The Service
menu appears.
3. Press the Configuration of sheet brake modules
button (Fig. 21/3). The Configuration of sheet
brake modules menu appears.
Configuration status display (Fig. 21/4): The currently
selected configuration is displayed in this section.
4. Configuration of the sheet brake modules on D.S.
(Fig. 21/5): Press the button to enter the config-
uration on the drive side. If the button is high-
lighted: The sheet brake module is equipped. If
the button is dark: The sheet brake module is not
equipped.
5. Configuration of sheet brake modules on O.S.
(Fig. 21/6): Press the button to enter the config-
uration on the operator's side. If the button is
highlighted: The sheet brake module is equipped.
If the button is dark: The sheet brake module is
not equipped.
Preferred configuration display (Fig. 21/7): The pre-
ferred configuration is displayed in this section. You
SC.999.0020/01 B.4.33
Control panels on the delivery
can only set the sheet brakes to the maximum sheet
size with the preferred configuration.
6. Press the OK button (Fig. 21/8) to save the con-
figuration of the sheet brake modules.
7. Press the Cancel button (Fig. 21/9) to leave the
menu without saving the changes.
B.4.34 SC.999.0020/01
Feeder
Feeder
Feeder
1 Feeder - safety instructions ................................................................................................. B.5.7
1.1 To be observed when performing work .......................................................................... B.5.7
2 Pile change ............................................................................................................................. B.5.8
2.1 Determining the actual sheet size ................................................................................. B.5.8
2.2 Normal pile change ....................................................................................................... B.5.8
2.3 Non-stop pile change (optional) .................................................................................... B.5.10
3 Automatic non-stop pile change (optional) ........................................................................ B.5.14
3.1 Function ......................................................................................................................... B.5.14
3.2 Performing a non-stop pile change ............................................................................... B.5.15
3.3 Deflecting marked sheets .............................................................................................. B.5.19
3.4 Malfunctions during automatic pile change ................................................................... B.5.20
3.5 Interrupting automatic sequences in the pile change .................................................... B.5.23
3.6 Maintenance work ......................................................................................................... B.5.25
3.7 Pile heights ................................................................................................................... B.5.26
4 Preloading and pile change ................................................................................................. B.5.28
4.1 Determining the actual sheet size ................................................................................. B.5.28
4.2 Preloading device (option) ............................................................................................. B.5.28
4.3 Pile change .................................................................................................................... B.5.29
5 Automatic pile alignment ..................................................................................................... B.5.30
5.1 Determining the actual sheet size ................................................................................. B.5.30
5.2 Function ......................................................................................................................... B.5.30
5.3 Function of the buttons .................................................................................................. B.5.31
5.4 Method of operation in "Automatic pile alignment" mode ............................................. B.5.32
6 Automatic non-stop pile change (optional) ........................................................................ B.5.33
6.1 Function ......................................................................................................................... B.5.33
6.2 Determining the actual sheet size ................................................................................. B.5.34
6.3 Performing a non-stop pile change ............................................................................... B.5.34
6.4 Deflecting marked sheets .............................................................................................. B.5.38
6.5 Malfunctions during automatic pile change ................................................................... B.5.40
6.6 Interrupting automatic sequences in the pile change .................................................... B.5.43
6.7 Maintenance work ......................................................................................................... B.5.45
6.8 Pile heights ................................................................................................................... B.5.46
7 Suction head ........................................................................................................................... B.5.48
7.1 Overview of the suction head ........................................................................................ B.5.48
7.2 Adjusting the sheet size ................................................................................................ B.5.49
SC.999.0020/01 B.5.1
Feeder
7.3 Setting the height .......................................................................................................... B.5.50
7.4 Lifting suckers ............................................................................................................... B.5.50
7.5 Forwarding suckers ....................................................................................................... B.5.52
7.6 Reducing the suction air of the forwarding suckers and lifting suckers ........................ B.5.53
8 Overview table - suction head settings for different printing materials .......................... B.5.54
8.1 Lifting suckers and forwarding suckers ......................................................................... B.5.54
8.2 Sheet separator fingers ................................................................................................. B.5.54
8.3 Sheet separation blowers ............................................................................................. B.5.55
8.4 Sheet stops and forwarding flap ................................................................................... B.5.55
9 Sheet separator fingers ......................................................................................................... B.5.57
9.1 Function ........................................................................................................................ B.5.57
9.2 Adjusting sheet separator fingers .................................................................................. B.5.57
10 Adjusting the blast air on the suction head ....................................................................... B.5.59
10.1 Overview ........................................................................................................................ B.5.59
10.2 Sheet separation blower ............................................................................................... B.5.59
10.3 Outer carrier air blowers ............................................................................................... B.5.60
10.4 Inner carrier air blowers ................................................................................................ B.5.60
10.5 Rear edge blowers ........................................................................................................ B.5.60
10.6 Pre-separation air ......................................................................................................... B.5.61
11 Pile stops on the suction head ............................................................................................ B.5.62
11.1 Design ............................................................................................................................ B.5.62
11.2 Adapting the pile weight to the printing material ........................................................... B.5.62
12 StaticStar - ionizing unit (option) ......................................................................................... B.5.63
12.1 Overview ........................................................................................................................ B.5.63
12.2 Locations of StaticStar Compact components .............................................................. B.5.63
13 Ionizing blowers at the suction head (optional) ................................................................. B.5.67
13.1 Function/design .............................................................................................................. B.5.67
13.2 Activation/deactivation .................................................................................................. B.5.67
13.3 Positioning the ionizing blowers .................................................................................... B.5.68
14 Foil printing (optional) .......................................................................................................... B.5.70
14.1 General .......................................................................................................................... B.5.70
14.2 Special air-blast nozzles for suction head and ionizing unit .......................................... B.5.70
14.3 Lifting and forwarding suckers ...................................................................................... B.5.72
14.4 Rear edge blowing unit ................................................................................................. B.5.73
B.5.2 SC.999.0020/01
Feeder
15 Lateral sheet separation blowers ........................................................................................ B.5.78
15.1 Function ......................................................................................................................... B.5.78
15.2 Automatic adjustment of the lateral sheet separation blowers ...................................... B.5.78
15.3 Manual adjustment of the lateral sheet separation blowers .......................................... B.5.78
15.4 Setting the blast air volume ........................................................................................... B.5.79
16 Rope guide and guide plate ................................................................................................. B.5.80
16.1 Function ......................................................................................................................... B.5.80
16.2 Adjusting the guide plate ............................................................................................... B.5.80
16.3 Changing the rope ........................................................................................................ B.5.81
17 Sheet monitoring ................................................................................................................... B.5.85
17.1 Overview ........................................................................................................................ B.5.85
17.2 Measuring range of the double/multiple-sheet detector ................................................. B.5.86
17.3 Ultrasonic double sheet detector .................................................................................. B.5.86
17.4 Double sheet detector in the pull lay (option) ................................................................ B.5.88
17.5 Multiple sheet detector .................................................................................................. B.5.88
17.6 Sheet stream / multiple-sheet detector optional ............................................................. B.5.91
17.7 Switching the feeder back on after double sheet detection .......................................... B.5.93
17.8 Switching the feeder back on after multiple sheet recognition ...................................... B.5.94
17.9 Clearing the feeder ....................................................................................................... B.5.95
17.10 Sheet alignment monitor ............................................................................................... B.5.96
17.11 Possible causes of early, late and misaligned sheets .................................................... B.5.100
17.12 Ultrasonic sheet drag monitor ....................................................................................... B.5.102
18 Forwarding rollers .................................................................................................................. B.5.103
18.1 Adjusting to sheet format .............................................................................................. B.5.103
19 Guide rolls on the suction tape ........................................................................................... B.5.104
19.1 General .......................................................................................................................... B.5.104
19.2 Mounting position ........................................................................................................... B.5.104
19.3 Guide rolls ...................................................................................................................... B.5.104
20 Pulling device ........................................................................................................................ B.5.106
20.1 Function ......................................................................................................................... B.5.106
20.2 Function elements .......................................................................................................... B.5.106
20.3 Setting the format .......................................................................................................... B.5.106
20.4 Adjusting the suction air ................................................................................................ B.5.107
20.5 Adjusting the pull stop to the stock ............................................................................... B.5.108
20.6 Pull lay monitor ............................................................................................................. B.5.109
20.7 Adjusting the pull lay monitor ........................................................................................ B.5.109
20.8 Adjusting the pull distance ............................................................................................ B.5.112
SC.999.0020/01 B.5.3
Feeder
20.9 Retainer ........................................................................................................................ B.5.112
20.10 Cleaning the pull lay ...................................................................................................... B.5.114
21 Separator rolls ........................................................................................................................ B.5.115
21.1 Function ........................................................................................................................ B.5.115
21.2 Adjusting the height of the separator rolls ..................................................................... B.5.115
21.3 Changing the separator roll position ............................................................................. B.5.116
21.4 Throwing on/off individual separator rolls ..................................................................... B.5.116
21.5 Cleaning the separator rolls .......................................................................................... B.5.116
21.6 Cleaning the sheet guide plate ..................................................................................... B.5.117
22 Front lays ............................................................................................................................... B.5.118
22.1 Function ......................................................................................................................... B.5.118
22.2 Throwing the front lays on/off ........................................................................................ B.5.118
22.3 Adjusting the gripper bite .............................................................................................. B.5.119
22.4 Cleaning the front lays .................................................................................................. B.5.119
22.5 Blowing/suction nozzles ................................................................................................ B.5.120
22.6 Raising the sheet stop fingers ....................................................................................... B.5.120
23 Crash bar ................................................................................................................................ B.5.121
23.1 Function ........................................................................................................................ B.5.121
23.2 Adjusting the crash bar ................................................................................................. B.5.121
24 Adjustment information for special printing material ....................................................... B.5.122
24.1 Special printing materials ............................................................................................... B.5.122
24.2 Book paper ..................................................................................................................... B.5.122
25 CutStar (sheeter) - Preset Plus feeder ................................................................................ B.5.124
25.1 Function/Task ................................................................................................................ B.5.124
25.2 Conversion to operation with CutStar ........................................................................... B.5.124
25.3 Conversion to operation without CutStar ...................................................................... B.5.127
26 Troubleshooting on the feeder ............................................................................................ B.5.129
26.1 Overview ........................................................................................................................ B.5.129
26.2 Pile ................................................................................................................................. B.5.129
26.3 Sheet separation ............................................................................................................ B.5.129
26.4 Double sheet detectors .................................................................................................. B.5.130
26.5 Suction tape feed table sheet transport ......................................................................... B.5.131
26.6 Sheet alignment system ................................................................................................. B.5.131
27 Emergency measures in the event of the failure of a servo-drive in the feeder ............. B.5.134
27.1 What is the purpose of these emergency measures? ................................................... B.5.134
27.2 Manually setting suction head to sheet size ................................................................. B.5.135
B.5.4 SC.999.0020/01
Feeder
27.3 Manual suction head height adjustment ....................................................................... B.5.136
27.4 Manually setting the side stops to sheet size ................................................................ B.5.137
27.5 Manually setting cover guide height .............................................................................. B.5.138
27.6 Manually setting separator rolls .................................................................................... B.5.140
27.7 Manually setting air volume controller for the blowing/suction nozzle .......................... B.5.141
27.8 Manually setting pull lays to sheet width ....................................................................... B.5.142
SC.999.0020/01 B.5.5
Feeder
B.5.6 SC.999.0020/01
Feeder
1 Feeder - safety instructions
SF.901.5000-000UTKENU_00
1.1 To be observed when performing work
Warning - Explosion hazard and fire
hazard due to dust deposits!
Dust, such as powder or paper dust,
can result in fire hazard or explosion
hazard.
Therefore, clean the areas affected by
dust regularly, at least once a week,
using a vacuum cleaner.
Only use suitable and approved indus-
trial vacuum cleaners and avoid work-
ing with compressed air, as this could
swirl up the dust.
Warning - Risk of injury from mov-
ing parts!
Pay particular attention to moving
parts and hazards in the material in-
feed area during work on the feeder.
Do not reach into the gap of the mate-
rial infeed.
Warning - Risk of injury from mov-
ing parts!
Do not reach into any moving parts,
such as pickup and forwarding suck-
ers or forwarding rollers.
Warning - Risk of injury by moving
pile support plate!
Prior to raising or lowering the pile sup-
port plate: Ensure, by means of a vi-
sual inspection that no-one is standing
in the hazardous area of moving parts
and that nothing can be jammed un-
derneath the pile support plate.
When the press is switched on: Never
stand underneath the pile support
plate. Do not sit on the pile support
plate. Do not ride on the pile support
plate.
SC.999.0020/01 B.5.7
Feeder
2 Pile change
SF.901.5010-000UTKENU_01
2.1 Determining the actual sheet size
Your press can process sheet sizes of up to 753 mm x
1060 mm.
When processing in perfecting mode, the sheet length
of 753 mm may be exceeded by a maximum of 2 mm.
Sheet lengths over 755 mm including tolerances can-
not be processed.
Caution - Damage to the press due to
too large sheet size!
When operating presses in perfecting
mode, ensure that the sheet length of
753 mm is not exceeded by more than
2 mm. Measure the sheet length directly
in the feeder pile to ensure that the max-
imum sheet size is not exceeded.
2.2 Normal pile change
Note
The maximum pile weight is 2000 kg.
The maximum auxiliary pile weight is
750 kg.
When the feeder is equipped with an op-
tional preloading device, the maximum
pile weight in conjunction with a pile car-
riage is 1400 kg (see chapter "Preload-
ing and pile setup").
Changing the pile
SF.901.1891-000GRAUND_00
1. Perform a visual check to ensure that there is no-
1 body in the hazardous zone of the pile support.
2. Press the Main pile down button (Fig. 1/6).
2 The pile support plate travels downward. For
safety reasons, the pile support plate stops the
down motion 12 cm above ground.
3. Press again the Main pile down button.
The pile support plate
● stops briefly above the ground,
3 5
● aligns itself automatically in center position,
● and continues its movement down to the
4 6 ground.
4. Move the empty pallet out of the feeder.
Fig. 1 Pile control panel
B.5.8 SC.999.0020/01
Feeder
5. Move a full pallet onto the pile support plate. Cen-
SG.901.5988-000GRAUND_00
ter the pallet when you insert it.
On D.S. and on O.S. (Fig. 2/1), the feeder is
equipped with a laser pointer. The laser pointers
assist you in aligning the pile. The laser pointer
emits a light beam that is visible as a light dot on
the pile. The distance between the sheet edge to
the light dot is approximately 6 ... 14 mm.
1 Note
The ex factory adjustments of the laser
pointers differ.
Feeder without non-stop device: The
light spot is on the pile.
Feeder with non-stop device: The light
spot is next to the pile in order to permit
the main pile to be aligned under the
auxiliary pile; see "Non-stop pile
change" in the following section.
6. Press the Main pile up button (Fig. 1/5).
The pile support plate moves upwards. It stops at
the alignment position below the side stops for
the pile alignment.
If pile alignment is switched on, it automatically
aligns the pile. If pile alignment is switched off,
Fig. 2 Laser pointer on O.S. you must use the Align pile buttons (Fig. 1/1 and
2) to align the pile manually.
If the feeder and pile alignment are switched on then
SG.901.5894-003GRAUND_00
the pile is automatically moved to the governor foot
after the alignment process.
If the feeder is not switched on, you must raise the pile
manually.
1
Note
The governor foot (Fig. 3/1) on the suc-
tion head must be in inquiry position
(Fig. 3).
7. If the governor foot is not in inquiry position,
switch the feeder off and back on.
The governor foot automatically swivels to the in-
Fig. 3 Governor foot in inquiry position quiry position.
8. Press the Main pile up button until the pile stops
automatically.
SC.999.0020/01 B.5.9
Feeder
2.3 Non-stop pile change (optional)
The non-stop pile change function enables you to re-
SG.901.5891-003GRAUND_00
place an empty pallet with a full one without interrupt-
ing production.
Note
The maximum auxiliary pile weight is
750 kg.
1
The on-stop accessories consist of 9 non-stop rods
and one non-stop bar.
The supporting members and the non-stop bar are in a
holding device (Fig. 4/1) on the feeder.
On D.S., there is a scale (Fig. 5) with a white and a
black area.
● White area (Fig. 5/2): Changing piles is possible
in this area. The menu item of the white area is
the lowest position that the non-stop bar can
reach.
● Black area (Fig. 5/1): Merging auxiliary pile and
main pile must be completed in this area. The
upper point of the black area is the highest posi-
tion the auxiliary pile can reach. Pile raising stops
if auxiliary pile and main pile have not yet merged
at this point.
Fig. 4 Supporting members and non-stop bar in
holding device
SG.901.5845-003GRAUND_00
Fig. 5 Scale
B.5.10 SC.999.0020/01
Feeder
Changing the pile
SF.901.1891-000GRAUND_00
1. Use the Heidelberg non-stop pallets (Fig. 7/2)
1 with recesses for the members.
2. Lower the auxiliary pile with the Auxiliary pile
down button (Fig. 6/4) until the bracket for the
2
non-stop bar on D.S. and on O.S. can easily be
reached.
3. Hook the non-stop bar (Fig. 7/3), with the guide
rail upwards, into the retainer on D.S. and on O.S.
(Fig. 7). The non-stop bar must lock home on
3 5 D.S. and O.S.
4. Press the Auxiliary pile down button. The non-
stop bar moves automatically down to the height
4 6 of the pile support plate (Fig. 7) or to the lowest
position - the menu item of the white scale range
(Fig. 5/2).
Note
Wait with inserting the supporting mem-
bers until the recesses of the pallet are
visible above the non-stop bar. The hor-
Fig. 6 Pile control panel izontally inserted supporting members
must not be in contact with the non-stop
SG.901.5001-001GRAUND_00
bar.
For a maximum sheet size, insert all 9
non-stop rods and for smaller sheet
sizes as many as possible. Distribute the
non-stop rods over the entire pile width.
This prevents the auxiliary pile from
falling down.
5. Push the supporting members (Fig. 7/1), with the
chamfer upwards, fully home into the recess of
the pallet.
6. Press the Auxiliary pile up button (Fig. 6/3) after
1 2 3 you have inserted all the supporting members.
Move the auxiliary pile system under the sup-
Fig. 7 Inserting the supporting members porting members.
A sensor in the area of the front non-stop bar senses
SG.901.5892-001GRAUND_00
the supporting members. The control system auto-
matically switches over the pile transport to the auxil-
iary pile. The pile support plate with the empty pallet
moves downwards. It stops 12 cm above the ground.
2
7. Press the Main pile down button (Fig. 6/6).
The pile support plate
● stops briefly above the ground,
● automatically aligns in center position,
1
● and continues its movement down to the
ground.
8. Move the empty pallet out of the feeder.
Fig. 8 Auxiliary pile and main pile
SC.999.0020/01 B.5.11
Feeder
9. Move the new pallet onto the pile support plate.
SG.901.5988-000GRAUND_00
Center the pallet when you insert it.
On D.S. and on O.S. (Fig. 9/1), the feeder is
equipped with a laser pointer. The laser pointers
assist you in aligning the pile. The light beam
emitted by the laser pointer should not be visible
on the pile. The distance between the light beam
and the sheet edge is approximately 6 ... 14 mm.
1 Note
The light point of the laser pointer is po-
sitioned next to the pile to permit the
main pile to be aligned under the auxil-
iary pile.
10. Move the main pile (Fig. 8/1) upwards until the
main pile is approximately 10 cm below the aux-
iliary pile (Fig. 8/2).
11. Use the Align pile buttons (Fig. 6/1 and 2) to align
the main pile laterally to the auxiliary pile.
12. Press the Main pile up button (Fig. 6/5).
Fig. 9 Laser pointer on O.S.
The lifting speed is automatically reduced when the
main pile approaches the auxiliary pile. The new main
pile moves underneath the supporting members of the
auxiliary pile at reduced speed.
The pile transport now switches automatically from
auxiliary pile over to the new main pile. The auxiliary
pile drive traverses automatically downward.
13. Starting from the inside, slowly pull out the sup-
porting members.
B.5.12 SC.999.0020/01
Feeder
End of run reached?
SG.901.5891-003GRAUND_00
14. Remove the non-stop bar from the feeder. Tilt the
non-stop bar against the direction of paper travel
and lift the non-stop bar out of the retainer.
Store the non-stop bar in the storage device on
the feeder (Fig. 10/1).
1 15. Press the Auxiliary pile up button to raise the non-
stop bar to the top position. This completes non-
stop operation.
Note
Pile support plate and non-stop bar can-
not collide. If you do not raise the non-
stop bar manually, it will be moved up-
wards as a function of the upwards mo-
tion of the pile support plate.
Fig. 10 Non-stop rods and non-stop bar in support
Feeder stop if the residual pile is too small
When the auxiliary pile reaches the upper end of the
black scale, the pile transport of main pile and auxiliary
pile and the feeder are switched off.
1. Lower the auxiliary pile by approximately 2 cm.
2. Press the Main pile up button until the non-stop
rods are in contact with the main pile.
3. Pull out the non-stop rods.
4. Press the Main pile up button until the pile stops.
5. Switch on sheet travel.
Note
Tables with maximum pile heights can
be found in the "Automatic non-stop pile
change" chapter.
SC.999.0020/01 B.5.13
Feeder
3 Automatic non-stop pile change (optional)
SG.901.5131-000UTKENU_10
3.1 Function
The automatic non-stop pile change enables you to
FS.901.5534-002GRAUND_00
replace an empty pallet with a full one without inter-
rupting production.
The non-stop rods move from their home position
against the direction of paper travel into the grooves of
the non-stop pallet. The auxiliary pile lifting unit takes
over the pile when the non-stop rods are in their work-
ing position (Fig. 11/2). The main pile moves down.
You can change the pallet. The new main pile is
aligned. Main pile and auxiliary pile are merged. The
1 2 non-stop rods are pulled out of the pile and move back
to their home position. (Fig. 11/1).
Fig. 11 Feeder
A pile change is carried out automatically if the follow-
SF.901.1800-000GRAUND_00
ing conditions are met:
1 ● If automatic non-stop operation is preselected.
The LED (Fig. 12/1) on the feeder pile control
panel lights up.
● The non-stop bar is ready to run.
● If you have closed the guards and acknowledged
Feeder free - reset. The LED (Fig. 16/2) on the
D.S. feeder support control panel lights up.
● The feeder pile reached the corresponding resid-
ual pile height.
Fig. 12 Pile control panel
Note
If, during the automatic Emergency-stop
pile change, a guard is opened on the
feeder, the automatic sequence is
stopped.
B.5.14 SC.999.0020/01
Feeder
Note
As soon as the last pallet of the current
job is in the feeder, the "Automatic non-
stop operation" preselection must be de-
activated either on the control panel or
the control station.
3.2 Performing a non-stop pile change
Note
LO.901.0206-000GRAUND_00
Only use Heidelberg non-stop pallets
with recesses for the non-stop rods.
Never use any soiled or damaged pal-
lets.
Note
Please note the following when you
place the new pile onto the pallet:
- The pile must be centered and flush at
one longitudinal side on the pallet
(Fig. 13). - The pile must be aligned ver-
tically (Fig. 13).
1. Engage the non-stop bar (Fig. 14/2) into the re-
ceptacle on D.S. and on O.S. (Fig. 14/1).
Fig. 13 Pallet on pile support plate The ramp must point towards the pile (Fig. 14).
The non-stop bar must lock into place.
SG.901.5984-000GRAUND_00
The non-stop bar is in a holding device on the
feeder support D.S.
2. Visually check that there is nobody in the haz-
ardous area of the feeder pile, particularly the pile
support plates and the non-stop device.
1
3. Close all guards on the feeder.
4. Press the Feeder free - reset button on the feeder
support control panel on D.S.
2 5. Press the Automatic non-stop operation button at
one of the following points:
● Control station
or
● Feeder control panel O.S.
Fig. 14 Engaging the non-stop bar
Based on the printing material properties entered and
the preselected production speed, the required resid-
ual pile height is calculated for the automatic pile
change.
Note
If necessary, change the preset value for
the duration of the non-stop pile change
on the feeder control panel or control
station.
Now, the following processes run automatically:
● Automatic pile alignment is activated.
SC.999.0020/01 B.5.15
Feeder
Automatic pile alignment cannot be deactivated
when non-stop operation is activated.
● After a pile change or after power-on, the non-
stop system moves to the reference position and
then to the computed height at which automatic
non-stop pile change starts.
● The non-stop rods align with the grooves in the
pallet when the pile support plate with the pallet
reaches the non-stop system.
Note
While an automatic pile change is being
performed on the feeder, it is not possi-
ble to change the printing speed using
the Increase printing speed and Reduce
printing speed buttons.
● The non-stop rods move into the grooves of the
pallet.
● The working position is reached when the non-
stop rods rest on the non-stop bar. The non-stop
rods take over the residual pile.
● The pile support plate, together with the empty
pallet, is lowered to the ground.
● The protective roller blind at the preselected
feeding side opens.
6. Move the empty pallet out of the feeder.
LO.901.0206-000GRAUND_00
7. Move the new pallet onto the pile support plate.
Align the pallet when you insert it. The pallet must
be centered on the pile support plate (Fig. 15).
8. Visually check that there is nobody in the haz-
ardous area of the feeder pile, particularly the pile
support plates and the non-stop device.
9. Press the Open/close protective roller blind but-
ton on the feeder support control panel D.S. The
protective roller blind is closed.
10. Press the Feeder free - reset button on the feeder
support control panel on D.S.
Fig. 15 Pile on pile pallet
11. Press the Main pile up button.
● The pile support plate, together with the new pile,
moves upwards.
● The main pile is aligned with respect to the aux-
iliary pile.
● Main pile and auxiliary pile are merged.
● The non-stop rods are pulled out of the pile and
move back to their home position.
● The non-stop system moves to the position for
the next pile change.
B.5.16 SC.999.0020/01
Feeder
Note
The guards on the feeder can be opened
once automatic non-stop pile change
has been completed. Ensure that all
guards are closed before the next pile
change, and that the Feeder free - reset
button has been pressed.
Notes on opening the guards
SG.901.5948-000GRAUND_00
The guards can not be opened under the following
conditions:
1 2 3
● When the control panel is disabled - the LED
(Fig. 16/2) is ON.
● While the non-stop rods are moving into the
4 grooves of the pallet.
5
● While the new main pile is aligned laterally with
respect to the residual pile.
6
● While the non-stop rods are pulled out of the pile.
● While the non-stop system is moving to the level
at which the next pile change takes place.
Fig. 16 Feeder support control panel D.S.
Opening a guard during the automatic non-stop pile
change has the following effects:
● The automatic movement of the pile support plate
stops.
● The printing press remains on impression.
● Depending on the direction of the pile movement,
you must press the Pile up or Pile down button to
resume automatic pile change.
Note
Interrupting an automatic non-stop pile
change may result in a paper stop be-
cause the time may prove insufficient for
a pile change.
Switching over from automatic mode to manual
mode
1. Switch off the "Automatic non-stop operation"
preselection. Press the Automatic non-stop op-
eration button.
The LED in the button goes out. The current au-
tomatic pile change is continued until the non-
stop rods are in idle position.
2. Press the Move rake manually button to switch
on manual mode.
The LED in the button lights up. It blinks if not all
preconditions for moving the rake manually are
fulfilled. A currently executing automatic pile
change is aborted. All guards are unlocked.
SC.999.0020/01 B.5.17
Feeder
Note
Ensure that there is no load on the non-
stop rods. If necessary, move the main
pile from below against the non-stop
rods.
3. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
The non-stop rods can only be moved
when the guards are closed and Feeder
free - reset has been acknowledged.
Switching over from manual mode to automatic
mode
If you want to continue printing operation with auto-
matic non-stop pile change:
1. Press the Automatic non-stop operation button.
The LED in the Move rake manually button goes
out. The LED in the Automatic non-stop operation
button is ON. It blinks if not all prerequisites for
automatic mode are fulfilled.
Changing the residual pile height for the next pile
change
Note
The change of the residual pile height via
the feeder control panel is valid only for
the next pile change. If you wish to
change the residual pile height for all pile
changes within the print job, please cor-
rect the settings on the control station.
1. Press the Auxiliary pile DOWN button on the
feeder control panel. The pile change is per-
formed at a larger residual pile. This gives you
more time for the pile change.
or
Press the Auxiliary pile UP button on the feeder
control panel. The pile change is performed at a
smaller residual pile. This enables you to fed a
larger new pile.
Note
The pile height may prove insufficient for
a pile change if you set the residual pile
height to a smaller value.
Note
Automatic non-stop pile change starts
immediately when the non-stop system
reaches the pallet on the pile support
plate during the down movement.
B.5.18 SC.999.0020/01
Feeder
3.3 Deflecting marked sheets
Depending on the type of printing material used,
sheets can get marked during non/stop pile change by
brushing against the non-stop rods.
The following procedure describes how to earmark the
marked sheet and remove it from the delivery.
1. Set the following selection options on the control
station:
● Sheet catcher ON/OFF
Extending the sheet catchers as soon as the
marked sheet has reached the delivery pile.
● Signal sound ON/OFF
Once the signal has been set, it will sound
before the sheet runs into the delivery
based on the prewarning time set.
● Prewarning time +/-
Time that elapses between the signal and
arrival of the marked sheet.
1 Direction of paper travel
SG.901.5991-001GRAUND_00
1
2 Pull stop O.S.
2 3 3 Pull stop D.S.
4 Stencil for identification
5 Identification (punch)
2. Earmark the uppermost sheet of the new main
4 pile on the pull side (Fig. 17).
5 Note
Use the pliers and stencil to remove a
small piece of paper, thereby identifying
the sheet.
Fig. 17 Identification earmarking on the pull side on
O.S.
3. On the pull side, place the stencil (Fig. 18/1) up
SG.901.5997-000GRAUND_00
against the front and side edges of the top sheet
of the new pile.
4. Use the pliers (Fig. 18/3), as shown in the figure,
level with the stencil marking (Fig. 18/2) and
1 make a stamp mark in the top sheet.
Depending on the setting on the control station the
control system will perform the following functions af-
ter each automatic non-stop pile change:
● Optional: a signal signifies that the marked sheet
2
will arrive in the delivery after the set prewarning
3 time has elapsed.
● At the same time the delivery display switches
over to sheet deflection. The display shows the
Fig. 18 Fitting stencil number of sheets until the earmarked sheet ar-
rives.
SC.999.0020/01 B.5.19
Feeder
● The active pull lay detects the earmarked sheet.
● A signal will sound 5 seconds before the sheet
arrives in the delivery.
● Optionally: as soon as the marked sheet has
been set down on the delivery pile, the sheet
catchers move in and retain the following sheets.
5. Press the Sample sheet removal button.
The front edge stop swings downward.
6. Remove the marked sheet from the delivery pile.
7. Press the Sample sheet removal button again.
● The front edge stop swings upward.
● The sheet catchers move back. Release the
retained sheets.
Note
If you do not press the Sample sheet re-
moval button, the sheet catchers move
back automatically as soon as the pile on
the sheet catchers has reached a height
of approximately 2.5 cm.
3.4 Malfunctions during automatic pile change
Malfunction Possible causes Remedy
The "Automatic non-stop pile change" ● The rear non-stop bar is not en- Engage the rear non-stop bar.
preselection cannot be activated. The gaged. Close all the guards.
LED is flashing. or If the pile area is free, press the Feed-
● The guards are not closed. er free - reset button.
or
● The Feeder free - reset button has
not been pressed.
Tab. 1
Malfunction Possible causes Remedy
Paper stop at the feeder. The auxiliary The available auxiliary pile height Merge main pile and auxiliary pile in
pile system is at its uppermost posi- proves insufficient for carrying out a manual mode.
tion. The non-stop rods still carry a complete pile change before the aux-
pile of approximately 240 mm. The iliary pile system reaches its upper-
new main pile cannot be moved up- most position.
wards. Fault display: "Auxiliary pile
upper end position".
Tab. 2
Mode of procedure:
1. Lower the auxiliary pile by several centimeters.
Press the Auxiliary pile DOWN button.
2. Raise the main pile until it is just under the aux-
iliary pile.
Press the Main pile up button.
3. Align the main pile laterally with respect to the
auxiliary pile.
B.5.20 SC.999.0020/01
Feeder
4. Raise the main pile until it applies no more load
onto the non-stop rods.
5. Deselect automatic non-stop operation.
Press the Automatic non-stop operation button.
The LED in the button goes out.
6. Press the Move rake manually button.
The LED in the button lights up.
7. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
Ensure that there is a sufficiently high
pile in the feeder before the pile change
is started. A new pile must be available in
time. The preselected production speed
must agree with the actual printing
speed. If necessary, adapt the prese-
lected time for the pile change on the
control station. Experience showed, that
180 s is a suitable value.
Malfunction Possible causes Remedy
Paper stop at the feeder. The auxiliary The new main pile is badly positioned Align the pile.
pile system is at its uppermost posi- on the pallet so that the lateral dis-
tion. The non-stop rods still carry a tance proves insufficient for aligning
pile of approximately 240 mm. The the main pile with respect to the aux-
new main pile is approximately 15 mm iliary pile.
below the non-stop rods. Fault dis-
play: "Auxiliary pile upper end posi-
tion" and "Pile support plate reached
adjusting limit".
Tab. 3
Mode of procedure:
1. Lower the main pile.
Press the Main pile DOWN button.
2. Align the main pile such that a further lateral
alignment is still possible, or merge the main pile
with an offset towards the auxiliary pile.
3. Lower the auxiliary pile by a few centimeters.
Press the Auxiliary pile DOWN button.
4. Raise the main pile until it is just under the aux-
iliary pile. Press the Main pile up button.
5. Align the main pile laterally with respect to the
auxiliary pile.
Press the Move pile towards D.S. or Move pile
towards O.S. button.
6. Raise the main pile until it applies no more load
onto the non-stop rods.
7. Deselect automatic non-stop operation.
Press the Automatic non-stop operation button.
8. Press the Move rake manually button.
SC.999.0020/01 B.5.21
Feeder
The LED in the button lights up.
9. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
Ensure that the pile is centered and in-
trinsically vertical on the pallet.
Malfunction Possible causes Remedy
The pile does not continue inching The surface of the main pile is cockled Take load off the non-stop rods.
during the removal of the non-stop heavily. Move the non-stop rods to their home
rods. The piles cannot be lowered or position.
raised via the buttons. Fault display:
"Movement of the non-stop rake un-
der load" and "Rods not in basic po-
sition"
Tab. 4
Procedure
1. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
2. Press the Move rake manually button.
The LED in the button lights up.
3. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
Ensure that the pile surface is level. Call
Heidelberg Service if the problem occurs
repeatedly even with good piles.
Malfunction Possible causes Remedy
The pile does not continue inching Incorrect sensor adjustment. Take load off the non-stop rods.
while the non-stop rods are inserted Move the non-stop rods to their home
into the grooves of the pallet. The position.
piles cannot be lowered or raised via
the buttons. Fault display: "Movement
of the non-stop rake under load" and
"Rods not in basic position"
Tab. 5
Procedure
1. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
2. Press the Move rake manually button.
The LED in the button lights up.
3. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
B.5.22 SC.999.0020/01
Feeder
Note
Notify Heidelberg Service if the problem
occurs repeatedly.
3.5 Interrupting automatic sequences in the pile change
Malfunction Possible causes Remedy
Interruption of the up or down move- ● Protective roller blind open Check guards, check Emergency-
ment of the main pile. ● The glass guard is open. stop palm button and start sequence
again.
● Emergency-stop palm button
pressed
● The Pile STOP button has been
pressed.
● The Main pile up button has been
pressed.
● The Main pile down button has
been pressed.
Tab. 6
Mode of procedure:
1. Close the protective devices protective roller
blind and glass guard.
2. Press the Feeder free - reset button.
3. Release each Emergency-stop palm button.
4. Press the Main pile up or Main pile down button
(depending on the direction of the movement).
The main pile resumes the initiated movement auto-
matically. The automatic non-stop pile change is com-
pleted.
Note
The height of the auxiliary pile may prove
insufficient for completing the current
pile change without a stop if the inter-
ruption of the automatic pile change
takes too long.
Malfunction Possible causes Remedy
Interruption of the up or down move- ● Emergency-stop palm button Check Emergency-stop palm button
ment of the auxiliary pile system. pressed and start sequence again.
● The Pile STOP button has been
pressed.
● The Auxiliary pile up button has
been pressed.
● The Auxiliary pile down button has
been pressed.
Tab. 7
SC.999.0020/01 B.5.23
Feeder
Mode of procedure:
1. Release each Emergency-stop palm button.
2. Deselect the preselection "Automatic non-stop
operation", and select it again. Press the Auto-
matic non-stop operation button twice.
The auxiliary pile system moves to the upper reference
position, and back down to the change position.
Note
The auxiliary pile height may prove in-
sufficient for completing the current pile
change without a paper stop if the pile in
the feeder is already rather small.
Malfunction Possible causes Remedy
Interruption when inserting the non- Emergency stop button actuated. Move the rake manually to its working
stop rods into the grooves of the pal- position.
let.
Tab. 8
Mode of procedure:
1. Release each Emergency-stop palm button.
2. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
3. Select manual mode. Press the Move rake man-
ually button.
4. Move the non-stop rods to their working position.
Press the Insert rods into the pile button.
5. Select the "Automatic non-stop operation" pres-
election. Press the Automatic non-stop operation
button.
The LED in the button lights up.
6. Take over the auxiliary pile with the non-stop
rods. Press the Auxiliary pile UP button.
7. Continue automatic pile change. Press the Main
pile DOWN button.
Faults Possible causes Remedy
Interruption when removing the non- Emergency-stop palm button pressed Move the rake manually to its home
stop rods from the pile. position.
Tab. 9
Mode of procedure:
1. Release each Emergency-stop palm button.
2. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
3. Select manual mode. Press the Move rake man-
ually button.
B.5.24 SC.999.0020/01
Feeder
4. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
5. Select the "Automatic non-stop operation" pres-
election. Press the Automatic non-stop operation
button.
The LED in the button lights up.
As soon as you switch sheet travel back on, the aux-
iliary pile system first moves to the upper reference
position, then down to the change position for the next
pile change.
3.6 Maintenance work
To perform maintenance work, you can move the non-
SF.901.1801-000GRAUND_00
stop rods in inching mode to their working position.
1 3 1. Engage the non-stop bar in the receptacle on
D.S. and on O.S. The ramp must point towards
the pile. The non-stop bar must lock into place.
2 4 The non-stop bar is in a holding device on the
feeder support D.S.
2. Visually check that there is nobody in the haz-
ardous area of the feeder pile, particularly the pile
support plates and the non-stop device.
3. Close all guards on the feeder.
4. Press the Feeder free - reset button on the feeder
support control panel on D.S.
5. Ensure that the "Automatic non-stop operation"
preselection is deselected. Press the Move rake
manually button (Fig. 19/2). The push buttons
Pull rods out of the pile (Fig. 19/3) and Insert rods
into the pile (Fig. 19/4) are enabled.
Note
The non-stop rods must be aligned to-
Fig. 19 Feeder pile control panel
wards the grooves of the pallet and with-
out load applied, or the entire pile area
must be free.
The non-stop rods only move when all
guards are closed and the Feeder free -
reset button has been pressed.
6. Press the Insert rods into the pile button
(Fig. 19/4).
The non-stop rods move to their working position.
7. Carry out the maintenance work. See mainte-
nance manual.
8. Press the Pull rods out of the pile button
(Fig. 19/3).
The non-stop rods move to their home position
under the feed table.
SC.999.0020/01 B.5.25
Feeder
3.7 Pile heights
1 Pile height
FS.901.5536-001GRAUND_00
The entered production parameters are used as the
basis for calculating the required residual pile height
for the automatic non-stop pile change. The faster the
press runs and the thicker the printing material, the
more the necessary residual pile height increases.
This reduces the maximum height of the new main pile
that can be fed under the residual pile.
Fig. 20 Pile heights on the non-stop feeder
Please observe the reference values for the maximum
pile height in the following tables to grant a smooth pile
change in automatic non-stop feeder operation. The
maximum pile height depends on the thickness of the
printing material and production speed. It is valid for
presses with Autopile Plus.
Note
Ensure that a new main pile is available
in time and that the preselected produc-
tion speed matches the actual printing
speed.
Note
Only valid for CD/CX 102 and not for
SX 102.
Maximum pile height for a printing press raised
500 mm (19.69 in)
Thickness of printing ma- Maximum pile height (1) [mm] ([in]) at printing speed
terial [mm] ([in])
15,000 [sheets/h] 13,000 [sheets/h] 11,000 [sheets/h]
0.3 (0.012) 1190 (46.85) 1210 (47.64) 1230 (48.43)
0.4 (0.016) 1150 (45.28) 1170 (45.67) 1190 (46.85)
0.5 (0.020) 1110 (43.70) 1140 (44.09) 1170 (46.06)
0.6 (0.024) 1070 (42.13) 1100 (42.52) 1130 (44.49)
0.8 (0.031) 990 (38.98) 1030 (40.55) 1070 (42.13)
Tab. 10 Pile heights in a printing press raised 500 mm (19.69 in)
(1) The specifications refer to pile heights (Fig. 20/1)
without a non-stop pallet.
B.5.26 SC.999.0020/01
Feeder
Maximum pile heights for a printing press raised
900 mm (35.43 in)
Note
Only valid for CD/CX 102 and not for
SX 102.
Thickness of printing ma- Maximum pile height (1) [mm] ([in]) at printing speed
terial [mm] ([in])
15,000 [sheets/h] 13,000 [sheets/h] 11,000 [sheets/h]
0.3 (0.012) 1590 (62.60) 1610 (63.39) 1630 (64.17)
0.4 (0.016) 1550 (61.02) 1570 (61.81) 1590 (62.60)
0.5 (0.020) 1510 (59.45) 1540 (60.63) 1570 (61.81)
0.6 (0.024) 1470 (57.87) 1500 (59.06) 1530 (60.24)
0.8 (0.031) 1390 (54.72) 1430 (56.30) 1470 (57.87)
Tab. 11 Pile heights for printing presses elevated by 900 mm (35.43 in)
(1) The specifications refer to pile heights (Fig. 20/1)
without a non-stop pallet.
SC.999.0020/01 B.5.27
Feeder
4 Preloading and pile change
SF.901.5140-000UTKENU_01
4.1 Determining the actual sheet size
It is vital that you observe the specifications for deter-
mining the actual sheet size for the sheet size to be
processed. See the "Pile change, Determining the ac-
tual sheet size" chapter for further information.
4.2 Preloading device (option)
Note
SF.901.5951-000GRAUND_00
1 1 The maximum weight of pile and pile
carriage is 1400 kg. The maximum
weight of the auxiliary pile is 750 kg.
1. Release the clamping levers at the stops
(Fig. 21/1).
2. Adjust the stop on the pull side to the sheet width.
The scale on the guard already takes the pull dis-
tance into account.
3. Adjust the stop on the non-pull side to the sheet
width plus 10 mm.
4. Close the clamping levers.
Fig. 21 Preloading device
5. Hook the middle stop (Fig. 22/1) in the center and
SF.901.5991-000GRAUND_00
3 1 3 to the cross bar on the floor (Fig. 22/2).
6. Release the clamping levers (Fig. 22/3) at the
guide pieces.
7. Push the guide pieces (Fig. 22/4) to the stops.
8. Close the clamping levers.
4 4 9. Push the pile carriage on the rails (Fig. 22/5) to
the stops.
10. Close the brakes (Fig. 22/6) on the pile carriage.
11. Align the pile (Fig. 22/7).
12. Release the brakes and pull back the pile car-
riage by a short way.
13. Push the guide piece towards D.S. or O.S.
7 Leave the stops at their positions for further pile
changes.
14. Unhook the middle stop.
6 5 6 5 2
Fig. 22 Pile change
B.5.28 SC.999.0020/01
Feeder
4.3 Pile change
1. Perform a visual check to ensure that there is no-
body or nothing in the danger zone of the pile
support.
2. Press the Main pile down button. The pile support
plate moves down. For safety reasons, the pile
support plate stops the down motion 12 cm
above ground.
3. Press the Main pile down button again. The pile
support plate
● stops briefly above the ground,
● aligns itself automatically in center position,
● and continues its movement down to the
ground.
4. Move the empty pile carriage out of the feeder.
5. Move the prealigned pile carriage on the rails up
to the front pile stops. Carefully observe the lat-
eral stops during this process.
6. Close the brakes on the pile carriage.
7. Press the Main pile up button. The pile support
plate moves upwards. It stops at the alignment
position below the side stops for pile centering. If
pile centering is switched on, it automatically
aligns the pile. If pile centering is switched off,
you must use the Align pile buttons to align the
pile manually.
When feeder and pile centering are switched on, the
SG.901.5894-002GRAUND_00
pile automatically moves to the governor foot after the
alignment process has been completed.
If the feeder is not switched on, you must raise the pile
manually.
1 Note
The governor foot (Fig. 23/1) on the suc-
tion head must be in inquiry position
(Fig. 23).
8. If the governor foot is not in inquiry position,
switch the feeder off and back on. The governor
foot automatically swivels to the inquiry position.
Fig. 23 Governor foot in inquiry position 9. Press the Main pile up button until the pile stops
automatically.
SC.999.0020/01 B.5.29
Feeder
5 Automatic pile alignment
SF.901.5020-000UTKENU_04
5.1 Determining the actual sheet size
It is vital that you observe the specifications for deter-
mining the actual sheet size for the sheet size to be
processed. See the "Pile change, Determining the ac-
tual sheet size" chapter for further information.
5.2 Function
Pile alignment
● corrects a sloping or stepped pile.
● positions the pile in order to guarantee a pull dis-
tance of approximately 5 mm towards D.S. or
O.S.
You can activate and deactivate the automatic pile
alignment function at the control station or at the feed-
er touch screen.
During alignment, pile support frame, pile support
plate and the auxiliary pile system are positioned joint-
ly. Starting from the pile center, the maximum motion
path is 35 mm to D.S. and 35 mm to O.S.
Depending on whether you have defined the pull side
on D.S. or on O.S., the sensors perform different tasks.
Sensor on pull side
SF.901.5875-000GRAUND_00
The sensor (Fig. 24/1) measures the lateral distance
between the pile and the lateral pile stop (Fig. 24/2).
The sensor controls the pile so that
● a constant distance to the lateral sheet separa-
tion blower is maintained;
● the sheet is aligned to a pull distance of approx-
imately 5 mm.
The control system sets the sensor in two different po-
sitions.
● Lower position (preset position): In the lower po-
sition, the pile is pre-aligned.
2 ● Upper position (production position): In the upper
position, the pile is aligned with respect to the
lateral sheet separation blower.
Sensor on non-pull side
1 The sensor on the non-pull side is used for positioning
the lateral sheet separation blowers. The lateral sheet
separation blowers are adjusted to a distance of ap-
proximately 3 mm from the pile edge.
Fig. 24 Sensor and pile stop
B.5.30 SC.999.0020/01
Feeder
5.3 Function of the buttons
Selecting the operating mode
SF.901.1191-001GRAUND_00
Button Automatic pile alignment ON/OFF (Fig. 25/1)
Button lit: "Automatic" operating mode
1 Button dark: "Manual" operating mode
2 3 4 Correcting the pull distance
● Button Pull distance correction toward D.S.
(Fig. 25/5)
The value appears on the display (Fig. 25/ 2). The ar-
row on the display shows the direction.
5
● Button Pull distance correction toward O.S.
(Fig. 25/6)
6 The value appears on the display (Fig. 25/ 2). The ar-
row on the display shows the direction.
Fig. 25 Feeder touch screen
Correcting the sheet size/moving the pile stops
SF.901.1192-000GRAUND_00
1 2
When automatic pile alignment (Fig. 25/1) is inactive,
you can change the position of the lateral sheet sep-
aration blowers manually.
● Button Lateral sheet separation blowers, larger
format (Fig. 26/1)
3 4 The lateral sheet separation blower on the pull side
remains. The opposite lateral sheet separation blower
moves away from the pile.
The value appears on the display (Fig. 25/ 3).
Fig. 26 Start-up control panel ● Button Lateral sheet separation blowers, smaller
format (Fig. 26/3)
The lateral sheet separation blower on the pull side
remains. The opposite lateral sheet separation blower
moves towards the pile.
The value appears on the display (Fig. 25/ 3).
Aligning the active pile
SF.901.1193-001GRAUND_00
1 In "Manual" operating mode, the pile (main pile or aux-
iliary pile) can be aligned with the buttons. These but-
2 tons do not have any function in "Automatic" mode.
The pile is aligned by the pile control system.
Note
You can align the pile at the start-up con-
3 trol panel (Fig. 26) or at the pile control
panel (Fig. 27).
● Button Pile toward D.S. (Fig. 26/2) or (Fig. 27/1)
The active pile moves to D.S.
The value appears on the display (Fig. 25/ 4). The ar-
row on the display shows the direction.
● Button Pile toward O.S. (Fig. 26/4) or (Fig. 27/2)
Fig. 27 Pile control panel
The active pile traverses to O.S.
The value appears on the display (Fig. 25/ 4). The ar-
row on the display shows the direction.
SC.999.0020/01 B.5.31
Feeder
5.4 Method of operation in "Automatic pile alignment" mode
In the operating mode "Automatic pile alignment", the
button Automatic pile alignment ON/OFF is lit.
1. When the button Main pile UP (Fig. 27/3) is
pressed, the pile moves up to the paper detection
sensor and stops at the sensor. The pile align-
ment system aligns the pile support plate.
If the feeder is switched on, the pile moves upwards to
the governor foot after the alignment process has been
completed.
If the feeder has stopped:
Note
The governor foot on the suction head
must be in inquiry position.
2. Press the Main pile up button until the pile stops.
The pile alignment system aligns the pile. The Auto-
matic pile alignment ON/OFF button
● blinks as long as the pile is aligned.
● lights steadily once the pile has been aligned.
3. When the button Automatic pile alignment
ON/OFF is lit: Move the pile up to the governor
foot with the button Main pile UP.
The sensor moves to the upper position.
Pile end reached
Just before the pile end is reached, the pile alignment
system switches over to the new operating mode.
Thus it prevents that the sensors are influenced by the
pallet.
Note
When the button Main pile DOWN is
pressed, the pile support plate automat-
ically moves down and stops approx.
12 cm above the floor.
If the button Main pile DOWN is pressed
again, the pile support plate moves
down, stops again just above the floor,
centers itself and then lowers completely
to the floor.
B.5.32 SC.999.0020/01
Feeder
6 Automatic non-stop pile change (optional)
SF.901.5131-000UTKENU_03
6.1 Function
The automatic non-stop pile change enables you to
FS.901.5534-002GRAUND_00
replace an empty pallet with a full one without inter-
rupting production.
From their home position, the non-stop rods move
against the direction of paper travel into the grooves of
the pile table. The auxiliary pile lifting unit takes over
the pile when the non-stop rods are in their working
position (Fig. 28/2). The main pile moves down. You
can change the pallet. The new main pile is aligned.
Main pile and auxiliary pile are merged. The non-stop
1 2 rods are pulled out of the pile and move back to their
home position. (Fig. 28/1).
Fig. 28 Feeder
A pile change is carried out automatically if the follow-
SF.901.1800-000GRAUND_00
ing conditions are met:
1 ● If automatic non-stop operation is preselected.
The LED (Fig. 29/1) on the feeder pile control
panel lights up.
● The non-stop bar is ready to run.
● If you have closed the guards and pressed the
Reset button described in the Safety chapter.
The LED (Fig. 33/2) on the D.S. feeder support
control panel lights up.
● The feeder pile reached the corresponding resid-
ual pile height.
Fig. 29 Control panel for non-stop pile control
Note
If, during the automatic Emergency-stop
pile change, a guard is opened on the
feeder, the automatic sequence is
stopped.
SC.999.0020/01 B.5.33
Feeder
Note
As soon as the last pallet of the current
job is in the feeder, the "Automatic non-
stop operation" preselection must be de-
activated either on the control panel or
the control station.
6.2 Determining the actual sheet size
It is vital that you observe the specifications for deter-
mining the actual sheet size for the sheet size to be
processed. See the "Pile change, Determining the ac-
tual sheet size" chapter for further information.
6.3 Performing a non-stop pile change
LO.901.0206-000GRAUND_00
Note
Use only Heidelberg pile tables with re-
cesses for the non-stop rods. Never use
any soiled or damaged pallets.
Note
When placing the new pile onto the pallet
you need to pay attention to the follow-
ing:
- The pile must be centered and flush at
one longitudinal side on the pallet
(Fig. 30).
- The pile must be aligned vertically
(Fig. 30).
Fig. 30 Pallet on pile support plate
1. Engage the non-stop bar (Fig. 31/2) into the re-
SG.901.5984-000GRAUND_01
ceptacle on D.S. and on O.S. (Fig. 31/1).
The ramp must point towards the pile (Fig. 31).
The non-stop bar must lock into place.
The non-stop bar is in a holding device on the
1 feeder support D.S.
2. Close all guards on the feeder.
3. Press the Reset button described in the Safety
chapter on the feeder support control panel on
2 D.S.
4. Press the Automatic non-stop operation button at
one of the following points:
● Control station
or
Fig. 31 Engaging the non-stop bar
● Feeder control panel O.S.
The control system employs the entered printing ma-
terial properties and the preselected production speed
to compute the required residual pile height for auto-
matic pile change.
B.5.34 SC.999.0020/01
Feeder
Note
If necessary, change the preset value for
the duration of the non-stop pile change
at the feeder control panel or at the con-
trol station.
Now, the following processes run automatically:
● Automatic pile alignment is activated.
Automatic pile alignment cannot be deactivated
when non-stop operation is activated.
● After a pile change or after power-on, the non-
stop system moves to the reference position and
then to the computed height at which automatic
non-stop pile change starts.
● The non-stop rods align with the grooves in the
pallet when the pile support plate with the pallet
reaches the non-stop system.
Note
While an automatic pile change is being
performed on the feeder, it is not possi-
ble to change the printing speed using
the Increase printing speed and Reduce
printing speed buttons.
● The non-stop rods move into the grooves of the
pallet.
● The working position is reached when the non-
stop rods rest on the non-stop bar. The non-stop
rods take over the residual pile.
● The pile support plate, together with the empty
pallet, is lowered to the ground.
● The protective roller blind at the preselected
feeding side opens.
For presses without Autopile:
LO.901.0206-000GRAUND_00
5. Move the empty pallet out of the feeder.
6. Move the new pallet onto the pile support plate.
Align the pallet when you insert it. The pallet must
be centered on the pile support plate (Fig. 32).
7. Press the Open/close protective roller blind but-
ton on the feeder support control panel D.S. The
protective roller blind is closed.
8. Press the Reset button described in the Safety
chapter on the feeder support control panel on
D.S.
9. Press the Main pile up button.
Fig. 32 Pile on pile pallet
SC.999.0020/01 B.5.35
Feeder
For presses with Autopile:
● The Autopile system moves the empty pallet out
of the feeder and the new main pile into the feed-
er.
● The pile support plate, together with the new pile,
moves upwards.
● The main pile is aligned with respect to the aux-
iliary pile.
● Main pile and auxiliary pile are merged.
● The non-stop rods are pulled out of the pile and
move back to their home position.
● The non-stop system moves to the position for
the next pile change.
Note
The guards on the feeder can be opened
once automatic non-stop pile change
has been completed. Ensure that all
guards are closed before the next pile
change, and that the Reset button de-
scribed in the Safety chapter has been
pressed.
Notes on opening the guards
SG.901.5948-000GRAUND_00
The guards can not be opened under the following
conditions:
1 2 3
● When the control panel is disabled - the LED
(Fig. 33/2) is ON.
● While the non-stop rods are moving into the
4 grooves of the pallet.
5
● While the new main pile is aligned laterally with
respect to the residual pile.
6
● While the non-stop rods are pulled out of the pile.
● While the non-stop system is moving to the level
at which the next pile change takes place.
Fig. 33 Feeder support control panel D.S.
Opening a guard during the automatic non-stop pile
change has the following effects:
● The automatic movement of the pile support plate
stops.
● The printing press remains on impression.
● Depending on the direction of the pile movement,
you must press the Pile up or Pile down button to
resume automatic pile change.
B.5.36 SC.999.0020/01
Feeder
Note
Interrupting an automatic non-stop pile
change may result in a paper stop be-
cause the time may prove insufficient for
a pile change.
Switching over from automatic mode to manual
mode
1. Switch off the "Automatic non-stop operation"
preselection. Press the Automatic non-stop op-
eration button.
The LED in the button goes out. The current au-
tomatic pile change is continued until the non-
stop rods are in idle position.
2. Press the Move rake manually button to switch
on manual mode.
The LED in the button lights up. It blinks if not all
preconditions for moving the rake manually are
fulfilled. A currently executing automatic pile
change is aborted. All guards are unlocked.
Note
Ensure that there is no load on the non-
stop rods. If necessary, move the main
pile from below against the non-stop
rods.
3. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
The non-stop rods can only be moved
when the guards are closed and the Re-
set button described in the Safety chap-
ter has been pressed.
Switching over from manual mode to automatic
mode
If you want to continue printing operation with auto-
matic non-stop pile change:
1. Press the Automatic non-stop operation button.
The LED in the Move rake manually button goes
out. The LED in the Automatic non-stop operation
button is ON. It blinks if not all prerequisites for
automatic mode are fulfilled.
Changing the residual pile height for the next pile
change
Note
The change of the residual pile height via
the feeder control panel is valid only for
the next pile change. If you wish to
change the residual pile height for all pile
changes within the print job, please cor-
rect the settings on the control station.
SC.999.0020/01 B.5.37
Feeder
1. Press the Auxiliary pile DOWN button on the
feeder control panel. The pile change is per-
formed at a larger residual pile. This gives you
more time for the pile change.
or
Press the Auxiliary pile UP button on the feeder
control panel. The pile change is performed at a
smaller residual pile. This enables you to fed a
larger new pile.
Note
The pile height may prove insufficient for
a pile change if you set the residual pile
height to a smaller value.
Note
Automatic non-stop pile change starts
immediately when the non-stop system
reaches the pallet on the pile support
plate during the down movement.
6.4 Deflecting marked sheets
Depending on the type of printing material used,
sheets can get marked during non/stop pile change by
brushing against the non-stop rods.
The following procedure describes how to earmark the
marked sheet and remove it from the delivery.
1. Set the following selection options on the control
station:
● Sheet catcher ON/OFF
Extending the sheet catchers as soon as the
marked sheet has reached the delivery pile.
● Signal sound ON/OFF
Once the signal has been set, it will sound
before the sheet runs into the delivery
based on the prewarning time set.
● Prewarning time +/-
Time that elapses between the signal and
arrival of the marked sheet.
Additional information on the setting options for
the control station is available in the separate
manual for the control system.
B.5.38 SC.999.0020/01
Feeder
2. Earmark the uppermost sheet of the new main
SG.901.6028-000GRAUND_00
1 pile on the pull side (Fig. 34).
Note
2 3
Use the pliers and stencil to remove a
small piece of paper, thereby identifying
the sheet.
● Direction of sheet travel (Fig. 34/1)
4 ● Pull stop O.S. (Fig. 34/2)
● Pull stop D.S. (Fig. 34/3)
5 ● Distance from the center of the earmark to the
front edge: 163 mm (Fig. 34/4)
● Earmark, zoomed in (Fig. 34/5)
Fig. 34 Identification earmarking on the pull side on
O.S.
3. On the pull side, place the stencil (Fig. 35/1) up
SG.901.5997-000GRAUND_00
against the side edge of the top sheet of the new
pile.
4. Use the pliers (Fig. 35/3) to punch a hole in the
top sheet level with the stencil marking
1 (Fig. 35/2).
Depending on the setting on the control station the
control system will perform the following functions af-
ter each automatic non-stop pile change:
● Optional: a signal signifies that the marked sheet
2
will arrive in the delivery after the set prewarning
3 time has elapsed.
● At the same time the delivery display switches
over to sheet ejection. The display shows the
Fig. 35 Fitting stencil number of sheets until the earmarked sheet ar-
rives.
● The active pull lay detects the earmarked sheet.
● A signal sounds 5 seconds before the marked
sheet arrives at the delivery.
● Optionally: as soon as the marked sheet has
been set down on the delivery pile, the sheet
catchers move in and retain the following sheets.
5. Press the Sample sheet removal button.
The front edge stop swings downward.
6. Remove the marked sheet from the delivery pile.
7. Press the Sample sheet removal button again.
● The front edge stop swings upward.
● The sheet catchers move back. Release the
retained sheets.
SC.999.0020/01 B.5.39
Feeder
Note
If you do not press the Sample sheet re-
moval button, the sheet catchers move
back automatically as soon as the pile on
the sheet catchers has reached a height
of approximately 2.5 cm.
6.5 Malfunctions during automatic pile change
Malfunction Possible causes Remedy
The "Automatic non-stop pile change" ● The rear non-stop bar is not en- Engage the rear non-stop bar.
preselection cannot be activated. The gaged. Close all the guards.
LED is flashing. or If the pile area is clear, press the Re-
● The guards are not closed. set button described in the Safety
or chapter.
● The Reset button described in the
Safety chapter has not been
pressed.
Paper stop at the feeder. The auxiliary The available auxiliary pile height Merge main pile and auxiliary pile in
pile system is at its uppermost posi- proves insufficient for carrying out a manual mode.
tion. The non-stop rods still carry a complete pile change before the aux-
pile of approximately 240 mm. The iliary pile system reaches its upper-
new main pile cannot be moved up- most position.
wards. Fault display: "Auxiliary pile
upper end position".
Tab. 12
Mode of procedure:
1. Lower the auxiliary pile by several centimeters.
Press the Auxiliary pile DOWN button.
2. Raise the main pile until it is just under the aux-
iliary pile.
Press the Main pile up button.
3. Align the main pile laterally with respect to the
auxiliary pile.
4. Raise the main pile until it applies no more load
onto the non-stop rods.
5. Deselect automatic non-stop operation.
Press the Automatic non-stop operation button.
The LED in the button goes out.
6. Press the Move rake manually button.
The LED in the button lights up.
7. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
B.5.40 SC.999.0020/01
Feeder
Note
Ensure that there is a sufficiently high
pile in the feeder before the pile change
is started. A new pile must be available in
time. The preselected production speed
must agree with the actual printing
speed. If necessary, adapt the prese-
lected time for the pile change on the
control station. Experience showed, that
180 s is a suitable value.
Malfunction Possible causes Remedy
Paper stop at the feeder. The auxiliary The new main pile is badly positioned Align the pile.
pile system is at its uppermost posi- on the pallet so that the lateral dis-
tion. The non-stop rods still carry a tance proves insufficient for aligning
pile of approximately 240 mm. The the main pile with respect to the aux-
new main pile is approximately 15 mm iliary pile.
below the non-stop rods. Fault dis-
play: "Auxiliary pile upper end posi-
tion" and "Pile support plate reached
adjusting limit".
Tab. 13
Mode of procedure:
1. Lower the main pile.
Press the Main pile DOWN button.
2. Align the main pile such that a further lateral
alignment is still possible, or merge the main pile
with an offset towards the auxiliary pile.
3. Lower the auxiliary pile by a few centimeters.
Press the Auxiliary pile DOWN button.
4. Raise the main pile until it is just under the aux-
iliary pile. Press the Main pile up button.
5. Align the main pile laterally with respect to the
auxiliary pile.
Press the Move pile towards D.S. or Move pile
towards O.S. button.
6. Raise the main pile until it applies no more load
onto the non-stop rods.
7. Deselect automatic non-stop operation.
Press the Automatic non-stop operation button.
8. Press the Move rake manually button.
The LED in the button lights up.
9. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
Ensure that the pile is centered and in-
trinsically vertical on the pallet.
SC.999.0020/01 B.5.41
Feeder
Malfunction Possible causes Remedy
The pile does not continue inching The surface of the main pile is cockled Take load off the non-stop rods.
during the removal of the non-stop heavily. Move the non-stop rods to their home
rods. The piles cannot be lowered or position.
raised via the buttons. Fault display:
"Movement of the non-stop rake un-
der load" and "Rods not in basic po-
sition"
Tab. 14
Procedure
1. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
2. Press the Move rake manually button.
The LED in the button lights up.
3. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
Ensure that the pile surface is level. Call
Heidelberg Service if the problem occurs
repeatedly even with good piles.
Malfunction Possible causes Remedy
The pile does not continue inching Incorrect sensor adjustment. Take load off the non-stop rods.
while the non-stop rods are inserted Move the non-stop rods to their home
into the grooves of the pallet. The position.
piles cannot be lowered or raised via
the buttons. Fault display: "Movement
of the non-stop rake under load" and
"Rods not in basic position"
Tab. 15
Procedure
1. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
2. Press the Move rake manually button.
The LED in the button lights up.
3. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
Note
Notify Heidelberg Service if the problem
occurs repeatedly.
B.5.42 SC.999.0020/01
Feeder
6.6 Interrupting automatic sequences in the pile change
Malfunction Possible causes Remedy
Interruption of the up or down move- ● Protective roller blind open Check guards, check Emergency-
ment of the main pile. ● The glass guard is open. stop palm button and start sequence
again.
● Emergency-stop palm button
pressed
● The Pile STOP button has been
pressed.
● The Main pile up button has been
pressed.
● The Main pile down button has
been pressed.
Tab. 16
Mode of procedure:
1. Close the protective devices protective roller
blind and glass guard.
2. Press the Reset button described in the Safety
chapter.
3. Release each Emergency-stop palm button.
4. Press the Main pile up or Main pile down button
(depending on the direction of the movement).
The main pile resumes the initiated movement auto-
matically. The automatic non-stop pile change is com-
pleted.
Note
The height of the auxiliary pile may prove
insufficient for completing the current
pile change without a stop if the inter-
ruption of the automatic pile change
takes too long.
Malfunction Possible causes Remedy
Interruption of the up or down move- ● Emergency-stop palm button Check the Emergency stop button,
ment of the auxiliary pile system. pressed and resume the sequence.
● The Pile STOP button has been
pressed.
● The Auxiliary pile up button has
been pressed.
● The Auxiliary pile down button has
been pressed.
Tab. 17
Mode of procedure:
1. Release each Emergency-stop palm button.
2. Deselect the preselection "Automatic non-stop
operation", and select it again. Press the Auto-
matic non-stop operation button twice.
The auxiliary pile system moves to the upper reference
position, and back down to the change position.
SC.999.0020/01 B.5.43
Feeder
Note
The auxiliary pile height may prove in-
sufficient for completing the current pile
change without a paper stop if the pile in
the feeder is already rather small.
Malfunction Possible causes Remedy
Interruption when inserting the non- Emergency stop button actuated. Move the rake manually to its working
stop rods into the grooves of the pal- position.
let.
Tab. 18
Mode of procedure:
1. Release each Emergency-stop palm button.
2. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
3. Select manual mode. Press the Move rake man-
ually button.
4. Move the non-stop rods to their working position.
Press the Insert rods into the pile button.
5. Select the "Automatic non-stop operation" pres-
election. Press the Automatic non-stop operation
button.
The LED in the button lights up.
6. Take over the auxiliary pile with the non-stop
rods. Press the Auxiliary pile UP button.
7. Continue automatic pile change. Press the Main
pile DOWN button.
Faults Possible causes Remedy
Interruption when removing the non- Emergency-stop palm button pressed Move the rake manually to its home
stop rods from the pile. position.
Tab. 19
Mode of procedure:
1. Release each Emergency-stop palm button.
2. Deselect the "Automatic non-stop operation" pre-
selection. Press the Automatic non-stop opera-
tion button.
The LED in the button goes out.
3. Select manual mode. Press the Move rake man-
ually button.
4. Move the non-stop rods to their home position.
Press the Pull rods out of the pile button.
5. Select the "Automatic non-stop operation" pres-
election. Press the Automatic non-stop operation
button.
The LED in the button lights up.
As soon as you switch sheet travel back on, the aux-
iliary pile system first moves to the upper reference
B.5.44 SC.999.0020/01
Feeder
position, then down to the change position for the next
pile change.
6.7 Maintenance work
To perform maintenance work, you can move the non-
SF.901.1801-000GRAUND_00
stop rods in inching mode to their working position.
1 3 1. Engage the non-stop bar in the receptacle on
D.S. and on O.S. The ramp must point towards
the pile. The non-stop bar must lock into place.
2 4 The non-stop bar is in a holding device on the
feeder support D.S.
2. Close all guards on the feeder.
3. Press the Reset button described in the Safety
chapter on the feeder support control panel on
D.S.
4. Ensure that the "Automatic non-stop operation"
preselection is deselected. Press the Move rake
manually button (Fig. 36/2). The push buttons
Pull rods out of the pile (Fig. 36/3) and Insert rods
into the pile (Fig. 36/4) are enabled.
Note
The non-stop rods must be aligned to-
wards the grooves of the pallet and with-
out load applied, or the entire pile area
Fig. 36 Control panel for non-stop pile control must be free.
The non-stop rods only move when all
guards are closed and the Reset button
described in the Safety chapter has
been pressed.
5. Press the Insert rods into the pile button
(Fig. 36/4).
The non-stop rods move to their working position.
6. Perform the maintenance work. You can find
notes on this in the "Maintenance and cleaning"
manual.
7. Press the Pull rods out of the pile button
(Fig. 36/3).
The non-stop rods move to their home position
under the feed table.
SC.999.0020/01 B.5.45
Feeder
6.8 Pile heights
● Pile height (Fig. 37/1)
FS.901.5536-001GRAUND_00
Based on the production parameters entered, the
press control system calculates the necessary resid-
ual pile height for automatic non-stop pile change. The
faster the press runs and the thicker the printing ma-
terial, the more the necessary residual pile height in-
creases. This reduces the maximum height of the new
main pile that can be fed under the residual pile.
Fig. 37 Pile heights on the non-stop feeder
Please observe the reference values for the maximum
pile height in the following tables to grant a smooth pile
change in automatic non-stop feeder operation. The
maximum pile height depends on the thickness of the
printing material and production speed. It is valid for
presses with Autopile Plus.
Note
Ensure that a new main pile is available
in time and that the preselected produc-
tion speed matches the actual printing
speed.
Maximum pile heights for a printing press raised
525 mm (20.67 in)
Thickness of print- Maximum pile height (1) [mm] ([in]) at printing speed
ing material [mm]
18,000 [sheets/h] 16,000 [sheets/h] 14,000 [sheets/h] 12,000 [sheets/h]
([in])
0.3 (0.012) 1190 (46.85) 1210 (47.64) 1220 (48.03) 1240 (48.82)
0.4 (0.016) 1140 (44.88) 1160 (45.67) 1190 (46.85) 1210 (47.64)
0.5 (0.020) 1100 (43.31) 1120 (44.09) 1150 (45.28) 1180 (46.46)
0.6 (0.024) 1050 (41.34) 1080 (42.52) 1110 (43.70) 1140 (44.88)
0.8 (0.031) (2) ( 2) 1040 (40.95) 1080 (42.52)
Tab. 20 Pile heights for printing presses elevated by 525 mm (20.67 in)
(1) The specifications refer to pile heights (Fig. 37/1)
without a non-stop pallet.
(2) The maximum printing speed for a stock thickness
of 0.8 mm is 15,000 sheets per hour.
Maximum pile heights for a printing press raised
875 mm (34.45 in)
B.5.46 SC.999.0020/01
Feeder
Thickness of print- Maximum pile height (1) [mm] ([in]) at printing speed
ing material [mm]
18,000 [sheets/h] 16,000 [sheets/h] 14,000 [sheets/h] 12,000 [sheets/h]
([in])
0.3 (0.012) 1540 (60.63) 1560 (61.42) 1570 (61.81) 1590 (62.60)
0.4 (0.016) 1490 (58.66) 1510 (59.45) 1540 (60.63) 1560 (61.42)
0.5 (0.020) 1450 (57.09) 1470 (57.87) 1500 (59.06) 1530 (60.24)
0.6 (0.024) 1400 (55.12) 1430 (56.30) 1460 (57.48) 1490 (58.66)
0.8 (0.031) (2) ( 2) 1390 (54.72) 1430 (56.30)
Tab. 21 Pile heights for printing presses elevated by 875 mm (34.45 in)
(1) The specifications refer to pile heights (Fig. 37/1)
without a non-stop pallet.
(2) The maximum printing speed for a stock thickness
of 0.8 mm is 15,000 sheets per hour.
SC.999.0020/01 B.5.47
Feeder
7 Suction head
SF.901.5030-000UTKENU_03
7.1 Overview of the suction head
SF.901.5805-000GRAUND_00
1
11 2
10 9 8 7 6 5 4 3
Fig. 38 Overview of the suction head
1 Suction head housing
2 Control panel
3 Pile stop
4 Carrier air blower
5 Separator finger
6 Sheet separation blower
7 Forwarding sucker
8 Carrier air blower
9 Lifting sucker
10 Governor foot
11 Rotary valve
B.5.48 SC.999.0020/01
Feeder
1 Forwarding sucker O.S., height adjustment
SF.901.1078-000GRAUND_00
2 Inclination of lifting sucker, inclination adjustment
3 Rear edge blower, blast air volume adjustment
4 Inner carrier air blower, blast air volume adjust-
ment
5 Outer carrier air blower, blast air volume adjust-
ment
6 Sheet separation blower, blast air volume adjust-
10.109.5499/02
ment
7 Lifting sucker, lifting movement adjustment
1 2 3 4 5 6 7 8
8 Forwarding sucker D.S., height adjustment
Fig. 39 Suction head control panel
7.2 Adjusting the sheet size
The suction head is positioned to match the format
SF.901.1802-000GRAUND_00
entry. You can change this setting via the buttons on
1 the feeder control console.
● Press the Increase suction head format button
(Fig. 40/1) to move the suction head away from
2 the forwarding rollers.
● Press the Reduce suction head format button
(Fig. 40/2) to move the suction head toward the
forwarding rollers.
Caution - Risk of collision when
changing the sheet size adjustment
manually!
Ensure that the suction head does not
collide with the pile or with the pallet.
Fig. 40 Pile control panel
SC.999.0020/01 B.5.49
Feeder
7.3 Setting the height
Manual operation
SG.901.5798-001GRAUND_00
In manual mode, the suction head does not change its
height adjustment. The height difference between up-
3 mm per pile edge and forwarding flap can therefore
1 change.
1. Adjust the suction head such that, during pro-
duction, the upper edge of the pile is approxi-
mately 3 mm below the upper edge of the for-
warding flap.
Fig. 41 Forwarding flap diagram
Manual operation - changing the height adjust-
1 SF.901.1881-000GRAUND_00 ment of the suction head
● Press the Suction head height adjustment up
button (Fig. 42/1) to move the suction head up.
Caution - Danger of collision!
The suction head can collide with the pile
when it is moved down. Lower the pile
before you move the suction head down-
2 wards.
● Press the Suction head height adjustment down
button (Fig. 42/2) to move the suction head down.
Fig. 42 Start-up control panel
7.4 Lifting suckers
The lifting suckers (Fig. 43/1) lift the topmost sheet by
SF.901.5852-000GRAUND_00
its rear corner and separate it from the pile.
Replacing the lifting sucker
There are different rubber disk shapes for different
printing materials.
1. Turn the lifting sucker (Fig. 43/1) by 90°. Pull out
the lifting sucker in downward direction.
2. Insert the new lifting sucker into the retainer on
the suction head from underneath. The collar
(Fig. 43/2) of the lifting sucker must be above the
3 2 1 edge of the angle (Fig. 43/3).
Fig. 43 Lifting sucker
B.5.50 SC.999.0020/01
Feeder
Note
Install the lifting suckers with integrated
magnets at the two inner lifting sucker
positions. Sheet travel is not possible
without these special lifting suckers.
The sheet travel monitor on the suction
head assumes that the inner lifting suck-
ers reach the upper end position after
the sheets have been lifted off.
3. Rotate the lifting sucker through 90° into the lock-
ing device. Check the proper seating of the new
lifting sucker.
Replacing the foam ring/foam strip on the lifting
sucker
On the lifting suckers, a foam ring is stuck to the upper
stop surface, and a foam strip is stuck to the stop sur-
face of the guide spring.
Worn, damaged, or missing foam rings/strips may dis-
turb the sheet travel.
1. Replace worn, damaged or missing foam rings/
strips.
Replacement foam rings/strips are enclosed with
the press.
Adjusting the lifting sucker height
SG.901.5799-001GRAUND_01
2 The height adjustment of the lifting suckers is only
visible during operation.
1. Switch on the feeder without sheet travel.
2. Adjust the height of the lifting suckers at the con-
trol knob (Fig. 44/1).
Adjust the height such that the suckers lightly rest on
the pile.
With double sheets: Correct the settings of the wipers.
The height adjustment can be checked on the suction
1 head indicators (Fig. 44/2). The marks indicate the up-
per, middle and lower end positions of the lifting suck-
ers.
Fig. 44 Setting the lifting suckers
SC.999.0020/01 B.5.51
Feeder
7.5 Forwarding suckers
The forwarding suckers (Fig. 45/1) take over the
SG.901.5952-000GRAUND_00
sheets that have been picked up by the lifting suckers.
Note
The forwarding suckers are suction-air
controlled. Always ensure smooth func-
tioning. Do not oil or grease them.
The distance between the forwarding suckers is fixed.
Fig. 45 Forwarding sucker
Adjusting the forwarding sucker height
SG.901.5998-000GRAUND_00
1 2 Adjust the height of the forwarding suckers during
sheet travel.
1. Adjust the following:
● The drop height of the forwarding suckers
on O.S. via the lever (Fig. 46/1)
● The drop height of the forwarding suckers
on D.S. via the lever (Fig. 46/2)
The drop height of the forwarding suckers with
respect to the sheet must be approximately
4 ... 5 mm.
Fig. 46 Setting the forwarding suckers
B.5.52 SC.999.0020/01
Feeder
7.6 Reducing the suction air of the forwarding suckers and lifting suckers
Note
SG.901.5800-003GRAUND_00
Reduce the suction air volume only in
exceptional cases when you process
thin or porous paper. When suction air is
reduced, the sheets may not be lifted by
the suction device or may be dropped
once they have been lifted.
1. Turn the clamp ring (Fig. 47/1) to adjust the suc-
1 tion air to the printing material.
Air is sucked in through the opening and the suc-
tion strength in the lifting and forwarding suckers
is reduced. The suction force on lifting suckers
and forwarding suckers is reduced as the visible
opening increases.
The currently selected vacuum is shown at the
manometer (Fig. 48/2) on the D.S. side frame of
the feeder.
Fig. 47 Reducing the forwarding sucker suction air
SF.901.5992-000GRAUND_00
Fig. 48 Manometer for the suction air vacuum
CutStar (sheeter)
SF.901.5993-000GRAUND_00
Note
If your machine is equipped with a
CutStar, the suction air control mecha-
nism is located behind the support on
D.S. (Fig. 49/1).
Fig. 49 Suction air control mechanism
SC.999.0020/01 B.5.53
Feeder
8 Overview table - suction head settings for different printing materials
SG.901.5055-000UTKENU_05
8.1 Lifting suckers and forwarding suckers
Printing materials
Voluminous, Onion skin pa- Labels, Art printing, Cardboard
porous per, lightweight pa- lightweight
Bible paper per, cardboard
art printing
(40 ... 100 g) (30 ... 60 g) (60 ... 130 g) (100 ... 200 g) (over 200 g)
Lifting suckers A A A A A
Suction discs Nipples B Nipples B Gray C / red D Red D/ gray C Red D/ gray C
Position Straight E Straight E Straight E Straight E Straight E
Height 0 ... 2 mm 0 ... 2 mm 0 ... 2 mm 0 ... 2 mm has contact
Tilt Slightly towards Slightly towards Slightly towards Straight Straight
the rear edge F the rear edge F the rear edge F
A B C D E F
Forwarding suck-
ers
Suction discs Gray C Gray C Gray C / red D Red D/ gray C Red D/ gray C
Height 5 mm A 5 mm A 5 mm A 5 mm A 5 mm A
A C D
5 mm
Tab. 22 Components of lifting suckers and forwarding suckers
8.2 Sheet separator fingers
Printing materials
Voluminous, Onion skin pa- Labels, Art printing, Cardboard
porous per, lightweight pa- lightweight
Bible paper per, cardboard
art printing
(40 ... 100 g) (30 ... 60 g) (60 ... 130 g) (100 ... 200 g) (over 200 g)
Separator finger
Inside Slotted A Slotted A Slotted A normal B normal C/
conic D conic D strong B
B.5.54 SC.999.0020/01
Feeder
Printing materials
conic D normal B
Height 0 mm 0 mm 0 mm 0 mm 3 mm
Outside Slotted A Slotted A Normal B/ normal B normal B
conic D conic D Slotted A
conic D
Height 0 mm 0 mm 0 mm 0 mm 0 mm
A B C D
Tab. 23 Adjusting the sheet separator finger
8.3 Sheet separation blowers
Note
Adjust the sheet separation blowers
such that the topmost sheets of the pile
are separated. There must be no packed
pile above the separated sheets. This
reduces the risk of double sheets.
Printing materials
Voluminous, Onion skin pa- Labels, Art printing, Cardboard
porous per, lightweight pa- lightweight
Bible paper per, cardboard
art printing
(40 ... 100 g) (30 ... 60 g) (60 ... 130 g) (100 ... 200 g) (over 200 g)
Sheet separation
blowers
Height 5 to 10 sheets 5 to 10 sheets 5 to 10 sheets 5 to 10 sheets 5 sheets
Air volume A Position 1...2 Position 1...2 Position 2...3 Position 2...3 Position 3...4
A 3 4
2
1
Tab. 24 Adjusting sheet separation blowers
8.4 Sheet stops and forwarding flap
Printing materials
Voluminous, Onion skin pa- Labels, Art printing, Cardboard
porous per,
SC.999.0020/01 B.5.55
Feeder
Printing materials
Bible paper lightweight pa- lightweight
per, cardboard
art printing
(40 ... 100 g) (30 ... 60 g) (60 ... 130 g) (100 ... 200 g) (over 200 g)
Rear sheet stops
Position Outside Outside Outside Outside Outside
Distance 1 mm 1 mm 1 mm 1 mm 1 mm
Steel weight Top Top Top or bottom Bottom Bottom
Plastic weight Bottom Bottom Bottom Bottom Bottom
1 mm
Forwarding flap
Height above pile A 3 ... 5 mm 3 ... 5 mm 3 ... 5 mm 3 ... 5 mm 3 ... 5 mm
A
3 bis 5 mm
Tab. 25 Adjusting sheet stops and forwarding flap
B.5.56 SC.999.0020/01
Feeder
9 Sheet separator fingers
SG.901.5045-000UTKENU_04
9.1 Function
1 Sheet separator fingers for light printing materials
SG.901.5804-004GRAUND_00
2 Sheet separator finger for light to medium-weight
printing material
1
3 Sheet separator fingers for medium-heavy print-
ing materials
4 Sheet separator fingers for heavy printing mate-
rials
2
The sheet separator fingers (Fig. 50/1...4) limit the
fanning of the sheets and prevent that double sheets
are drawn off.
The sheet separator finger retain the sheets when car-
3 rier air blowers blow air underneath the sheets.
2Ć10 mm
5 6
0Ć3 mm
Fig. 50 Sheet separator fingers
9.2 Adjusting sheet separator fingers
Fitting the supports
SG.901.5813-001GRAUND_00
1. Loosen the knurled head screw (Fig. 51/2).
2. Install the required sheet separator finger be-
tween knurled head screw and support.
3. Manually tighten the knurled head screw
(Fig. 51/2).
Adjusting the height
1. Adjust the height of the sheet separator finger at
the knurled nut (Fig. 51/1).
The distance between the upper edge of the sheet and
the sheet separator finger must be between 0 and
1 2 3 mm (Fig. 50/5).
Fig. 51 Sheet separator finger - outer carrier air Adjusting the distance to the pile
blower 1. Loosen the knurled head screw (Fig. 51/2).
2. Move the sheet separator finger until it protrudes
into the pile by 2...10 mm (Fig. 50/6).
SC.999.0020/01 B.5.57
Feeder
3. Position the sheet separator fingers, obliquely to-
SG.901.5812-001GRAUND_00
wards the inside, underneath the carrier air blow-
ers (Fig. 52/1 through 4).
● Set the inner separator fingers (Fig. 52/2, 3)
so that they point slightly inward, below the
inner carrier air blower.
● Set the outer separator fingers (Fig. 52/1, 4)
so that they point slightly inward, below the
outer carrier air blowers.
4. Manually tighten the knurled head screw
(Fig. 51/2).
1 2 3 4
Fig. 52 Aligned sheet separator finger
B.5.58 SC.999.0020/01
Feeder
10 Adjusting the blast air on the suction head
SF.901.5040-000UTKENU_00
10.1 Overview
1 Forwarding sucker O.S., height adjustment
SF.901.1078-000GRAUND_00
2 Inclination of lifting sucker, inclination adjustment
3 Rear edge blower, blast air volume adjustment
4 Inner carrier air blower, blast air volume adjust-
ment
5 Outer carrier air blower, blast air volume adjust-
ment
6 Sheet separation blower, blast air volume adjust-
10.109.5499/02
ment
7 Lifting sucker, lifting movement adjustment
1 2 3 4 5 6 7 8
8 Forwarding sucker D.S., height adjustment
Fig. 53 Control panel on the suction head
Adjusting blast air
1. Adjust the blast air in such a way that air is blown
securely under the top sheet all the way up to the
front edge and the rear edge of the raised sheet is
not bent down.
Recommended setting
If the center of the sheet sags, increase the blast air of
the inner carrier air blowers (Fig. 53/4).
If the front corners of the sheet get stuck, increase the
blast air of the outer carrier air blowers (Fig. 53/5).
If sheets get stuck, increase the blast air.
10.2 Sheet separation blower
Adjusting the blast air
SG.901.5801-001GRAUND_00
1. Adjust the blast air volume of the sheet separa-
tion blowers (Fig. 54/1) on the control knob
(Fig. 53/6).
1 1 1 1
Fig. 54 Sheet separation blower
SC.999.0020/01 B.5.59
Feeder
Adjusting the height
SG.901.5802-001GRAUND_00
1. Adjust the height of the sheet separation blowers
with the knurled nut (Fig. 55/1).
Recommended setting
The sheet separation blowers should separate approx.
5 ... 10 sheets.
Note
Adjust the sheet separation blowers
such that the topmost sheets of the pile
1 are separated. There must be no packed
pile above the separated sheets. This
reduces the risk of double sheets.
Fig. 55 Sheet separation blowers, adjusting the
height
10.3 Outer carrier air blowers
Adjusting the blast air
SG.901.5889-001GRAUND_00
1. Adjust the blast air of the outer carrier air blowers
(Fig. 56/1) at the control knob (Fig. 53/5).
2 Adjusting the height
1. Adjust the height of the outer carrier air blowers
(Fig. 56/1) with the knurled nut (Fig. 56/2).
The carrier air blowers blow air under the picked
up sheet up to the front edge of the sheet.
1 3 Adjusting the direction of blast air
You can adjust the direction of blast air of the outer
carrier air blowers.
1. Loosen the screw (Fig. 56/3) on the support.
Fig. 56 Outer carrier air blowers 2. Adjust the carrier air blower (Fig. 56/1) on D.S.
slightly toward the outside in the direction of the
pile edge on D.S.
3. Tighten the screw on the support.
4. Using the same method, adjust the carrier air
blower on O.S. slightly toward the outside in the
direction of the pile edge on O.S.
10.4 Inner carrier air blowers
Adjusting the blast air
1. Adjust the blast air of the inner carrier air blowers
at the control knob (Fig. 53/4)
You cannot adjust the direction of blast air of the inner
carrier air blowers.
10.5 Rear edge blowers
The rear edge blowers continuously blow air onto the
pile edges.
B.5.60 SC.999.0020/01
Feeder
Adjusting the blast air
1. Adjust the blast air volume at the control knob
(Fig. 53/3).
Adjusting the direction of blast air
SG.901.5803-001GRAUND_00
1. Loosen the tommy bar screw (Fig. 57/2) on the
rear edge blower.
2. Adjust the rear edge blower (Fig. 57/1) on O.S.
slightly toward the outside in the direction of the
pile edge on O.S.
3. Retighten the tommy bar screw on the rear edge
blower.
4. Using the same method, adjust the rear edge
blower on D.S. slightly toward the outside in the
direction of the pile edge on D.S.
1 2
Fig. 57 Adjusting the rear edge blowers
10.6 Pre-separation air
Adjusting the pre-separation air
SF.901.1803-000GRAUND_00
The control knob (Fig. 58/1) on the feeder air control
panel enables you to adjust the pre-separation air in
the suction head area.
In order to prevent double sheets, the pre-separation
air is blown into the pile before sheet travel is started.
During sheet travel, the control knob does not have
any influence on the air volume on the suction head.
1. Adjust the total air volume on the control knob
(Fig. 58/1) such that the upper sheets of the pile
are slightly fanned.
Ensure that the fanned sheets do not float too
much.
Fig. 58 Control panel feeder air control
SC.999.0020/01 B.5.61
Feeder
11 Pile stops on the suction head
SF.901.5050-000UTKENU_00
11.1 Design
● Locking screw for sheet size adjustment
SG.901.5815-001GRAUND_00
6
1 (Fig. 59/1)
● Locking screw - swiveling the pile stop (Fig. 59/2)
● Stop plate at rear edge of pile (Fig. 59/3)
2 ● Steel sheet steadier (Fig. 59/4)
● Plastic sheet steadier (Fig. 59/5)
3 ● Thrust piece for arresting the steel sheet steadier
(Fig. 59/6)
Fig. 59 Pile stop
11.2 Adapting the pile weight to the printing material
Position for standard printing materials
SG.901.5817-001GRAUND_00
In the normal position, a steel weight (Fig. 60/1) and
plastic weight (Fig. 60/2) of the pile stop rest on the
pile.
This setting is suitable for medium weight papers and
cardboard.
1. Check whether the weights can be lifted without
resistance.
1
Fig. 60 Pile stop in normal position
Position for thin printing materials
SG.901.5819-001GRAUND_00
In this position, merely the plastic weight (Fig. 61/2)
rests on the pile. The steel weight is locked in its upper
position.
1. Slide the steel weight (Fig. 61/1) up.
1 2. Push the steel weight against the resistance of
the thrust piece into the upper park position.
3. Check whether the plastic weight can be easily
lifted.
2
Fig. 61 Pile stop without steel weight
B.5.62 SC.999.0020/01
Feeder
12 StaticStar - ionizing unit (option)
SG.901.5046-000UTKENU_00
12.1 Overview
The StaticStar ionizing unit is an optional accessory
SF.901.5155-000GRAUND_00
and hence not installed in every press.
Equipment versions
Your press may be equipped with different ionizing
components, depending on its configuration.
Equipment versions: Compact, Advanced, foil printing
kit.
Components
The main components of the ionizing unit are the ion-
izing blowers (Fig. 62) in the feeder and the ionizing
bars (Fig. 63) in the feeder and in the delivery. The foil
printing kit includes a rear edge blower, additional
hold-down rods and ultrasonic sheet travel sensors
that are installed in the PU and CU.
Below you can see diagrams of the different equip-
Fig. 62 Ionizing blowers at the feeder ment versions.
SF.901.5165-000GRAUND_00
Other chapters
Please also read the chapters "Ionizing unit at the suc-
tion head" and "Foil printing".
Fig. 63 Ionizing bars
12.2 Locations of StaticStar Compact components
Note
Your press may be equipped with differ-
ent ionizing blowers/bars, depending on
its configuration. This document de-
scribes the most comprehensive config-
uration, regardless of the actual compo-
nents in your press.
SC.999.0020/01 B.5.63
Feeder
12.2.1 Antistatic device for PowderStar AP 500
SG.901.5046-010GRAUND_00
1
Fig. 64 Ionizing unit for PowderStar
Ionizing bars
1 On the powder tube
One power unit is located at the delivery.
12.2.2 StaticStar Compact (variant 1)
SG.901.5046-000GRAUND_00
3 2 1
Fig. 65 Ionizing unit StaticStar Compact
Ion blower
1 Rear pile edge at the feeder (2x)
Ionizing bars
2 At the front edge of the pile (sheet transfer)
3 In the delivery air system above the delivery pile
(2x)
One power unit is located at the feeder, another at the
delivery.
B.5.64 SC.999.0020/01
Feeder
12.2.3 StaticStar Compact (variant 2)
SG.901.5046-020GRAUND_00
4 3 2 1
Fig. 66 Ionizing unit StaticStar Compact
Ion blower
1 Rear pile edge at the feeder (2x)
Ionizing bars
2 At the front edge of the pile (sheet transfer)
3 On the powder tube
4 In the delivery air system above the delivery pile
(2x)
One power unit is located at the feeder, another at the
delivery.
12.2.4 StaticStar Advanced
SG.901.5046-030GRAUND_00
5 4 3 2 1
Fig. 67 Ionizing unit StaticStar Advanced
Ion blower
1 Rear pile edge at the feeder (2x)
2 On D.S. and O.S. of the feeder pile
Ionizing bars
3 At the front edge of the pile (sheet transfer)
4 On the powder tube (2x)
5 In the delivery air system above the delivery pile
(2x)
6 Under the sheet brake
SC.999.0020/01 B.5.65
Feeder
One power unit is located at the feeder, another at the
delivery.
B.5.66 SC.999.0020/01
Feeder
13 Ionizing blowers at the suction head (optional)
SF.901.5060-000UTKENU_01
13.1 Function/design
As the ionizing unit is a special accessory, it is not in-
SF.901.5889-000GRAUND_00
stalled in every press.
Function
The ionizing unit removes static charges from the
stock. We particularly recommend using the ionizing
unit when printing on foils. See the chapter "Foil print-
ing (optional)".
Design
An ionizing unit can consist of several components,
depending on the configuration of your press:
1 1 ● ionizing blowers at the suction head (Fig. 68/1),
Fig. 68 Suction head with ionizing blowers ● ionizing blowers on D.S. and O.S.
● an ionizer in the feeder,
● one or more ionizers in the delivery.
The section below describes the ionizers at the suction
head.
13.2 Activation/deactivation
1. Switch on the ionizing blowers on the control sta-
tion.
The ionizing blowers become active:
● after sheet travel has been switched on.
● after production has been switched on.
SC.999.0020/01 B.5.67
Feeder
13.3 Positioning the ionizing blowers
Laterally aligning the ionizing blowers
SF.901.5816-001GRAUND_00
1. Adjust the ionizing blowers (Fig. 69/1) to the
sheet size.
2. Loosen the tommy bar screw (Fig. 69/2).
3. Move the ionizing blowers in accordance with the
2
sheet size.
Fig. 69 Laterally aligning the ionizing blowers
Position the two ionizing blowers at 1/4 of the sheet
SF.901.5884-000GRAUND_00
width from the outer pile edge on both sides.
4. Retighten the locking screw.
1/4 1/4 1/4 1/4
Fig. 70 Lateral distance
B.5.68 SC.999.0020/01
Feeder
Adjusting the height of the ionizing blowers
SF.901.5891-000GRAUND_00
1. Adjust the height of the ionizing blowers
(Fig. 71/1) with respect to the upper pile edge.
2 2. Loosen the tommy bar screw (Fig. 71/2).
Align the center of the ionizing blowers with the upper
pile edge (Fig. 72/1).
3. Retighten the locking screw.
Setting the volume of blast air
1. Adjust the blast air volume for the respective ion-
izing blower at the valve (Fig. 71/3).
The blast air volume can be set continuously.
2. Turn the valve:
1
● Vertical position: blast air on full.
● Horizontal position: blast air off.
Fig. 71 Adjusting the height of the ionizing blowers
SF.901.5890-000GRAUND_00
Fig. 72 Aligning the ionizing blowers with the pile
edge
SC.999.0020/01 B.5.69
Feeder
14 Foil printing (optional)
SG.901.5160-000UTKENU_06
14.1 General
For foil printing, your printing press must be equipped
with special equipment. The special equipment for foil
printing includes:
● special air-blast nozzles for the suction head,
● an ionizing unit,
● special lifting and forwarding suckers,
● a rear edge blowing device,
● a scale on the feed table,
● sheet travel monitor.
14.2 Special air-blast nozzles for suction head and ionizing unit
The special equipment for foil printing on the feeder
FS.901.5954-000GRAUND_00
includes:
1 Ion blowers at the rear edge of the pile
2 Lateral ion blowers
3 Ionizing bar above the front edge of the pile
Note
Ion blowers and ionizing bar are con-
nected to high voltage. The high voltage
is not hazardous for humans due to the
3 2 1 low current. Nevertheless, avoid touch-
ing the discharge tips while the machine
is running.
Fig. 73 Ionizing unit on the feeder
There is one ionizing blower each on D.S. and O.S. at
FS.901.5958-000GRAUND_00
the rear edge of pile.
The two ion blowers (Fig. 74/1) loosen up the rear
edge of the pile.
The integrated ionizing unit (Fig. 74/2) prevents unde-
sired electrostatic adhesion between the top printing
foil and the pile.
Note
You can find more information on the ion
2
blowers in the separate documentation
from the manufacturer.
1
Fig. 74 Ion blowers (D.S.) at the rear edge of the pile
B.5.70 SC.999.0020/01
Feeder
There are two lateral ion blowers each on D.S. and
FS.901.5955-000GRAUND_00
O.S.
The two lateral ion blowers (Fig. 75/1) loosen up the
pile laterally.
The integrated ionizing unit (Fig. 75/2) prevents unde-
2 sired electrostatic adhesion between the top printing
foil and the pile.
Note
You can find more information on the ion
blowers in the separate documentation
from the manufacturer.
Fig. 75 Lateral ion blowers (O.S.)
There is one front edge nozzle each on D.S. and O.S.
FS.901.5956-000GRAUND_00
The front edge nozzles (Fig. 76/2) loosen up the pile at
the front edge.
The function of the ionizing bar above the front edge of
the pile (Fig. 76/1) is to reduce electrostatic charge on
the sheets that pass through beneath it.
Note
You can find more information on the
ionizing bar above the front edge of the
pile in the separate documentation from
2 1 the manufacturer.
Fig. 76 Ionizing bar above the front edge of the pile
Depending on the press configuration, the special
FS.901.5957-001GRAUND_00
equipment for foil printing can include up to 7 ionizing
1 2 3 bars on the delivery.
● 4 ionizing bars in the delivery fan (Fig. 77/1)
● 1 ionizing bar on the sheet brake (Fig. 77/2)
● 2 ionizing bars on the powder tube (Fig. 77/3)
Note
Avoid touching the discharge tips while
the press is running.
Fig. 77 Ionizing bars at the delivery
SC.999.0020/01 B.5.71
Feeder
● Delivery fan (Fig. 78/1)
SG.901.0530-000GRAUND_00
1 2 ● Ionizing bar (Fig. 78/2)
Four ionizing bars (Fig. 78/2) are fitted in the delivery
between the delivery fans (Fig. 78/21).
Note
You can find more information on the
ionizing bars in the separate documen-
tation from the manufacturer.
Fig. 78 Ionizing bar in the delivery fan
You can switch the ionizing unit on and off on the con-
trol station.
14.3 Lifting and forwarding suckers
Lifting sucker nozzle Forwarding sucker nozzle
Printing master
Printing master thinner than
0.1 mm
Tab. 26 Overview
Chiefly thin and unstable printing foils tend to bend
when the standard lifting suckers or the standard for-
warding suckers are used. In this case use the special
suction nozzles for thin printing foils.
B.5.72 SC.999.0020/01
Feeder
Adjusting the lifting suckers to the printing mate-
FS.901.5952-001GRAUND_00
rial
Note
You may need special flat lifting suckers
for foil printing. These are included in the
standard spare parts set. Use the stan-
dard lifting suckers for other printing ma-
terial or stiff printing foils.
Example: Retrofitting for foil printing
1. Turn the conventional lifting sucker (Fig. 79/2) by
90°. Remove the lifting sucker from the lifting
1
sucker guide (Fig. 79/1).
2. Fit the special lifting sucker for foil printing.
2
Note
Always store lifting suckers you do not
need carefully in the standard spare
parts set.
Fig. 79 Adjusting the lifting suckers to the printing
material
Adjusting the forwarding suckers to the printing
FS.904.0002-001GRAUND_00
material
Note
1 Foil printing may require special forward-
ing suckers. Use the standard forward-
ing suckers for other printing material or
stiff printing foils. The special forwarding
2 suckers are in the separate parts set.
Example: Retrofitting for foil printing
1. Slacken the Allen screws (Fig. 80/2). Release the
3 bayonet catch (Fig. 80/4) by turning it to the left.
Remove the conventional forwarding sucker
(Fig. 80/3).
2. Fit the special forwarding sucker for thin printing
materials.
4
Note
Always store forwarding suckers you do
Fig. 80 Adjusting the forwarding suckers to the print- not need carefully in the standard spare
ing material parts set.
14.4 Rear edge blowing unit
Printing foils tend to stick together. The rear edge
blowing unit separates the sheets in the feeder.
SC.999.0020/01 B.5.73
Feeder
Sheet size adjustment
FS.901.5938-000GRAUND_00
1. Release the locking device of the rear edge.
1
Open the clamping lever (Fig. 81/1).
2 2. Use the handwheel (Fig. 81/2) to set the mark
(Fig. 81/3) to the sheet size.
Use the scale on the feed table (Fig. 81/4) for the
setting.
3. Lock the rear edge.
Close the clamping lever (Fig. 81/1).
4 3
Fig. 81 Sheet size adjustment
FS.901.5941-001GRAUND_00
Note
A part of the crash part must be removed
when you select a sheet size of less than
440 mm.
4. Release the two Allen screws (Fig. 82/1).
1 5. Remove the rod (Fig. 82/2) and keep it at a safe
place.
2 Note
You cannot set sheet sizes of less than
1 380 mm.
6. If you want to print a sheet size of less than
380 mm.
Fig. 82 Crash bar ● Adjust the rear edge blowing unit to the
smallest possible sheet size.
● Close the main cock for the rear edge blow-
ers (see Fig. 85)
● Adjust the blast air for the sheet separation
blowers.
Engaging the format wheels
FS.901.5944-000GRAUND_00
The format wheels support the conveying effect of the
suction tape. They prevent the sheets from bouncing
1
back.
1. You can use the knurled screws (Fig. 83/1) to
engage the format wheels until they ensure even
sheet travel.
Fig. 83 Format wheels
B.5.74 SC.999.0020/01
Feeder
Engaging the transport rollers
FS.901.5940-000GRAUND_00
The transport rollers (Fig. 84/3) support the conveying
2 effect of the suction tape when processing printing
1
material that is difficult to pick up with suction.
3 1. Open the clamping lever (Fig. 84/1). Adjust the
transport rollers to the printing material.
2. Engage the transport rollers by turning the
knurled screws (Fig. 84/2).
Fig. 84 Transport rollers
FS.901.5943-000GRAUND_00 Setting the blast air
1 ● Main cock of the sheet separation blower
2 (Fig. 85/1)
● Individual adjustment of the sheet separation
blower (Fig. 85/2)
4 ● Individual adjustment of the rear edge blower
(Fig. 85/3)
● Main cock of the rear edge blower (Fig. 85/4)
3 1. Close all valves for the individual adjustment
(Figs. 85/2 and 85/3) which are positioned out-
side the sheet size. All valves inside the sheet
size must be fully opened.
Note
With many printing substrates it is suffi-
Fig. 85 Setting the blast air
cient to use only fanning air.
2. Run the press with printing material.
3. Regulate the blast air for the sheet separation
blowers at the main cock (Fig. 85/1) until the
sheets are transported smoothly and evenly. You
need to find a compromise between overtension-
ing and causing the printing foils to become
wavy.
With heavy or very adherent printing materials, the
fanning air may be blown over the sheet. This means
that the rear edge of the sheet is in contact with the
next sheet. This may lead to problems in the sheet
travel.
4. Stop the press if the rear edge of the sheet rests
on the next sheet. A sheet must rest against the
front lays.
5. Shut off the blast air for the sheet separation
blower at the main cock (Fig. 85/1).
SC.999.0020/01 B.5.75
Feeder
6. Adjust the blast air for the rear edge blowers at
the main cock (Fig. 85/1) so that the rear edge of
the sheet is just about lifted up.
7. Repeat steps 2 and 3.
Swinging up the rear edge blowing device
FS.901.5942-001GRAUND_00
If you wish to swing up the table section of the feed
table on O.S., swing the rear edge blowing device up-
ward by 50°.
If you wish to print paper, swing the rear edge blowing
device upward by 90°.
1. Set the rear edge blowing unit to maximum for-
mat.
2. Swing the rear edge blowing device upward. The
rear edge blowing device stops at approx. 50° or
at approx. 90°.
Note
If you are processing small sheet sizes,
you can only swing up the rear edge
Fig. 86 Rear edge blowing device blowing device to approx. 50° or not at all
in order to avoid a collision with the
1st printing unit.
Swinging down the rear edge blowing device
1. Swing the rear edge blowing device downward
against the spring force.
Lifting up sheet stop fingers
FS.901.5945-000GRAUND_00
The sheet stop fingers hold double sheets, early
1 sheets and late sheets on the feed table. To perform
certain adjustment work or to remove sheets you can
raise the sheet stop fingers.
Note
Firmly grasp the sheet furthest forward
or highest up while lifting up the sheet
stop finger. This enables you to avoid the
sheets running into the press and caus-
ing an emergency-stoppage.
1. Press the Release sheet stop fingers push button
(Fig. 88/1) on the control panel of the first printing
unit.
Fig. 87 Rear edge blowing device ● The sheet stop fingers are raised.
● The pneumatic cylinder (Fig. 87/1) moves
the rear edge blowing device upward.
2. Remove the sheets in the infeed section.
B.5.76 SC.999.0020/01
Feeder
FS.901.5990-000GRAUND_00
1
Fig. 88 Control panel PU 1
Closing the pull lay bypass
SG.901.5940-000GRAUND_00
When processing heavy or very adherent printing ma-
terials, the suction air of the pull lay may not suffice to
1
align the sheet laterally.
1. Switch the press off and secure it from being
switched back on without authorization.
2. Remove the cover of the pull lay gap.
3. Push in the pin (Fig. 89/1). The pull lay bypass is
closed.
4. Attach the cover of the pull lay gap.
Note
Open the pull lay bypass again once the
print job is complete. Pull out the pin
again.
Fig. 89 Pull lay bypass
SC.999.0020/01 B.5.77
Feeder
15 Lateral sheet separation blowers
SF.901.5070-000UTKENU_01
15.1 Function
There are lateral sheet separation blowers on D.S. and
FS.901.1273-000GRAUND_00
1 2 on O.S. The lateral sheet separation blowers consist
of:
● a lateral sheet separation blower (Fig. 90/1)
● and a movable diagonal blower bar (Fig. 90/2).
The lateral sheet separation blowers must be adjusted
such that they separate the upper sheets of the pile.
Fig. 90 Lateral sheet separation blowers
15.2 Automatic adjustment of the lateral sheet separation blowers
The lateral sheet separation blowers are automatically
adjusted, after entry of the format on the control sta-
tion. Distance to the pile edge: approx. 3 mm
15.3 Manual adjustment of the lateral sheet separation blowers
Setting the height
FS.901.1073-001GRAUND_00
1 2 3 1. Turned the knurled ring (Fig. 91/1) to adjust the
height of the lateral sheet separation blower.
2. Move the movable diagonal blower (Fig. 91/3) to
the desired position. The distance to the pile
edge must be approx. 10 mm.
Note
Position the diagonal blowers outside
the travel range of the pile support plate/
pallet and outside the detection range of
the sensor for automatic pile alignment
(Fig. 91/2).
Setting the distance
The position of the lateral sheet separation blower is
Fig. 91 Pile alignment sensor fixed. You can change the distance between the diag-
onal blower and the lateral sheet separation blower.
1. Release the tommy bar screw on the diagonal
blower.
2. Adjust the diagonal blower bar corresponding to
the sheet size.
3. Retighten the tommy bar screw on the diagonal
blower.
B.5.78 SC.999.0020/01
Feeder
15.4 Setting the blast air volume
● Blast air volume on the lateral sheet separation
SF.901.1077-000GRAUND_00
1 3 5 blower on D.S. (Fig. 92/1)
● Blast air volume on the lateral sheet separation
blower on O.S. (Fig. 92/2)
● Blast air volume on the diagonal blower on D.S.
(Fig. 92/3)
● Blast air volume on the diagonal blower on O.S.
(Fig. 92/4)
● Height adjustment of the guide plate (Fig. 92/5)
● Pre-separation air of the suction head (Fig. 92/6)
The blast air volume for the lateral sheet separation
blowers can be adjusted via the feeder control panel
(Fig. 92).
Note
2 4 6 Adjust the air volume such that the top
sheets are fanned. There must be no
Fig. 92 Control panel feeder air control bulge on the pile surface.
1. Use the controllers (Fig. 92/1 ... 6) to adjust the
blast air volume to the current printing material
properties.
SC.999.0020/01 B.5.79
Feeder
16 Rope guide and guide plate
SF.901.5150-000UTKENU_01
16.1 Function
The rope (Fig. 93/1) guides the printing material on its
FS.901.1074-001GRAUND_00
2 1 way from the pile to the forwarding roller. Tension
springs maintain a constant rope tension regardless of
the sheet size adjustment.
The guide plate (Fig. 93/2) prevents thin printing ma-
terials from bulging.
Fig. 93 Rope guide
16.2 Adjusting the guide plate
With thin printing materials, the smoothness of the
SF.901.1081-000GRAUND_00
1 shingle edge on the feed table depends very much on
the guide plate adjustment.
Note
Use the guide plate only for thin printing
material of up to approximately 0.1 mm.
Throw off the guide plate for stock thick-
ness of 0.1 mm and more. Failure to do
so would expose the guide strings to a
heavy wear.
1. Adjust the guide plate at the control knob
(Fig. 94/1) according to the employed printing
material.
● Stock thickness less than 0.1 mm: Adjust a
small distance between the guide plate and
the pile.
Fig. 94 Control panel feeder air control ● Stock thickness greater than or equal to
0.1 mm: Adjust a large distance between
the guide plate and the pile.
● When processing cardboard, set the guide
plate to the highest position.
The guide plate is disengaged in the upper
position.
B.5.80 SC.999.0020/01
Feeder
16.3 Changing the rope
Removing the rope
SG.901.5896-002GRAUND_01
If the rope is worn or broken, you must install a new
rope in the rope guide.
Tip
The rope guide on O.S. mirrors the rope
guide on D.S. Initially, only replace the
rope on one side. When mounting the
new rope, you can use the intact rope
guide for orientation.
1. Move the suction head to the position for the
largest sheet size. This gives you enough space
to carry out the rope change.
2. Using the control knob (Fig. 94/1) on the control
3 2 1 panel for Air control, move the guide plate down.
3. Secure the press against starting up again: Press
Fig. 95 Releasing the guide roll the Emergency-stop palm button on the next-
nearest control panel.
4. Slacken the rope (Fig. 95/3). Release the screw
(Fig. 95/1) on the suction head and remove the
rope from the guide roll (Fig. 95/2).
5. Slide the actuating bar (Fig. 96/1) for the limit
FS.901.1189-000GRAUND_00
switch upwards.
3
6. Insert a tool, e.g. a key wrench (Fig. 96/3) into the
borehole (Fig. 96/2) of the actuating bar.
The actuating bar is locked in the upper position.
2
Fig. 96 Actuating bar
SC.999.0020/01 B.5.81
Feeder
Note
FS.901.1188-000GRAUND_00
1 1 2 1 You do not need to fully remove the
screws. They only need to be slackened
off.
7. Release all five screws (Fig. 97/1) on the cover
plate (Fig. 97/2).
8. Remove the cover plate from the feeder.
Place the cover plate on a clean flat surface.
9. Detach the rope from the center of the guide
plate.
Fig. 97 Screws on the cover plate
10. Detach the rope next to the lateral sheet separa-
SG.901.5882-002GRAUND_00
tion blower (Fig. 98/1).
Fig. 98 Guide roll on the lateral sheet separation
blower
11. Lift the tension spring (Fig. 99/1) out of the plate
SG.901.5880-001GRAUND_00
1 guide and detach the tension spring.
12. Remove the fastening pin (Fig. 99/2) on the pin
2 (Fig. 99/3) and remove the rope.
3
4
Fig. 99 Releasing the tension springs
B.5.82 SC.999.0020/01
Feeder
SG.901.5885-002GRAUND_01
Fig. 100 Diagram of the rope guide
Inserting a new rope
SG.901.5880-001GRAUND_00
1 1. Hook the ear of the new rope to the rope pulley
(Fig. 101/4). Thread the pin (Fig. 101/3) through
2 the rope pulley and through the ear on the rope.
2. Insert the fastening pin (Fig. 101/2) into the
groove of the pin.
3. Attach the tension spring and place the spring in-
to the plate guide (Fig. 100).
3
4. Thread the rope through the guide pulleys. See
4
the diagram of the rope guide in Fig. 100.
Also use the existing rope guide for orientation
while doing so.
5. Hook the loose rope end into the hook on the
guide plate.
Fig. 101 Attaching the tension spring
SC.999.0020/01 B.5.83
Feeder
6. Tighten the rope (Fig. 102/3). Place the rope onto
SG.901.5896-002GRAUND_01
the guide roll (Fig. 102/2) and tighten the screw
(Fig. 102/1) on the suction head.
3 2 1
Fig. 102 Guide roll on the suction head
7. Attach the rope in the center of the guide plate.
FS.901.1188-000GRAUND_00
1 1 2 1 8. Mount the cover plate (Fig. 103/2).
9. Tighten all five screws (Fig. 103/1) on the cover
plate.
Fig. 103 Tightening the screws on the cover plate
10. Remove the tool (Fig. 104/1) from the borehole
FS.901.1190-000GRAUND_00
on the actuating bar (Fig. 104/2).
The actuating bar then slides downwards and
protrudes into the cover plate.
1 11. Lift up the actuating bar to check that the limit
switch triggers.
12. Release the Emergency stop button.
Fig. 104 Releasing the actuating bar
B.5.84 SC.999.0020/01
Feeder
17 Sheet monitoring
SG.901.5080-000UTKENU_16
17.1 Overview
The sheet stream is checked for double sheets and
SG.901.5835-010GRAUND_00
correct sheet alignment in the feeder. The sheet mon-
itor includes several systems:
1 ● Double sheet detector
● Sheet alignment monitor
Depending on the configuration, the feeder can be
equipped with up to four systems for double-sheet/
multiple-sheet detection.
Detection of double sheets:
● Ultrasonic double sheet detector (Fig. 105/1)
● Double sheet detector in the pulling device (op-
tional) (Fig. 105/2)
2
Fig. 105 Ultrasonic DSD and pull lay DSD
Detection of multiple sheets/double sheets:
SF.901.5892-000GRAUND_00
● Multiple sheet detector (Fig. 106/1)
● Sheet stream/multiple sheet detector (optional)
1 (Fig. 106/2)
The four systems work independently of each other.
Use the press with at least one double sheet detector
and one multiple-sheet detector.
Please notify Heidelberg Service immediately when a
double/multiple-sheet detector fails (due to a mechan-
ical/electrical malfunction, for example).
Caution - Risk of press damage!
When the double/multiple sheet detector
is inactive, double/multiple sheets can
be fed into the press and damage the
press.
Use an alternative protection when the
2 double/multiple sheet detector is inac-
tive. An alternative protection can be
guaranteed by activating optional sys-
tems for the detection of double/multiple
Fig. 106 Multiple sheet and sheet stream detector
sheets.
Optional systems can also be retrofitted.
SC.999.0020/01 B.5.85
Feeder
Note
If your machine is equipped with an ul-
trasonic double sheet detector and an
optional double sheet detector in the
pulling device, you can deactivate one of
the systems. Deactivating both double
sheet detectors at the same time is not
possible.
17.2 Measuring range of the double/multiple-sheet detector
Double/multiple-sheet detec- Stock thickness in
tor mm
From to
Ultrasonic double sheet detec- 0.03 1.0
tor
Double sheet detector in the 0.06 1.0
pulling device (optional)
Multiple sheet detector (double 0.4 1.0
sheet detection)
Sheet stream/multiple sheet de- 0.1 1.0
tector (optional)
Tab. 27 Measuring range
17.3 Ultrasonic double sheet detector
The ultrasonic double sheet detector (Fig. 107/1) is the
SG.901.5835-003GRAUND_00
sheet monitoring system with the widest application
range and protects the machine from damage caused
by the infeed of double and multiple sheets. The ultra-
sonic double sheet detector is active once the feeder is
1 switched on.
Detection of double sheets
With the exception of multi-layer printing materials or
thick printing masters, the ultrasonic double sheet de-
tector recognizes all standard printing materials. In
rare cases and with some types of stock, the ultrasonic
double sheet detector may respond even though the
sheet stream is perfect, or it may not detect double
Fig. 107 Ultrasonic double sheet detector sheets. It is important to distinguish between these two
cases:
● Case 1: faulty response: The DSD responds
even though the sheets are shingled properly.
Due to its functioning principle, the ultrasonic
double sheet detector is not suitable for stock
with air pockets and internal boundary layers.
These include corrugated boards and possibly
also other types of board in which the individual
layers become separated without this being visi-
ble from the outside. Very thick boards and thick
printing foils may not be penetrated adequately
B.5.86 SC.999.0020/01
Feeder
by the ultrasonic waves, causing a faulty re-
sponse of the double sheet detector.
● Case 2: failure to respond: The DSD does not
respond even though there is a double sheet.
If the stock is very thin, double sheets may not be
accurately detected.
In extremely rare cases, this may also happen
with thin boards. If you are processing such crit-
ical stocks and want to exclude any residual risk
in double sheet detection, use the optional dou-
ble sheet detector in the pulling device and the
sheet stream/multiple sheet monitor.
These systems are available as options and can
usually be retrofitted.
Ultrasonic double sheet detector - three sensitivity
levels
The ultrasonic double sheet detector has three sensi-
tivity levels that you can adjust to your requirements:
● Sensitive
● Standard
● Insensitive
Note
For information on how to change the
sensitivity, please see the separate op-
erating manual for the control station,
chapter "Paper run - feeder".
Thickness of printing material Automatically preselected Manual changeover possible
Less than 0.08 mm Sensitive If double sheets are detected erro-
neously:
switch to "standard" mode.
0.08 mm or more Standard If double sheets are not detected:
switch to "sensitive" mode.
0.2 mm or more Standard If double sheets are detected erro-
neously:
switch to "insensitive" mode.
Tab. 28
The diagram in Fig. 108 shows the automatically pre-
SF.901.0235-001GRAENU_00
selected intensities for various stock thicknesses.
Intensity range
Sensitive Standard
0.03 0.08 0.1
Stock thickness (mm)
Fig. 108 Diagram of intensity levels
SC.999.0020/01 B.5.87
Feeder
Switching off the ultrasonic double sheet detector
In order to process special multi-layer printing materi-
als or thick printing masters, you can switch off the ul-
trasonic double sheet detector via the control station.
After a format change, the ultrasonic double sheet de-
tector automatically becomes operational again.
Note
Information on switching off the ultrason-
ic double sheet detector can be found in
the separate operating manual for the
control station.
17.4 Double sheet detector in the pull lay (option)
The double sheet detector in the pull lay (Fig. 109/1) is
FS.901.5832-005GRAUND_00
1 adjusted automatically in accordance with the print-
ing material thickness entered at the control station. A
sensor in the pull lay measures the thickness of the
sheet during the pull procedure. The control system
produces an average value from the measured values
of the last five sheets. This average value is the refer-
ence value for the subsequent sheets.
Note
Only use stock types as advance sheets
that correspond to the thickness of the
press sheets. If the press sheets are
more than 1.3 times thicker than the ad-
vance sheets, the double sheet detector
may respond erroneously when the first
Fig. 109 Double sheet detector in the pull lay press sheet is fed.
Switching off the double sheet detector in the pull
lay
1. You can find information on switching off the pull
lay double sheet detector in the separate oper-
ating manual for the control system.
17.5 Multiple sheet detector
The multiple sheet detector adjusts automatically as a
SG.901.6813-001GRAUND_00
function of the stock thickness entered via the control
station.
1 2 The multiple sheet detector (Fig. 110/2) checks the
shingle thickness in the infeed roller area. Different
measures are taken, depending on whether the mul-
tiple sheet detector detects a double sheet or multiple
sheets:
Fig. 110 Multiple sheet detector
B.5.88 SC.999.0020/01
Feeder
Note
If, in the area of the multiple sheet de-
tector, the upper pile edge is higher than
the upper edge of the forwarding flap,
there may be a false triggering of the
multiple sheet detector.
Distinction between double sheets and
multiple sheets is only possible if the
stock thickness of a sheet is at least
0.4 mm. The multiple sheet detector only
detects multiple sheets if the stock thick-
ness is less than 0.4 mm.
Double sheets
The double sheet is stopped as the 2nd
sheet in front of the sheet alignment sys-
tem.
This is what happens:
- The sheet alignment system is locked.
- The sheet stop fingers are extended.
- The feeder is switched off.
- The machine control system reports a double sheet.
How can you restart the machine?
1. Take the sheet in the sheet alignment system off
the feed table.
2. Take the double sheet (2nd sheet) off the feed
table.
3. Start the machine with "Production".
Note
If the 2nd sheet of the stream is not a
double sheet, check the entire shingle
stream for double sheets or pieces of
sheets.
Multiple sheets
The multiple/double sheets are posi-
tioned under the multiple sheet detector/
forwarding roller.
This is what happens:
- The sheet alignment system is locked.
- The sheet stop fingers are extended.
- The feeder is switched off.
- The machine reports multiple sheets.
How can you restart the machine?
1. Proceed as described under Option 1 or Op-
tion 2 in the section "Switching the feeder back
on after multiple sheet detection".
SC.999.0020/01 B.5.89
Feeder
Switching the multiple sheet detector off
Caution - Risk of press damage!
Multiple sheets are not detected when
you switch off the double/multiple sheet
detector. Double/multiple sheets can be
fed into the press and damage the press.
An alternative protection can be guaran-
teed by activating optional systems for
the detection of double/multiple sheets.
Optional systems can also be retrofitted.
The multiple sheet detector can be switched off at the
control station. The multiple sheet detector is auto-
matically reactivated after 5000 sheets.
1. See the separate operating manual for the con-
trol station for information on how to deactivate
the multiple sheet detector.
Moving the multiple sheet detector on the forward-
SF.901.5895-000GRAUND_00
1
ing roller shaft
Note
Switch off the feeder before you shift the
multiple sheet detector. Shifting the mul-
tiple sheet detector while the feeder is
running may lead to "stoppers".
1. Loosen the tommy bar screw (Fig. 111/1) on the
multiple sheet detector.
2. Move the multiple sheet detector to the required
position.
3. Tighten the tommy bar screw (Fig. 111/1) on the
multiple sheet detector.
Fig. 111 Moving the multiple sheet detector
B.5.90 SC.999.0020/01
Feeder
17.6 Sheet stream / multiple-sheet detector optional
The double sheet detector above the suction tape
SG.901.5833-004GRAUND_00
drive roller consists of a cross bar (Fig. 112/2) that can
be equipped with 1...24 feeler rollers (Fig. 112/1). It
detects:
● double sheets
1
● multiple sheets
● paper shreds of different sizes depending on
number and position of the feeler rollers.
The double sheet is stopped as the 2nd sheet in front
of the sheet alignment system.
2
This is what happens:
3
- The sheet alignment system is locked.
- The sheet stop fingers are extended.
- The feeder is switched off.
- The machine reports a double sheet.
1
How can you restart the machine?
1. Take the sheet in the sheet alignment system off
the feed table.
2. Take the double sheet (2nd sheet) off the feed
Fig. 112 Double sheet detector above the suction table.
tape drive roller
3. Start the machine with "Production".
Note
If the 2nd sheet of the stream is not a
double sheet, check the entire shingle
stream for double sheets or pieces of
sheets.
The sheet stream/multiple sheet detector can also
complement the existing double sheet detectors when
thinner stocks are processed.
The overlapping of the shingle stream depends on the
sheet length. Smaller paper trimmings that lie in the
shingle stream may remain undetected.
You can adjust the sheet stream / multiple-sheet de-
tector by means of the control knob (Fig. 112/3). The
control knob has a notch division of 0.025 mm.
Adjusting to the stock thickness
1. Switch on feeder and sheet travel.
2. Turn the control knob (Fig. 112/3) clockwise until
the double sheet detector is just activated.
SC.999.0020/01 B.5.91
Feeder
Note
If you keep the +/- buttons for the pro-
duction speed pressed simultaneously,
the press does not stop when the double
sheet detector responds. The response
of the double sheet detector is displayed
on the feeder touch screen or on the
press display. This means you can ad-
just the double sheet detector without
stopping the press.
3. Establish the setting values (stock thickness) for
the current print job.
4. Turn the control knob (Fig. 112/3) anti-clockwise
by the calculated number of notches.
One notch corresponds to a distance of 0.025 mm. Set
the double sheet detector to half the stock thickness
beyond switching point.
Example:
● Stock thickness 0.1 mm:
Operating distance 0.05 mm = 2 notches
● Cardboard 0.8 mm:
Operating distance 0.4 mm = 16 notches
Note
When you have completed the adjust-
ment, the sheet stream/multiple sheet
detector is set to a distance of approx.
half the stock thickness from the sheet
stream.
Fitting the sensing roller
SG.901.5834-002GRAUND_00
You can install 1...24 feeler rollers on the cross bar.
Four feeler rollers are included in the scope of delivery
2 of the shingle / multiple-sheet detector. The more feel-
er rollers are installed on the cross bar, the smaller are
the bits of paper that can be detected.
To avoid overrunning sheets it is usually enough to use
just one feeler roller. Depending on the print job, po-
sition the feeler roller inside image free areas or at the
1 edges of the printing material.
Note
The feeler roller must not be positioned
above the suction tape and not above
the slit area of the guide roll.
Fig. 113 Feeler roller 1. Place the feeler roller (Fig. 113) onto the cross-
bar. Slide the feeler roller into the required posi-
tion.
2. Secure the feeler roller on the cross bar with the
knurled head screw (Fig. 113/1).
B.5.92 SC.999.0020/01
Feeder
Basic setting
You must check the basic adjustment
● when you install additional feeler rollers,
or
● when you move one or more feeler rollers.
1. Switch on the feeder.
2. Adjust the stock thickness to minimum at the con-
trol knob (Fig. 112/3) (turn the control knob all the
way to the right).
3. Adjust each feeler roller at the stud (Fig. 113/2)
such that it just follows the suction tape drive
roller.
17.7 Switching the feeder back on after double sheet detection
Note
Ensure that there are no multiple sheets
or bits of paper in the printing units or the
perfector. See the chapter "Removing
sheets that have not been gripped" for
details on how to remove missing
sheets.
Condition: The feeder was switched off after the de-
tection of double or multiple sheets.
The machine reports a double sheet,
1. Press the button Disengage sheet stop finger at
the feeder control panel to remove the sheets
under the sheet stop finger. The sheet stop finger
remains released (sheet stop finger up) as long
as you press the button.
2. Remove the double or multiple sheets from the
feeder.
● If the double sheet was detected by the ul-
trasonic double sheet detector or by the
double sheet detector in the pull lay, the
double sheet is positioned at the front lay.
● If the double sheet was detected by the for-
warding rollers/multiple sheet detector (only
for thick stock) or by the sheet stream de-
tector, the triggering sheet is usually the 2nd
sheet in the stream in front of the sheet
alignment system.
If the 2nd sheet in front of the sheet align-
ment system is not a double sheet, check
the entire shingle stream for double sheets
or pieces of sheets.
SC.999.0020/01 B.5.93
Feeder
Note
If you take sheets off the feed table that
are still under the sheet stream/multiple
sheet detector, you will influence the
measurement of the sheet thickness,
causing faulty detector responses in
spite of a perfect sheet stream down the
line. In this case you must clear the feed
table. See the section "Clearing the
feeder".
3. Switch the feeder and paper run back on.
17.8 Switching the feeder back on after multiple sheet recognition
Note
Ensure that there are no multiple sheets
or bits of paper in the printing units or the
perfector. See the chapter "Removing
sheets that have not been gripped" for
details on how to remove missing
sheets.
Prerequisite
The feeder was switched off after multiple sheets were
detected.
The machine reports a package/multiple
sheets,
The sheets are still positioned under the multiple sheet
detector/forwarding roller shaft.
There are two possibilities of removing the multiple
sheets from the feeder.
1st option
SF.901.1804-000GRAUND_00
1. Clear the feed table. See the section "Clearing
1 2 the feeder".
2. Switch on the feeder (Fig. 114/1) and the sheet
travel (Fig. 114/2) again.
Option 2
1. Lower the main pile.
3
2. Pull all print sheets that are jammed underneath
the forwarding roller back onto the pile.
3. Remove all other sheets from the feed table.
Fig. 114 Feeder control panel, dependent on the
press configuration
B.5.94 SC.999.0020/01
Feeder
Note
If the machine did not detect multiple
sheets but only a double sheet, the con-
trol system does not expect a change in
the sheet stream under the forwarding
rollers. This expectation does not
change with "Pile down".
If you now remove sheets from under the
forwarding rollers, you will cause faulty
responses of the multiple sheet detector
even if the sheet stream is perfect. In this
case, use option 1 (clearing the feeder).
The machine control system will reset
the multiple sheet detector to default.
4. Switch on the feeder (Fig. 114/1) and the sheet
travel (Fig. 114/2) again.
17.9 Clearing the feeder
You can find the Clear feeder button in
the Production menu on the feeder dis-
play. This function enables you to clear
the sheets from the feed table.
Requirement
The press turns in basic speed.
After a machine stop, e.g. due to overrunning sheets,
you must first eliminate the problem and then restart
the machine. See the section "Double sheet detectors/
sheet alignment monitor".
1. Press the Release sheet stop fingers button
SF.901.1804-000GRAUND_00
(Fig. 115/3) on the control panel for Sheet con-
1 2 trol. The sheet stop finger remains released
(sheet stop finger up) as long as you press the
button. Remove the sheet above the sheet align-
ment monitor.
2. Press the Clear feeder button on the Production
menu.
3
The paper run is stopped. The sheets on the feed
table are transported to the printing unit in the
running direction of paper. The ratchet pawl
blocks the sheet infeed. The sheet stop fingers
are closed.
3. Remove the sheets from the feed table before
Fig. 115 Feeder control panel, dependent on the they reach the sheet alignment.
press configuration
SC.999.0020/01 B.5.95
Feeder
17.10 Sheet alignment monitor
FS.901.2060-000GRAUND_00
1
Fig. 116 Footer in the feeder display
The sheet alignment monitor at the front and side lays
checks whether the sheet arrives within a defined time
window. If the sheet arrives at the front lays outside the
correct time window, the feeder or the press stops. The
status displays on the feeder touch screen (Fig. 116/1)
show trends in the sheet arrival or malfunctions. The
display changes color depending on the deviation from
the reference value.
Note
In presses without a touchscreen, sheet
arrival is shown on the press display. For
more information on this, see the chap-
ter "Control panels on the feeder, press
display".
● Black: Sheet arrival matches the reference value.
● Yellow: Trend value; sheet arrival is within toler-
ances.
● Red: Sheet arrival is outside of tolerances. The
feeder/press stops.
There are different displays for:
● Early sheet or overrunning sheet
● Late sheet or missing sheet
● Misaligned sheet
● Sheet infeed/pull lay
Early sheet or overrunning sheet
The sheet arrives before the front lays are in the align-
ment position. The status display shows the following
view:
Symbol Meaning
Correct sheet arrival
left, black symbol: lead edge is correct
right, black symbol: side edge is correct
Sheet arrival: Trend towards early
sheet
left, yellow symbol: lead edge is within the
correct time window. There is a trend to-
wards early sheet arrival.
B.5.96 SC.999.0020/01
Feeder
Symbol Meaning
right, black symbol: side edge is correct
Sheet arrival: Early sheet/Overrunning
sheet
left, red symbol: lead edge is outside the
time window, early sheet
right, black symbol: side edge is correct
Tab. 29 Fault symbols on the status display
Overrunning or early sheets are detected by the press,
and the press stops immediately. Depending on the
stock properties and the press speed, entire sheets or
sheet pieces may be drawn into the press until it
comes to a standstill.
● The sheets or sheet pieces may be clamped be-
tween the gripper systems. When the press starts
up again, they may be transported through sev-
eral printing units and even reach the delivery.
The sheets or sheet pieces may be folded sev-
eral times during this process and cause press
damage.
● The sheets or sheet pieces may bypass the grip-
pers and remain in the press. If they are not re-
moved they may be transported in uncontrolled
manner into the sheet guiding system when the
press starts up again, and cause press damage.
What do you need to do in the event of early or
overrunning sheets?
The press stops immediately.
1. Press the Release sheet stop fingers button.
Sheets that are still in the feeder are released.
2. Take the sheet or sheet piece off the feed table.
3. Open the guard above the front lays. Check the
transfer gripper and the feed cylinder.
4. Remove any sheets or sheet pieces from the
transfer gripper and feed cylinder.
5. Check the entire sheet guiding system of the
press for lost sheets. Proceed as follows:
Removing the non-gripped sheet
1. Open all inking unit guards at all printing units.
2. Check all printing units to see if sheets or sheet
pieces are sticking to the blanket cylinder or have
been drawn into the inking unit.
3. Open the transfer guards between the printing
units.
4. Search for all non-gripped sheets and pieces of
sheets and remove them from the press.
Search for pieces of sheets, which got stuck on
the guide plate prongs, for example. Even small
SC.999.0020/01 B.5.97
Feeder
scraps of paper can damage the sheet-guiding
cylinders and grippers.
5. Check the sheets and scraps of paper you have
● found inside the press and
● removed in the delivery
to see whether you have really found and re-
moved all pieces of paper.
6. Once you have checked the entire sheet guiding
system, close all guards.
Note
Try to inch the press as little as possible
for this purpose. If this is necessary, only
inch in the direction of sheet travel.
Caution - Risk of damage to the
press!
If there are still sheets or pieces of
sheets in the press, you may only crank
the press backward in emergencies. The
existing sheets can damage sheet-
transferring cylinders and grippers when
the press is cranked backward.
Late sheet or missing sheet
The sheet arrives late or not at all at the front lays. The
status display shows the following view:
Symbol Meaning
Sheet arrival: Trend towards late sheet
left, yellow symbol: lead edge is within the
correct time window. There is a trend to-
wards late sheet arrival.
right, black symbol: side edge is correct
Sheet arrival: Late sheet
left, red symbol: lead edge is outside the
time window, late sheet
right, black symbol: side edge is correct
Tab. 30 Fault symbols on the status display
● The sheet does not arrive until the front lays are
no longer in alignment position.
● The sheet does not arrive at all.
The feeder stops. You have to remove the late sheet
from the feed table. If missing sheets continue to oc-
cur, check the feeder and suction head settings.
Misaligned sheet
The sheet does not arrive simultaneously at the mon-
itor of the front lays on D.S. and O.S. The status dis-
play shows the following view:
B.5.98 SC.999.0020/01
Feeder
Symbol Meaning
Sheet arrival: Trend towards mis-
aligned sheet O.S.
The sheet does not arrive simultaneously
on D.S. and O.S. There is a trend towards
misaligned sheets in direction of O.S.
Sheet arrival: Trend towards mis-
aligned sheet D.S.
The sheet does not arrive simultaneously
on D.S. and O.S. There is a trend towards
misaligned sheets in direction of D.S.
Sheet arrival: Misaligned sheet on O.S.
Sheet arrival on D.S. and O.S. is outside a
defined tolerance. The feeder stops.
Sheet arrival: Misaligned sheet on D.S.
Sheet arrival on D.S. and O.S. is outside a
defined tolerance. The feeder stops.
Tab. 31 Fault symbols on the status display
The sheet is so misaligned when it arrives at the front
lays that its position can no longer be corrected.
This is what happens:
The feeder stops.
- The machine reports a misaligned sheet.
How can you restart the machine?
1. Remove the misaligned sheet from the feed ta-
ble.
Note
If the sheet stream on the feed table is
faulty and you want to remove it, use the
clearing function.
If you clear the feed table manually and
remove sheets from under the forward-
ing rollers/multiple sheet detector, you
may cause faulty responses of the for-
warding rollers/multiple sheet detector.
2. Use the "Clear" function.
3. If misaligned sheets occur repeatedly, check the
settings at the feeder and the suction head.
Sheet infeed/Pull distance
The side edge of the sheet is monitored on D.S. and
O.S., and the result is shown in a diagram on the status
display. The monitoring results are only displayed and
do not cause a press or feeder stop.
In addition to the graphic display, the system also
emits an acoustic warning.
SC.999.0020/01 B.5.99
Feeder
Symbol Meaning
Sheet infeed: Trend, sheet infeed too
far on D.S.
The sheet is too close to the stop prior to
pulling.
Remedy: Increase the pull distance.
Pull lay: Trend, pull distance too great
on D.S.
The sheet is not at the stop after pulling.
Remedy: Decrease the pull distance, in-
crease the pulling suction, if necessary.
Sheet infeed: Trend, sheet infeed too
far on O.S.
The sheet is too close to the stop prior to
pulling.
Remedy: Increase the pull distance.
Pull lay: Trend, pull distance too great
on O.S.
The sheet is not at the stop after pulling.
Remedy: Decrease the pull distance, in-
crease the pulling suction, if necessary.
Tab. 32 Fault symbols on the status display
17.11 Possible causes of early, late and misaligned sheets
Malfunction Possible cause Remedy
Early sheet Sheet is not held correctly on the suction tape feed table. Increase the suction of the
tape.
In case of restart after a stopper: excessive adjustment of Clear the sheet stream
the sheet arrival control. completely.
Late sheet Pile does not rest correctly against the forwarding flap. Push the pile forward.
Sheet is held too strongly on the suction tape feed table. Decrease the suction of the
tape slightly.
Bottlenecks on the feed table / in the sheet alignment Check the sheet path for
system slow the sheets down. bottlenecks.
B.5.100 SC.999.0020/01
Feeder
Malfunction Possible cause Remedy
Misaligned sheet The pile (or one side of it) does not rest properly against Push the pile forward.
the forwarding flap.
Sheet separation does not work properly. Check sheet separation
(air, separator fingers, suc-
tion head settings etc.).
Sheets are not separated Not enough carrier air avail- Increase carrier air. Shake
correctly. able for sheet separation. up the sheets manually.
Sheet loss at the lifting Reduce the lifting air.
sucker: air is subsequently Check the height of the car-
blown over the sheet in- rier air blowers.
stead of under it.
Sheets adhere to each other (glass plate effect). Aerate the sheets manual-
ly, increase the separating
air.
Sheets are statically charged and stick together. Check the room climate,
aerate the pile, allow pallets
to acclimatize.
Bottlenecks on the feed table or in the sheet alignment Check the sheet path for
system slow down the sheets. bottlenecks.
Tab. 33 Early, late and misaligned sheets
Note
See the section "Troubleshooting at the
feeder" at the end of the chapter.
SC.999.0020/01 B.5.101
Feeder
17.12 Ultrasonic sheet drag monitor
Note
SF.901.2054-000GRAUND_00
The ultrasonic sheet drag monitor is only
available in conjunction with the foil
1 printing kit at the feeder.
The ultrasonic sheet drag monitor (Fig. 117/1) is lo-
cated in the direction of paper travel, downstream of
the front lays. The ultrasonic sheet drag monitor is op-
erational after the feeder has been switched on. It
checks whether an infed sheet has dragged another
sheet along with it.
If the ultrasonic sheet drag monitor detects a dragged
sheet, the control system applies the following protec-
tive measures:
● The sheet stop fingers are extended.
● Production is interrupted - emergency stop func-
tion.
● The feeder switches off.
Fig. 117 Ultrasonic sheet drag monitor
The ultrasonic sheet drag monitor detects all conven-
tional printing materials.
However, the monitor may respond even if sheet travel
is perfect when certain special stocks are processed.
This can be the case with the following printing mate-
rials:
● Multi-layer printing materials
● Thick printing foils
● Kraft board
● Printing materials that tend to blister (bubble for-
mation)
See also the explanations on the ultrasonic double
sheet detector. Both systems work according to the
same measuring principle and are subject to similar
restrictions.
Switching off the ultrasonic sheet drag monitor
When processing special printing materials, you can
switch off the ultrasonic sheet drag monitor at the con-
trol station. When the machine is switched on again,
the ultrasonic sheet drag monitor is automatically back
in operation.
You can find more details on switching off the ultra-
sonic sheet drag monitor in the Prinect Press Center
operating manual.
B.5.102 SC.999.0020/01
Feeder
18 Forwarding rollers
FS.901.5090-000UTKENU_00
18.1 Adjusting to sheet format
Note
FS.901.1092-000GRAUND_00
Clear the feed table before you start po-
sitioning the forwarding rollers. Due to
1 2 multiple sheet detection, there can be
startup problems when you move the
forwarding rollers on the sheets.
1. Loosen the tommy bar screw (Fig. 118/1).
2. Move the forwarding roller (Fig. 118/2) to the re-
quired position.
Recommended adjustment: Set the distance be-
tween the forwarding rollers to half the sheet
width.
3. Tighten the tommy bar screw (Fig. 118/1).
Fig. 118 Forwarding roller
SC.999.0020/01 B.5.103
Feeder
19 Guide rolls on the suction tape
SF.901.5095-000UTKENU_00
19.1 General
Function
The guide rolls support the sheet infeed by guiding the
sheet in the shingle onto the suction tape. With rigid
printing materials in particular, using and correctly set-
ting the guide rolls can aid smooth sheet transport into
the machine.
19.2 Mounting position
Position above the suction tape
SF.901.5039-000GRAUND_00
1 2 Fit the guide rolls (Fig. 119/1) in such a way that they
are positioned above the suction tape driving roller
(Fig. 119/2).
Ensure that the guide rolls are not positioned directly
on the side edges of the suction tape (Fig. 119/3).
Fig. 119 Diagram - fitting location of the guide rolls
on the suction tape
19.3 Guide rolls
Guide rolls (Fig. 120/1) are fitted on the feeder of your
SF.901.5037-000GRAUND_00
1 machine near the suction tape drive shaft above the
suction tape.
Fig. 120 Support with guide rolls
B.5.104 SC.999.0020/01
Feeder
Setting the rolling pressure
SF.901.5040-000GRAUND_00
1 1
Note
If the rolling pressure of the guide rolls is
too high on the printing material, in par-
ticular with smooth printing materials,
this can cause the sheets to stick to one
another. This can then cause problems
with sheet alignment. In this case, re-
duce the rolling pressure or remove the
guide rolls completely.
The guide rolls sit in a plate spring. Adjust the rolling
pressure very carefully.
1. Feed in printing material until the shingle covers
the entire feed table.
2. Turn the knurled screw (Fig. 121/1).
Fig. 121 Setting the rolling pressure
. Clockwise:
The rolling pressure increases.
. Counterclockwise:
The rolling pressure decreases.
3. Turn until the guide rolls lightly touch the shingle.
4. If necessary, turn the knurled screw another half
revolution clockwise.
5. Correct the rolling pressure to suit the thickness
and stiffness of the printing material if necessary.
Result
The two guide rolls are in contact with
the shingle with a slight spring pressure.
Installing the guide rolls
SF.901.5042-000GRAUND_00
1 2
Note
Make sure that the fitting location is cor-
rect when doing this.
1. Loosen the tommy bar screw (Fig. 122/1).
2. Place the support on the cross bar (Fig. 122/2) in
the desired position.
3. Retighten the locking screw.
4. Install the second guide roll the same way.
Fig. 122 Support on the cross bar - correct fitting lo-
cation
SC.999.0020/01 B.5.105
Feeder
20 Pulling device
SF.901.5100-000UTKENU_06
20.1 Function
The feed table is equipped with a pulling device each
on D.S. and O.S., a short distance away from the
1st unit. You can preselect the desired pulling direction
(usually O.S.) by selecting the corresponding pulling
device (D.S. or O.S.) at the control station.
The purpose of the integrated pull lays is to align all
sheets laterally before they are transported into the
1st unit.
The pulling device on D.S. pulls the sheet against a
pull stop on D.S. The pulling device on O.S. pulls the
sheet against a pull stop on O.S.
20.2 Function elements
● Adjusting screw for retainer height (Fig. 123/1)
SF.901.5998-000GRAUND_00
1 2 3 4 ● Feeler roller for double sheet detection
(Fig. 123/2)
● Pull plate (Fig. 123/3)
● Traction roll (Fig. 123/4)
● Retainers removable (Fig. 123/5)
● Pull sensor (Fig. 123/6)
● Clamping lever (Fig. 123/7)
● Adjusting screw for pull sensor (Fig. 123/8)
8 7 6 5
Fig. 123 Overview of pulling device, here on the op-
erator's side
20.3 Setting the format
The pulling device and pull side are preselected at the
control station.
Once the job data has been accepted, the preselected
pulling device moves to the position at which the sheet
runs centered through the press.
The inactive pulling device moves out of the format to
an extent that the measuring lever of the double sheet
detector still remains effective. The pull lay channel is
covered automatically when the pulling device is po-
sitioned.
Malfunction during positioning
If during the positioning of the pulling device, the
Emergency stop button is pressed, the pulling device
comes to a standstill.
B.5.106 SC.999.0020/01
Feeder
Confirm the selected sheet size again at the control
station. The pull unit then moves to the preselected
position.
20.4 Adjusting the suction air
Pull plate and traction rolls pick up the sheet. The con-
trol system regulates the suction air volume as a func-
tion of the stock thickness.
● Light printing material - low suction force.
● Heavy printing material - high suction force.
You can adjust the suction air volume of the pull plate
and traction roll separately.
Adjusting the suction air for the traction roll
SF.901.5897-000GRAUND_00
1. In the Production menu on the feeder display,
you can:
● the button Increase suction air volume, trac-
1 3 tion roller (Fig. 124/1) to increase the suc-
tion air volume at the traction roller.
or
● the button Decrease suction air volume,
traction roller (Fig. 124/2) to decrease the
suction air volume at the traction roller.
The current working pressure of the traction roll is
2 4 shown on the manometer (Fig. 125/1).
If there is not enough suction air, the sheet is not guid-
ed correctly to the front lays.
Fig. 124 Feeder display, Production menu
If there is too much suction air, thin (light) stocks may
SF.901.5846-000GRAUND_00
be distorted in the area of the traction rolls.
1 2
Adjusting the suction air for the pull plate
1. In the Production menu on the feeder display,
you can:
● press the button Increase suction air vol-
ume (Fig. 124/3) to increase the suction air
volume at the pull plate.
or
● press the button Decrease suction air vol-
ume (Fig. 124/4) to decrease the suction air
volume at the pull plate.
The current working pressure of the pull plate is
shown on the manometer (Fig. 125/2).
If the suction air is too low, the sheet is not guided cor-
rectly up to the pull stop.
Fig. 125 Feeder side frame D.S., suction air for the If there is too much suction air, the sheet is deformed
traction roll and pull lay at the pull stop.
SC.999.0020/01 B.5.107
Feeder
20.5 Adjusting the pull stop to the stock
You can adjust the angle of the pull stop if the sheets
SF.901.5996-002GRAUND_00
are not cut at right angles or if the front lays are askew.
1. Remove the retainer. See section on "Removing/
installing retainers".
2. Set the front lays straight. Same gripper bite on
D.S. and O.S.
3. Place a sheet of the stock against the front lays
and push the sheet against the pull stop
(Fig. 126/2).
4. Use the adjustment eccentric (Fig. 126/1) to set
the angle at the pull stop to the edge of the sheet.
5. Reinstall the retainer.
1 2
Fig. 126 Pull stop adjusting elements
● Basic position: pull stop is set at a right angle
SF.901.1886-000GRAUND_00
(Fig. 127/1)
1 ● Pull stop leans toward the left (Fig. 127/2)
● Pull stop leans toward the right (Fig. 127/3)
Basic position of the pull stop
Note
2 It may become necessary to repeat the
basic adjustment after the printing ma-
terial has been changed.
1. Set the front lays straight. Same gripper bite on
D.S. and O.S.
3 2. Position the pull stop at a right angle to the front
lays.
To do so, align the long mark on the adjustment
eccentric with the mark on the pull stop
(Fig. 127/1).
Fig. 127 Positions of the adjustment eccentric, pull
stop
B.5.108 SC.999.0020/01
Feeder
20.6 Pull lay monitor
The light sensor (Fig. 128/1) checks if the pulling de-
SF.901.5849-000GRAUND_00
vice functions correctly. A signal sounds (only during
sheet travel) if a sheet has not been pulled correctly to
the stop of the pulling device. A pull error (Fig. 129/1) is
indicated in the footer at the feeder display and at the
control station.
An infeed error is indicated if the sheet is too close to
the pull stop before pulling begins. The press remains
in production.
If an infeed error occurs
● Increase the pull distance.
If a pull error occurs
1 ● Check the pull distance.
Check the vacuum at the pull plate and the trac-
Fig. 128 Light sensor in the pull lay tion roll.
SF.901.5997-001GRAUND_00
Preselecting the pull lay monitor
● Select the pull lay monitor on the control station.
Fig. 129 Feeder display, pull error
20.7 Adjusting the pull lay monitor
You can adjust the pull lay monitor during the paper
run or while the press is at standstill. Both adjustment
options are described below.
SC.999.0020/01 B.5.109
Feeder
Adjustment principle
SF.901.5840-000GRAUND_00
Turn the knurled screw (Fig. 130/1) to move the light
sensor (Fig. 130/2) in the desired direction. See the
arrows (Fig. 130/A and 130/B).
1
A 2
B
Fig. 130 Adjusting the pull lay
20.7.1 Adjustment during the paper run
You will be guided by an acoustic signal. Note also the
SF.901.5896-000GRAUND_00
sheet travel trend information (Fig. 132/1) on the feed-
er display in the Production menu.
A B 1. Switch on the paper run.
2. Check if the sheet is pulled correctly against the
pull stop.
3. Turn the knurled screw towards "A" (Fig. 131/A)
until you hear the signal of the pull monitor.
● The light sensor moves toward O.S.
Fig. 131 Knurled screw, adjusting the pull lay
4. Turn the knurled screw in the other direction, to-
wards "B", (Fig. 131/B) until the pull monitor falls
SF.901.5997-001GRAUND_00
silent.
● The light sensor moves toward D.S.
5. Then turn the knurled screw another 10 incre-
ments.
Note
You may have to repeat this adjustment
after a change of stock.
Fig. 132 Feeder display, Production menu
B.5.110 SC.999.0020/01
Feeder
20.7.2 Adjustment during press standstill
1. Press the Control panel selection button twice
SF.901.5851-000GRAUND_00
(Fig. 133/1).
The LED in the button lights up.
2. Inch the press until the front lays are positioned at
the feed table (Fig. 133/2).
3. Release the sheet stop finger.
Press the button Release sheet stop fingers
(Fig. 133/3).
The LED in the button lights up.
or
Press the button at the touchscreen of the feeder
3 2 1 control panel.
Fig. 133 Feeder control panel
4. Place a sheet of the current stock (Fig. 134/1) on
SF.901.5845-000GRAUND_00
the feed table. The sheet must touch the front
lays and the pull stop.
Fig. 134 Aligning the sheet, here: O.S.
5. Turn the knurled screw towards "A" (Fig. 135/A).
SF.901.5896-000GRAUND_00
● The light sensor moves toward O.S.
A B If there was information (Fig. 136/1) on the feeder
display, it is no longer displayed.
6. Turn the knurled screw to the opposite direction
"B" (Fig. 135/B).
● The light sensor moves toward D.S.
The green illuminated dot (Fig. 136/1) indi-
cates that the light sensor has detected the
Fig. 135 Knurled screw, adjusting the pull lay
stock.
7. Then turn the knurled screw another 10 incre-
ments.
Deviation from the basic setting
● The further you turn the knurled screw, the less
sensitive the monitor. A more significant pull error
may occur.
● The less you turn the knurled screw, the more
sensitive the monitor.
SC.999.0020/01 B.5.111
Feeder
Example - turning the knurled screw another 10 in-
SF.901.5850-000GRAUND_00
crements
A.S.
D.S. One increment corresponds to 0.03 mm. With the ba-
C.E. sic setting, a pull error is indicated if the distance be-
L.I. tween the sheet and the sheet stop after pulling is
L.V. larger than 0.3 mm.
B.S.
O.S.
C.S.
L.S.
L.M.
Fig. 136 Excerpt from the menu Feeder, pull lay
20.8 Adjusting the pull distance
Once the sheet size has been entered, the control
system automatically adjusts the feeder pile to the
preselected pull distance. You can adjust the pull dis-
tance on the control station and the feeder display.
Recommended setting
Adjust a pull distance of 4 ... 6 mm. A pull distance of
less than 2 mm may lead to malfunctions in the lateral
alignment.
The maximum pull distance is 12 mm.
20.9 Retainer
Each of the pull lays on D.S. and O.S. is equipped with
SF.901.5841-000GRAUND_00
a retainer. You can install and remove the retainers
without tools and adjust their height to the stock thick-
ness.
Fig. 137 Retainer O.S.
B.5.112 SC.999.0020/01
Feeder
20.9.1 Adjusting the retainers
1. Slide three strips of the current stock (Fig. 138/3)
SF.901.5842-001GRAUND_00
1 under each retainer on D.S. and O.S.
2. Using the knurled head screw (Fig. 138/1), adjust
the height of the retainer (Fig. 138/2).
One revolution of the knurled screw corresponds
to a height difference of 0.5 mm.
Direction:
●
clockwise = retainer moves down
●
counterclockwise = retainer moves
up
The retainers must guide the paper strips lightly
without pinching them.
2 3
Fig. 138 Adjusting the retainers
20.9.2 Removing/installing the retainers
Caution - Damaged retainers can ob-
SF.901.5994-000GRAUND_00
2 1 struct sheet travel!
Do not bend or scratch the retainers.
Handle the retainers with great care dur-
ing removal and installation.
Removing the retainer
1. Swivel the clamping lever (Fig. 139/1) upwards.
2. Remove the retainer (Fig. 139/2) in the direction
of the arrow from the pull lay.
Fig. 139 Removing the retainers; here: O.S.
SC.999.0020/01 B.5.113
Feeder
Installing the retainer
SF.901.5995-000GRAUND_00
2 1 1. Slide the retainer (Fig. 140/2) up to the stop
(Fig. 140/3) into the pull lay.
2. Swivel the clamping lever (Fig. 140/1) down-
wards up to the stop.
Note
3 The clamping lever must be in a hori-
zontal position after closing when a re-
tainer is installed. If the clamping lever is
not in a horizontal position, the retainer
has not been inserted incorrectly.
The clamping lever achieves the neces-
sary clamping force through the horizon-
tal position. Do not press the clamping
lever down additionally.
3. Adjust the retainer to match the current stock
Fig. 140 Installing the retainers; here: O.S. thickness. See section on "Adjusting retainer".
20.10 Cleaning the pull lay
The pull lay is equipped with an automatic cleaning
SF.901.5989-001GRAUND_00
facility. When the pile is fanned, the pull rail and pull
sensor are blown free.
If the pull lay is very dirty, you can also clean it with a
suitable industrial-type vacuum cleaner.
You will find notes on this in the separate "Mainte-
nance and cleaning, customer" manual.
Removing paper shred
1. Remove the retainer. See section on "Removing/
installing retainers".
2. Remove the paper shred from the area under-
neath the holding-down device (Fig. 141/arrows).
3. Fit the retainer.
Fig. 141 Removing paper shred
B.5.114 SC.999.0020/01
Feeder
21 Separator rolls
SG.901.5110-000UTKENU_04
21.1 Function
The separator rolls guide the sheets under the cover
SG.901.5826-002GRAUND_00
guides. They provide for minimized marking and se-
1 cure infeed into the press.
With a stock thickness of 0.2 mm and more, the sep-
arator rolls automatically swing to the cardboard posi-
tion after the first sheet has arrived at the front lays.
You can manually change the position and height ad-
justment of the separator rolls and switch off the indi-
2 2 vidual separator rolls.
Fig. 142 Separator rolls
21.2 Adjusting the height of the separator rolls
To adjust the separator rolls, use three strips of print-
ing material of the current print job.
1. Push the strips of printing material between sep-
arator roll and feed table.
2. Turn the knurled head screw (Fig. 142/1) to ad-
just the height of the separator rolls.
The strips of printing material should run tightly
between separator roll and feed table, without
getting pinched.
● Turning clockwise reduces the distance be-
tween separator rolls and feed table.
● Turning counterclockwise increases the
distance between separator rolls and feed
table.
● Each notch of the knurled screw changes
the distance between separator rolls and
feed table by 0.1 mm.
The maximum distance between separator rolls and
feed table is approximately 10 mm.
The minimum distance between the separator rolls
and the feed table is:
● 0.2 mm in paper position,
● 0.4 mm in cardboard position.
SC.999.0020/01 B.5.115
Feeder
21.3 Changing the separator roll position
The separator rolls are positioned according to the en-
try of the stock thickness at the control station. The
separator rolls can swivel to two positions:
● Paper mode: Up to a stock thickness of < 0.2 mm,
the separator rolls remain in paper position.
● Cardboard mode: If the stock is thicker than
0.2 mm, the separator rolls swing to the card-
board position after the first print sheet has ar-
rived.
● For stock thickness values between 0.3 mm and
< 0.4 mm you may select paper mode or card-
board mode. Recommendation: Select card-
board mode to print very stiff material in this thick-
ness range.
● Paper mode cannot be selected if the stock thick-
ness exceeds 0.4 mm.
21.4 Throwing on/off individual separator rolls
You can throw the separator rolls on and off individu-
SG.901.5826-002GRAUND_00
ally.
1
Throwing off the separator roll
1. Move the lever (Fig. 143/2) at the separator roll
clockwise towards O.S.
Engaging the separator roll
1. Move the lever (Fig. 143/1) at the separator roll
2 2
counterclockwise towards D.S.
Fig. 143 Throwing on/off separator rolls
21.5 Cleaning the separator rolls
1. Using a brush or compressed air, remove the pa-
per dust daily.
2. If a separator roll marks on the print sheet:
Clean the separator roll with a lightly dampened
cloth. Use only water and the cleaners that are
approved by Heidelberg.
The separator roll must be replaced by Heidelberg
Service if it is still tight after it has been cleaned.
B.5.116 SC.999.0020/01
Feeder
21.6 Cleaning the sheet guide plate
1. Turn the screw (Fig. 144/1) back by one turn.
SG.901.5886-003GRAUND_00
2. Pull the sheet guide plate (Fig. 144/2) from D.S.
out of the retainer.
1 3. Clean the sheet guide plate with a lightly damp-
ened cloth. Use only water and the cleaners that
are approved by Heidelberg.
4. Push the cleaned sheet guide plate towards O.S.
into the retainer.
2 5. Tighten the screw (Fig. 144/1).
Fig. 144 Cleaning the sheet guide plate
SC.999.0020/01 B.5.117
Feeder
22 Front lays
SG.901.5120-000UTKENU_06
22.1 Function
The printing press has 15 swivel-type front lays
SG.901.5841-002GRAUND_00
(Fig. 145/1) underneath the feed table. These front
lays can be thrown on and off step by step. The front
lays align the front edge of the print sheets true to reg-
ister. The following settings are possible:
● Throwing on and throwing off: A front lay that has
been thrown on is in contact with the front edge of
the print sheet during the alignment procedure.
● Setting forward and backward: This function is
used for adjusting the gripper bite.
1 ● Convex or concave adjustment: To adjust the
front lay shaft to the cut edge of the printing ma-
terial, you may use a convex or concave adjust-
ment.
Fig. 145 Front lays
22.2 Throwing the front lays on/off
To throw on/off the front lays you need the 3 mm Allen
SG.901.5840-003GRAUND_00
1 key with handle, that is included in the delivery.
Note
The front lays must be in contact with the
feed table to engage or disengage them.
If necessary, inch the press until the front
lays are positioned at the feed table.
1. Open the glass guard on the printing unit. The
separator rolls swing back.
2. Secure the press against being started up: Press
the Emergency stop button on the feeder control
panel.
3. Insert the Allen key (Fig. 146/1) through the bore-
hole in the sheet guide plate (Fig. 146/2) into the
adjusting screw of the required front lay.
2
4. Turn the screw 90°.
● clockwise, if you wish to throw on the front
lay.
● anti-clockwise, if you wish to throw off the
front lay.
Note
When you turn the screw, you can feel a
Fig. 146 Front lays on / off
notched division. The rotary distance be-
tween "front lays thrown on" and "front
lays thrown off" is subdivided into
15 notches.
5. Release the Emergency stop button.
6. Close the glass guard on the printing unit.
B.5.118 SC.999.0020/01
Feeder
Note
When the job is finished, set the front
lays back to the normal position.
22.3 Adjusting the gripper bite
You can adjust the gripper bite at the control station.
With the front lays In the middle position the gripper
bite on both D.S. and O.S. is 11 mm each. You may
change the setting by +/- 1 mm in 0.02 mm increments:
● parallel forwards or backwards,
● forwards or backwards in different steps for D.S.
and O.S.
● deflecting in the range from +0.5 through -0.3 mm
○ with a gripper bite of 11.9 mm: from +0.4
through -0.3
○ with a gripper bite of 12 mm: from +0.3
through -0.3
Observe the following points:
● On a new job, start in the middle position. In this
way you will still have elbow room in all directions.
● Do not change the adjustment of the front lays
when you print on front and rear side in several
press passes. There can be deviations in the reg-
ister truth of front and rear side.
● If you adjust the front lays while a job is being
printed, mark the pile in this position. Finishing
will then be able to check the press setting at the
corresponding point.
22.4 Cleaning the front lays
1. Using a brush or compressed air, remove the pa-
per dust daily.
2. You should clean the roller when a front lay or a
front lay supporting roller marks on the print
sheet. Use only the cleaners that are approved
by Heidelberg. The roller must be replaced by
Heidelberg Service if it is still tight after it has
been cleaned.
SC.999.0020/01 B.5.119
Feeder
22.5 Blowing/suction nozzles
The blowing/suction nozzles (Fig. 147/1) guide the
SG.901.5843-001GRAUND_00
sheet under the cover guides.
1. Adjust the volume of blast air at the control sta-
tion, or using the buttons on the feeder control
console, or in the Production menu on the feeder
touch screen.
● Blowing/suction nozzle + button increases
the blast air volume.
● Blowing/suction nozzle - button reduces the
blast air volume.
1
Fig. 147 Blowing/suction nozzles
22.6 Raising the sheet stop fingers
The sheet stop fingers (Fig. 148/1) are used for re-
SG.901.5846-002GRAUND_00
taining double sheets, overrunning sheets and late
1 sheets on the feed table. To perform certain adjust-
ment work or to remove sheets you can raise the sheet
stop fingers.
1. Press the Release sheet stop fingers button on
the control panel of the first printing unit. The
sheet stop fingers (Fig. 148/1) are raised.
or
2. Inch the press until the feeder engages and the
sheet stop fingers are raised.
Fig. 148 Sheet stop fingers
B.5.120 SC.999.0020/01
Feeder
23 Crash bar
FS.901.5151-000UTKENU_04
23.1 Function
The crash bar prevents larger loose objects from being
fed into the printing unit.
Caution - Penetrating foreign bodies
can damage the sheet alignment sys-
tem and the printing unit!
The crash bar must be installed on the
feed table and be adjusted to the cur-
rently relevant stock thickness.
23.2 Adjusting the crash bar
1. Set the smallest possible gap (approx. 1 mm) be-
SF.901.5898-000GRAUND_00 tween the crash bar (Fig. 149/1) and the stock.
Use the lever (Fig. 149/2) to adjust the gap.
● Move the lever down: the gap becomes nar-
1 rower.
● Move the lever up: the gap becomes wider.
2
Fig. 149 Crash bar
SC.999.0020/01 B.5.121
Feeder
24 Adjustment information for special printing material
SG.901.5152-000UTKENU_04
24.1 Special printing materials
Special printing materials require special settings on
the press.
This chapter gives you some information about the
processing of special printing materials. The sheet
travel depends on a large number of factors. For this
reason, Heidelberg can give you only setting recom-
mendations here.
The fine correction of the recommended values must
be determined during operation.
24.2 Book paper
Book paper is a wood-free or slightly wood pulp print-
ing material. Its high volume and a light coloring are
typical for this printing material.
When processing this printing material you must
chiefly take the porosity into account.
Suction head
1. Install the form-B tissue paper suckers on the lift-
ing suckers.
2. Adjust the sucking level of the lifting suckers such
that the tissue paper suckers touch the unfanned
pile.
3. Insert the form-A sheet separator fingers into the
supports on the suction head.
● Sheet separator fingers that protrude too far
into the pile tear the sucked-on sheet off the
lifting suckers.
● Sheet separator fingers that reach not far
enough into the pile favor the formation of
double sheets.
4. Reduce the suction air on the suction head as
required.
Note
Reducing the suction air too much re-
sults in sheet loss on the lifting suckers.
Suction tape
In most cases, the suction air at the suction tape must
be reduced significantly.
Too high a vacuum at the suction tape results in waves
on the fed sheets and in pull errors.
Note
The bypass air flap must be open when
you adjust a vacuum of ≤ 25 %.
B.5.122 SC.999.0020/01
Feeder
1. Reduce the suction air on the suction tape as re-
quired.
Some book papers require a vacuum of 10 % and
less to be adjusted.
Prior to adjusting a vacuum of ≤ 25 %:
2. Switch off the feeder.
3. Open the bypass air flap on the suction tape.
To do so, press the Suction tape bypass button
on the control station.
4. Switch the feeder back on.
Pull lay
1. In case of pull errors, increase the suction air vol-
ume to approximately 60 ... 80 %.
SC.999.0020/01 B.5.123
Feeder
25 CutStar (sheeter) - Preset Plus feeder
SG.901.5162-000UTKENU_03
25.1 Function/Task
The CutStar unwinds a paper web from a paper roll.
The CutStar cuts the unrolled paper web into separate
sheets.
The sheet width is determined by the width of the pa-
per roll. The sheet length can - inside certain limits - be
specified by the operator.
The individual sheets are fed directly to the feed table.
The suction head is not required when the CutStar is
used.
25.2 Conversion to operation with CutStar
SG.901.5992-000GRAUND_00 1. Press the Main pile down push button
(Fig. 150/1). Lower the pile support plate to the
end position.
2. Detach the optional non-stop bar.
3. Press the Auxiliary pile up push button
2 (Fig. 150/2). Raise the auxiliary pile system to the
1 topmost position.
Fig. 150 Control panel on the feeder - section
4. Set the stops of the optional preloading device on
SG.901.5954-000GRAUND_00
2 1 2 D.S. and on O.S. to the outermost position.
● Release the levers (Fig. 151/2) on D.S. and
on O.S.
● Set each stop (Fig. 151/3) fully to the out-
side.
3 3
● Close the levers (Fig. 151/2).
5. Detach the optional middle stop (Fig. 151/1).
Fig. 151 Preloading device (option)
B.5.124 SC.999.0020/01
Feeder
Press without CANopen connection
SG.901.5993-000GRAUND_00
Note
On presses without CANopen connec-
tion the control panel is located on the
feeder.
1
6. Press the Position printing press for sheeter op-
eration (Fig. 152/1) button on the feeder control
panel.
Fig. 152 Control panel on the feeder - section
Press with CANopen connection
SG.901.5994-000GRAUND_00
Note
1 On presses with CANopen connection
the control panel is located on the
CutStar.
7. Press the Position printing press for sheeter op-
eration push button (Fig. 153/1) on the CutStar
control panel.
Fig. 153 Control panel on the CutStar
Regardless of the equipment of your printing press, by
pressing the Position printing press for sheeter oper-
ation button the following settings are automatically
made on the feeder:
● The side stops move to maximum sheet size.
● The suction head moves to its topmost position.
● The servo-drives are locked.
● Automatic sheet arrival control and misaligned
sheet control are deactivated.
Note
The LED in the Position printing press for
sheeter operation button (Fig. 152/1 or
Fig. 153/1) flashes as long as the suction
head and side stops are moving.
SC.999.0020/01 B.5.125
Feeder
8. Secure the 4 brush rolls (Fig. 154/1) at the sup-
SG.901.5956-000GRAUND_00
port bar underneath the suction head.
9. Adjust all the other subassemblies (e.g. sheet
separation blower, rear edge blower, ionizing
unit ...) that are fixed to the support bar such that
they are above the lower edge of the brush rolls.
Except for the brush rolls, no other subassembly
may be in contact with the passing sheets.
1 10. Fold up the suction feed board of the CutStar, see
operating manual from the "Bielomatik" manu-
1 facturer.
The control station automatically performs the
following activities when the suction feed board is
folded up:
Fig. 154 Installing the brush rolls ● The forwarding flap is folded down and
fixed.
● The suction head drive is disengaged.
The suction feed board stops if it collides with the
preloading device or the non-stop bar when it is
folded up.
11. The brush rolls must stand on the transport tapes
of the suction feed board.
Correct the position of the brush rolls if neces-
sary.
Note
Please refer to the operating manual of
the "Bielomatik" manufacturer for addi-
tional operating information on the
CutStar.
Recognizing splices
The employed paper rolls may contain production-re-
lated splices. The double sheet detector detects these
splices.
1. Adjust the double sheet detector to the printing
material (see chapter "Press, Preset Plus feeder,
double sheet detector").
Feeder and CutStar stop when the double sheet de-
tector detects a sheet with a splice. The press goes off
impression and continues running at 3000 iph.
1. Remove the sheet with the splice from the feed
table.
2. Press the Clear feeder push button.
Sheet travel is switched off. The sheets on the
feed table are transported to the printing unit in
the running direction of paper. The ratchet pawl
blocks the sheet infeed. The sheet stop fingers
are closed.
3. Remove the sheets from the feed table.
4. Put the feeder and the CutStar back into opera-
tion.
B.5.126 SC.999.0020/01
Feeder
Signal lamps
SG.901.9922-000GRAUND_00
The sleeves of the rolls are available with different di-
1
ameters. You must therefore select the following di-
ameters at the CutStar:
● Warning roll diameter
● Minimum roll diameter
A horn sounds when the paper roll reaches the warn-
ing roll diameter. The signal lamp (Fig. 155/1) lights up.
The infeed roller of the CutStar and the paper roll stop
when the paper roll reaches the minimum roll diame-
ter. The sheets on the sheeter table are transported to
the feeder. The CutStar stops. The signal lamp
(Fig. 155/1) goes out.
Fig. 155 Delivery
25.3 Conversion to operation without CutStar
1. Fold down the suction feed board of the CutStar,
see operating manual from the "Bielomatik" man-
ufacturer.
The control station automatically performs the
following activities when the suction feed board is
folded down:
● The forwarding flap swings upwards.
● The suction head drive is engaged.
● The LED in the Position printing press for
sheeter operation button (Fig. 152/1 or
Fig. 153/1) goes out.
● Misaligned sheet control and automatic
sheet arrival control are activated (provided
they are not deselected at the control sta-
tion).
2. Remove the 4 brush rolls (Fig. 156/1) from the
SG.901.5956-000GRAUND_00
support bar underneath the suction head.
Note
Please refer to the operating manual of
the "Bielomatik" manufacturer for addi-
tional operating information on the
CutStar.
Fig. 156 Installing the brush rolls
Among other things, the side stops and the suction
head are adjusted to the specified sheet size when you
SC.999.0020/01 B.5.127
Feeder
enter the job data of a new job at the control station and
automatic pile height control has been switched on.
B.5.128 SC.999.0020/01
Feeder
26 Troubleshooting on the feeder
FS.901.5161-000UTKENU_05
26.1 Overview
The following table will support you in localizing and
rectifying faults that may occur in the feeder area.
Contact your Heidelberg agency if you are unable to
eliminate the malfunction with the help of this table.
26.2 Pile
Malfunction Possible cause Remedy
Pile centering does not work. The "Bottom of pile support plate" limit Remove any foreign bodies; clean the
switch is jammed or soiled. limit switch.
Pile only moves downward slowly The "Pile support plate is 120 mm Remove any foreign bodies; clean the
from a higher position when the Pile above the base" limit switch is mechanical components for activat-
down button is held down and does jammed or soiled. ing the limit switch.
not move downward of its own mo-
mentum.
Tab. 34 Pile
26.3 Sheet separation
Malfunction Possible cause Remedy
Missing sheet Pressure drop at the lifting suckers Close the bypass valve.
due to an open bypass valve at the
suction head.
Sheet separator fingers tear the Reduce the strength of the sheet sep-
sheets off the lifting suckers. arator finger.
Extremely misaligned sheet in the Misaligned sheet control is at stop be- Switch off control system and locate
shingle cause the sheets get stuck in the fault location.
sheet alignment system.
Double sheets The sheet separation blower sepa- Readjust the sheet separation blow-
rates the top sheets on the pile insuf- er. The top sheets must visibly be
ficiently. separated.
The sheets escape from underneath Set the sheet separator fingers further
the sheet separator fingers. into the pile.
Set the weights of the pile stop onto
the pile.
Use additional sheet separator fin-
gers.
Reduce the separating air.
Porous material. Use a tissue paper sucker.
Insert slotted sheet separator fingers
(form A).
Reduce the suction air of forwarding
and lifting suckers (see the "Suction
head" chapter).
SC.999.0020/01 B.5.129
Feeder
Malfunction Possible cause Remedy
Caution: Risk of missing sheets!
Close the bypass valve after the end
of job.
Sheet is lost at the lifting suckers. Reduce the lifting air.
Reduce the pressure of the sheet
separator fingers on the pile. Do not
place the sheet separator fingers too
far into the pile.
The pile is too high at the forwarding Set the pile approximately 5 mm un-
flap. derneath the forwarding flap.
The sheets are not properly separat- The lifting air is not sufficient for sep- Increase carrier air.
ed from the pile (thin paper). arating the sheets.
Increase the blast air compensation.
The lifting air flow tears the sheets off Reduce the lifting air.
the suckers.
Reduce the blast air compensation.
The lateral sheet control on the lateral Loosen the locking screw, and swing
sheet separation blowers is too close the lateral sheet control slightly away
to the pile so that sheets are pinched from the pile.
and cannot be separated.
The pile centering device moves the Foreign objects, pile wedges, or the Do not obstruct the visible area of the
pile laterally away. flexible lateral sheet separation blow- side sensors.
ers may affect the visual range of the
lateral sensors of the pile centering.
The end cutoff of the lateral pile cen- The end cutoff sensor must be read-
tering at the pallet end does not work. justed.
Tab. 35 Sheet separation
26.4 Double sheet detectors
Malfunction Possible cause Remedy
Multiple sheet detector signals double The pile is too high in the multiple In the multiple sheet detector area,
sheet although there is no double sheet detector area. the upper pile edge must not be high-
sheet (with heavily warped card- er than the forwarding flap. Lower the
board). upper pile edge so that it is 3 ... 5 mm
below the forwarding flap, or reposi-
tion the multiple sheet detector.
Pile stroke too high. Reduce the pile stroke from 5 fold
(default) to 3 fold printing material
thickness.
Ultrasonic double sheet detector sig- The printing material is not suitable for The ultrasonic double sheet detector
nals double sheet although there is a the ultrasonic double sheet detector. is not suitable for multi-layer printing
single sheet. materials (such as micro-corrugated
cardboard) or for printing masters that
are thicker than 0.5 mm. Switch off
the ultrasonic double sheet detector,
and activate pull lay and/or shingle
detector (adjustment).
B.5.130 SC.999.0020/01
Feeder
Malfunction Possible cause Remedy
The transmitter in the sheet guide Clean the transmitter as described in
plate is soiled. the maintenance and cleaning manu-
al.
Double sheet fault at the pull lay dou- The entered stock thickness deviates Check the entered stock thickness.
ble sheet detector. too much from the actual stock thick-
Caution at infeed of waste sheet of a
ness.
different stock thickness.
Tab. 36 Double sheet detectors
26.5 Suction tape feed table sheet transport
Malfunction Possible cause Remedy
The sheet buckles on the feed table in The forward drive of the suction tape Reduce the suction tape vacuum. At a
front of the separator rolls. on the sheet is too strong. vacuum of less than 25% the bypass
valve on the suction tape must be
open (see the operating manual for
the control system).
If necessary, open the flap on the suc-
tion tape for thin grammages.
Reduce the contact force of the rub-
ber idler rollers.
Install the plate retainer at the sheet
alignment.
Late sheet with cardboard. Slip of the suction tape with respect to Reduce the vacuum in the suction
the tape drive roller. tape.
Check the suction tape tension.
Slip of the sheet on the suction tape. Increase the vacuum in the suction
tape.
Waves in the fed sheet on the suction Porous paper. Reduce the vacuum in the suction
tape feed table. tape.
Tab. 37 Suction tape feed table sheet transport
26.6 Sheet alignment system
Malfunction Possible cause Remedy
Lay register problems (lateral) The hold-down rod on the pull lay Adjust the hold-down rod (2 sheets
pinches the sheet. clear; 3 sheets light suction applied).
The distance between hold-down rod Adjust the hold-down rod (2 sheets
and pull rail is too great. clear; 3 sheets light suction applied).
The pull distance is too small. The pull distance must be more than
2 mm (optimum 5 mm ... 8 mm).
The pull stop is askew. Adjust the pull stop to the sheet edge.
Paper shreds jammed under the pull Remove and clean the pull lay retain-
lay retainer. er.
SC.999.0020/01 B.5.131
Feeder
Malfunction Possible cause Remedy
Lay register problems (circumfer- Front lay deflection Adjust front lay deflection on sheet or
ence) deflect front lay shaft in the center
slightly towards first printing unit.
Individual front lays do not carry the Throw on the front lays.
sheet.
The pressure of the blast suction noz- Reduce the pressure.
zles is too high (thin grammage).
The pressure of the blast suction noz- Increase the pressure.
zles is too low (thick grammage).
Incorrectly set separator roll height. Set the separator roll height to three
times the stock thickness.
The force at which suction tape and/or Increase suction tape pressure
traction roll push the sheet towards and/or traction roll pressure.
the front lays is not strong enough.
The force at which suction tape and/or Reduce suction tape pressure and/or
traction roll push the sheet towards traction roll pressure.
the front lays is too strong.
Pull errors The pull vacuum is low. Increase the vacuum.
The pull lay retainer pinches the Adjust the retainer.
sheet.
Suction tape pressure is high (porous Reduce the suction tape pressure; in-
papers). crease the pull pressure.
Pull distance too large. Adjust the pull distance to
5 mm ... 8 mm.
The blowing/suction nozzles hold the Reduce the vacuum at the blowing/
sheet too strongly. suction nozzles; move the separator
rolls to a lower position if necessary.
The sheet is pinched by a separator Set the separator rolls higher or
roll. switch off individual separator rolls.
Porous paper. Increase the vacuum at the pull lay.
The cover guides are set too low and Set the cover guides higher.
clamp the sheets at 300° ... 330°.
Powder build-up on the blanket due to The separator rolls press to heavily Switch off individual separator roll.
the separator rolls. onto the sheet.
Raise all separator rolls, if necessary
increase the pressure of the blowing/
suction nozzles (for sheet separation
on the cover guide), if necessary fas-
ten the hold-down rod on the front lay
guard (to prevent high waves from
appearing in the sheet during infeed).
Set the separator rolls to the card-
board position, if necessary increase
the pressure of the blowing/suction
nozzles (for sheet separation on the
cover guide), if necessary fasten
hold-down rod on the front lay guard
B.5.132 SC.999.0020/01
Feeder
Malfunction Possible cause Remedy
(to prevent high waves from appear-
ing in the sheet during infeed).
High infeed wave: Sheet tears at the Retention force on the incoming sheet Set the separator rolls to the preset
rear edge. is too low. height. If necessary check the setting
with a sheet and have it readjusted by
Heidelberg Service.
Set the separator rolls to the paper
position.
Increase the pressure of the blowing/
suction nozzles.
If the 3 aforementioned troubleshoot-
ing measures cannot be applied due
to a build-up of powder on the blanket
through the separator rolls: Fasten
the hold-down rod on the front lay
guard.
Missing sheet reported, although the The sheet feeder sensors do not rec- Check whether the sheet is correctly
sheet exists at the front lays. ognize the fed sheet. in contact with the front lays.
Replace the hold-down rod in the area
of the light probes.
Tab. 38 Sheet alignment system
SC.999.0020/01 B.5.133
Feeder
27 Emergency measures in the event of the failure of a servo-drive in the feeder
SF.901.5159-000UTKENU_03
27.1 What is the purpose of these emergency measures?
The feeder is fitted with servo-drives that adjust the
feeder elements to different sheet sizes, printing ma-
terials, etc. You should notify Heidelberg Service in the
event of a servo-drive failure. Emergency measures
enable you to maintain production through manual in-
terventions until a service engineer arrives.
Caution - Risk of press damage!
Before you carry out any manual adjust-
ment, check whether the servo-drive is
really defective. First check the adjust-
ments on the control system, the air fil-
ters or the motion path of the servo-drive
or the driven subassembly. Never apply
force when turning the servo-drives. The
cause of a tight servo-drive is often a
blocked motion path. Once the adjust-
ment work is terminated: Remove all
tools and cranking aids.
Detecting a faulty servo-drive
A servo-drive failure is a rare malfunction.
Check the following points first when a servo-drive
does not respond:
● Is the motion path of the servo-drive unobstruct-
ed?
● Is the press ready to run?
● Is any motion blocking device active (e.g. Emer-
gency stop button pressed)?
Take the emergency measures only after you have
excluded these causes of the fault.
You can directly control the majority of servo-drives on
the feeder control console or using the control system
on the control station. The reaction of a servo-drive
can be noticed by a motor noise or a movement of the
corresponding subassembly.
Adjustable servo-drives
Manual adjustment is possible for the following servo-
drives:
● Suction head sheet size adjustment
● Suction head height adjustment
● Sheet size adjustment of the side stops
● Cover guide height
● Sheet size adjustment of the pull lay
B.5.134 SC.999.0020/01
Feeder
27.2 Manually setting suction head to sheet size
Checking the servo-drive
SF.901.1802-000GRAUND_00
When the suction head functions normally and the
1 sheet size has been entered correctly, it moves to the
rear edge of the pile. When the suction head does not
move, use the following procedure to check the servo-
2 drive:
Requirement
The press is operative. The motion path
of the servo-drive is unobstructed. There
is no motion blocking device active (e.g.
Emergency stop button pressed).
1. Press the Increase suction head sheet size but-
ton (Fig. 157/1).
If the suction head still has some motion path, it
moves away from the pile.
2. Press the Decrease suction head sheet size but-
ton (Fig. 157/2).
If the suction head still has some motion path, it
moves towards the pile. Ensure that the suction
head elements do not collide with the pile.
Fig. 157 Suction head format push buttons
If the suction head moves, check the sheet size input
and the pile position.
The servo-drive may be defective if the suction head
does not move and if there is no noise from the servo-
drive.
Setting the suction head manually to size
SG.901.5963-000GRAUND_00
The position of the suction head depends on the sheet
length. Place the suction head such that the mark on
the governor foot is flush with the rear edge of the pile
(Fig. 158/1).
You can adjust the suction head via the feed table.
There is a borehole (Fig. 159/1) in the cross bar that
permits access to the adjusting element.
1. Secure the press against being started up: Press
the Emergency stop button on the feeder control
1 panel.
Fig. 158 Position of the governor foot
SC.999.0020/01 B.5.135
Feeder
The gear for the manual adjustment is downstream of
SF.901.1877-001GRAUND_00
the borehole (Fig. 159/1). To reach the gear you will
1 require a size 19 Allen wrench with extension. The
gear sits approximately 35 cm behind the guard.
2. Insert the size 19 Allen wrench into the borehole
on the guard (Fig. 159/1) and mount it on the
hexagon of the gear behind it.
3. To increase the sheet size turn the screw in a
clockwise direction.
4. To reduce the sheet size turn the screw in a
counterclockwise direction.
5. Remove the Allen wrench.
6. Release the Emergency stop button.
Fig. 159 Borehole in the center of the guard
27.3 Manual suction head height adjustment
Checking the servo-drive
SF.901.1194-000GRAUND_00
1 When functioning normally and if the correct sheet size
has been entered the suction head moves relative to
the center position 30 mm upwards or 40 mm down-
wards. When the suction head does not move, use the
following procedure to check the servo-drive:
Requirement
The press is operative. The motion path
of the servo-drive is unobstructed. There
is no motion blocking device active (e.g.
2 Emergency stop button pressed).
1. Press the Suction head height adjustment up-
wards button (Fig. 160/1).
If the suction head still has some motion path, the
suction head moves upwards. The pile may then
inch after it.
2. Press the Suction head height adjustment down-
Fig. 160 Section of control panel for Start control wards button (Fig. 160/2).
If the suction head still has some motion path, the
suction head moves downwards. Make sure that
the governor foot and the suckers do not collide
with the pile. Move the pile downwards.
The servo-drive may be defective if the suction head
does not move after a button has been pressed, and if
there is no noise from the servo-drive.
B.5.136 SC.999.0020/01
Feeder
Manual suction head height adjustment
SF.901.1876-001GRAUND_00
1 The suction head height adjustment enables you to set
the position of the upper pile edge relative to the for-
warding flap.
You can set the suction head from above. The cover
plate has a borehole (Fig. 161/1), which can only be
reached with the aid of a ladder.
If the suction head has not been set to a sheet size of
700 +/- 10 mm, move the pile downwards. This will
help you to avoid colliding with the suction head. Move
the suction head to sheet size 700 +/-10 mm.
Result
The threaded spindle with the hexagon
socket for manual setting is directly be-
low the borehole in the cover plate.
Fig. 161 Borehole in the center of the cover plate To make the setting you will require a size 4 Allen
wrench, min. 50 mm long.
1. Secure the press against being started up: Press
the Emergency stop button on the feeder control
panel.
2. Insert the Allen wrench through the borehole in
the cover plate and into the hexagon socket of the
threaded spindle.
3. Turn the threaded spindle in a clockwise direc-
tion, to move the suction head upwards.
4. Turn the threaded spindle in a counterclockwise
direction, to move the suction head downwards.
5. Remove the Allen wrench.
6. Release the Emergency stop button.
27.4 Manually setting the side stops to sheet size
Checking the servo-drives
SF.901.1195-000GRAUND_00
1 If they are functioning normally and the format has
been entered correctly, the lateral pile guide rails move
toward the pile until there is a gap of approximately
1 mm. The lateral sheet separation blowers have a
distance of approximately 3 mm to the pile. Use the
following procedure to check the function of the servo-
drives if the side stops do not move:
Requirement
The press is operative. The motion path
2 of the side stop is unobstructed. There is
no motion blocking device active (e.g.
Emergency stop button pressed).
1. Switch off the automatic pile centering.
2. Press the Increase lateral sheet separation blow-
er sheet size button (Fig. 162/1).
The side stop on the pull side stops. The side stop
Fig. 162 Section of control panel for Start control at the opposite side moves outwards.
3. Press the Reduce lateral sheet separation blower
sheet size button (Fig. 162/2).
SC.999.0020/01 B.5.137
Feeder
The side stop on the pull side stops. The side stop
at the opposite side moves inwards. Ensure that
the side stop does not collide with the pile.
The servo-drive may be defective if the side stop does
not move and if there is no noise from the servo-drive.
The position of the side stops depends on the sheet
width and the lateral alignment of the pile. Position the
pile guide rails as follows:
● on D.S. and O.S. a distance of 1 mm to the pile.
The lateral sheet separation blowers have a dis-
tance of approximately 3 mm to the pile.
The side stops are accessible from the side of the
feeder table. The adjusting element for the side stop
O.S. is on the O.S. The adjusting element for the side
stop D.S. is on the D.S.
SG.901.4265-001GRAUND_00 1. Position the pile such that the required pull dis-
1 tance (5...7 mm) is reached.
2. Secure the press against being started up: Press
the Emergency stop button on the feeder control
panel.
3. Fit a size 19 Allen wrench onto the hexagon of the
gear (Fig. 163/1).
4. Turn the gear on the D.S. to adjust the side stop
on D.S.
5. Turn the gear on the O.S. to adjust the side stop
on O.S.
6. To reduce the sheet size turn the screw in a
clockwise direction.
7. To increase the sheet size turn the screw in a
counterclockwise direction.
8. Remove the Allen wrench.
9. Release the Emergency stop button.
Fig. 163 Gear side stop servo-drive
27.5 Manually setting cover guide height
Checking the servo-drive
In standard operation the control system automatically
sets the height of the cover guides to twice the stock
thickness of the current print job +0.1 mm. Irrespective
of this you can set the height adjustment for the cover
guides using the control system or the Cover guides up
and Cover guides down buttons of the control panel on
the first printing unit.
Requirement
The press is operative. There is no mo-
tion blocking device active (e.g. Emer-
gency stop button pressed).
B.5.138 SC.999.0020/01
Feeder
If the cover guides fail to execute the following func-
tions, the servomotor can be defective.
● Thick printing material does not arrive at the front
lays. This can result in missing sheets.
● This printing materials buckle or overpile at the
front lays. This causes early sheets and overrun-
ning sheets.
● You cannot use the Cover guides up and Cover
guides down buttons or the Prinect Press Center
to move the cover guides up or down.
In this case, set the cover guides manually.
Adjusting the cover guide manually
SG.901.5965-001GRAUND_00
The setting element for the cover guide height is lo-
cated behind the guard below the feed table.
1. Secure the press against being switched on: by
setting the main switch to O/Off and locking it with
a padlock. Leave a sign with the name of the per-
son authorized to switch on the press.
2. Open the guard door below the feed table.
3. Fold up the feed table on O.S.
4. Remove the protective flap (Fig. 164/1).
1
Fig. 164 Protective flap
5. Release the four 3-mm Allen screws (Fig. 165/2)
FS.901.5949-001GRAUND_00
2 1 2 on the servomotor (Fig. 165/1).
The four Allen screws are not captive.
2 2
Fig. 165 Cover guide servomotor
SC.999.0020/01 B.5.139
Feeder
Note
FS.901.5950-000GRAUND_00
2 The servomotor transfers the torque via
1 three compression springs (Fig. 166/2).
The compression springs are not cap-
tive. When removing the servomotor the
springs can fall out.
6. Pull the servomotor off the flange.
Be careful with the three compression springs
(Fig. 166/2) when removing the servomotor.
7. Insert a 6-mm Allen key into the shaft in the flange
(Fig. 166/1).
The cover guide height depends on the stock thick-
ness. Adjust the cover guide height as follows:
● Twice the stock thickness + 0.1 mm.
Fig. 166 Adjusting the cover guide manually
8. To reduce the cover guide height: Turn the shaft
clockwise using the Allen key.
or
To increase the cover guide height: Turn the
shaft counterclockwise using the Allen key.
Caution - Risk of damaging the press
by incorrect adjustment!
Check the adjustment: Pushing two lay-
ers of printing material and a 1/10-mm
feeler gauge underneath the cover
guides must be possible. Set the cover
guide height to at least twice the stock
thickness. If incorrectly set the sheet
guide plate or the cover guides may be
damaged.
9. Remove the Allen key from the shaft.
10. Hook the protective flap (Fig. 164/1) into position.
11. Fold down the feed table on O.S.
12. Close the guard door below the feed table.
13. Switch the press on again.
27.6 Manually setting separator rolls
Checking the servo-drive
In standard operation the control system automatically
sets the height of the separator rolls to three times the
stock thickness of the current print job. Yet you can still
change the height adjustment of the separator rolls
using the Separator rolls up and Separator rolls down
push buttons on the control panel of the first printing
unit.
Requirement
The press is operative. There is no mo-
tion blocking device active (e.g. Emer-
gency stop button pressed).
B.5.140 SC.999.0020/01
Feeder
If the separator rolls fail to execute the following func-
tions, the servomotor can be defective.
● The separator rolls fail to adjust to the current
printing material thickness.
● You cannot move the separator rolls upward or
downward using the Separator rolls up or Sepa-
rator rolls down push buttons.
In this case, disengage the separator rolls manually.
Throwing off the separator roll
FS.901.5112-003GRAUND_00
1 1. Fold up the lever on the separator roll in clock-
wise direction (Fig. 167/1).
Please refer to the chapter "Press, Feeder, Sep-
arator rolls" for further information on the sepa-
rator rolls.
Fig. 167 Throwing on/off separator rolls
27.7 Manually setting air volume controller for the blowing/suction nozzle
Checking the servo-drive
Requirement
The press is operative. The air supply at
the feeder is active. The press is at a de-
gree value of 260...270 degrees.
1. Press the Blowing/suction nozzle, more blast air
button.
You can hear the sound of the servo-drive. In
maximum setting, you can clearly feel the air
emerging from the blowing/suction nozzles.
2. Press the Blowing/suction nozzle, less blast air
button.
You can hear the sound of the servo-drive. In
minimum setting, you cannot feel the air emerg-
ing from the blowing/suction nozzles.
There may be a defect in the servo-drive if you cannot
hear a sound from the servo-drive and if there is no
sensible change in the air volume at the blowing/
suction nozzles.
SC.999.0020/01 B.5.141
Feeder
The air volume controller regulates the blast air for the
SG.901.5915-001GRAUND_00
blowing/suction nozzles. The adjusting element for the
air volume controller sits underneath the feed table on
D.S.
1. Secure the press against being started up: Press
the Emergency stop button on the feeder control
panel.
2. Open the guard door in front of the feed table.
3. Fold up the feed table on O.S.
4. Plug a square wrench onto the air volume con-
troller (Fig. 168/1). Using this square wrench, ad-
just the air volume controller as required.
5. Remove the square wrench (Fig. 168/1) from the
air volume controller.
6. Fold down the feed table on O.S.
7. Close the guard door in front of the feed table.
8. Ensure that all tools have been removed from the
press, and that all guards are in place.
9. Release the Emergency stop button.
Fig. 168 Air volume controller
27.8 Manually setting pull lays to sheet width
Checking the servo-drives
When the pull lays function normally and the sheet size
has been entered correctly, the pull lays move:
● on the pull side up to the point where the distance
between pull stop and feeder center is exactly
half the sheet width;
● on the opposite side 20 mm beyond the half of the
sheet width.
Use the following procedure to check the function of
the servo-drives if the pull lays do not move to the
sheet width:
Requirement
The press is operative. There is no mo-
tion blocking device active (e.g. Emer-
gency stop button pressed).
1. Select Paper run/feeder on the control station.
2. Press the Pull lay position button.
The pull lays move to the entered sheet size if the
servo-drive is OK.
The servo-drive may be defective if the pull lay does
not move and if there is no noise from the servo-drive.
B.5.142 SC.999.0020/01
Feeder
The adjusting elements for the pull lays are located
SF.901.5104-001GRAUND_00
behind the guard underneath the feed table.
1. Secure the press against being started up: Press
the Emergency stop button on the feeder control
panel.
1 2. Open the guard O.S. (Fig. 169/1) at the feed ta-
ble.
Fig. 169 Feeder, O.S.
3. Remove the guard underneath the feed table
SG.901.5964-001GRAUND_00
(Fig. 170/1).
Fig. 170 Guard underneath feed table
4. Fit a size 19 ratchet onto the hexagon of the ser-
SG.901.5982-001GRAUND_00
1 2 vo-drive.
● For the pull lay on O.S.: hexagon at the O.S. ser-
vo-drive (Fig. 171/1).
● For the pull lay on D.S.: hexagon at the D.S. ser-
vo-drive (Fig. 171/2).
Fig. 171 Pull lay servo-drives
SC.999.0020/01 B.5.143
Feeder
SG.901.5103-000GRAUND_00
1
4
2 2
3
5 6 7
Fig. 172 Adjusting the pull lay manually
● Sheet width (Fig. 172/1)
● Half sheet width (Fig. 172/2)
● Center mark on the middle sheet guide plate
(Fig. 172/3)
● 20 mm (Fig. 172/4)
● Active pull lay (Fig. 172/5)
● Middle sheet guide plate (Fig. 172/6)
● Inactive pull lay (Fig. 172/7)
● Folded press sheet (Fig. 172/8)
5. Mark the center of the middle sheet guide plate
(Fig. 172/3). This mark is the reference point for
the pull lay adjustment.
6. Fold a press sheet to half the sheet width. This
sheet is your adjustment gauge.
7. Pull lay of the pull side: Adjust the pull lay position
such that the folded sheet reaches from the mid-
dle of the sheet guide plate to the pull stop (= half
the sheet width).
8. Pull lay of the opposite side: Adjust the pull lay
position such that the folded sheet reaches from
the middle of the sheet guide plate to the pull
stop. From here, set the pull lay by another
20 mm towards the outside (= half the sheet width
+ 20 mm).
Note
If you do not set the distance to more
than 20 mm, the inactive pull lay stabi-
lizes the sheet during the lateral align-
ment.
B.5.144 SC.999.0020/01
Feeder
9. Remove the ratchet.
SG.901.5964-001GRAUND_00
10. Install the guard underneath the feed table
(Fig. 173/1).
1 11. Ensure that all tools have been removed from the
press, and that all guards are in place.
12. Release the Emergency stop button.
Fig. 173 Guard underneath feed table
SC.999.0020/01 B.5.145
Feeder
B.5.146 SC.999.0020/01
Printing unit
Printing unit
unit
Printing
1 Printing unit - safety instructions ......................................................................................... B.6.5
1.1 To be observed when performing work .......................................................................... B.6.5
2 Printing-related notes on cylinder rolling ........................................................................... B.6.9
2.1 Bearer-to-bearer presses ............................................................................................... B.6.9
2.2 Cylinder undercut .......................................................................................................... B.6.9
2.3 Cylinder rolling .............................................................................................................. B.6.10
2.4 Packing, packing thickness ........................................................................................... B.6.10
2.5 Consequences of incorrect packing height .................................................................... B.6.10
2.6 Printing pressure ........................................................................................................... B.6.10
2.7 Influence of cylinder rolling ........................................................................................... B.6.11
2.8 Measuring the packing thickness .................................................................................. B.6.11
2.9 Packing thickness of the cylinders ................................................................................ B.6.12
3 Height adjustment of the gripper pads on the feed cylinder ............................................ B.6.13
3.1 Feed cylinder ................................................................................................................ B.6.13
3.2 Gripper pad height ......................................................................................................... B.6.13
3.3 Setting ranges ................................................................................................................ B.6.14
3.4 Adjusting the height of the gripper pads on the feed cylinder ........................................ B.6.14
4 Removing lost sheets ........................................................................................................... B.6.16
4.1 Sheet travel monitor ....................................................................................................... B.6.16
4.2 Sheet loss in the printing unit/coating unit .................................................................... B.6.16
4.3 Sheet loss in the perfector ............................................................................................ B.6.18
4.4 Sheet loss in sheet ascent of delivery ........................................................................... B.6.20
5 Suction brush ......................................................................................................................... B.6.21
5.1 Utilization note ............................................................................................................... B.6.21
5.2 Design and function ....................................................................................................... B.6.21
5.3 Removing the suction brush .......................................................................................... B.6.22
5.4 Fitting the suction brush ................................................................................................. B.6.25
5.5 Adjusting the suction brush with respect to the impression cylinder .............................. B.6.25
5.6 Adjusting operating position or home position ............................................................... B.6.26
5.7 Cleaning the dust filters in the vacuum pump ................................................................ B.6.27
SC.999.0020/01 B.6.1
Printing unit
6 Plate cylinder ......................................................................................................................... B.6.28
6.1 Gluing on the polyester underlay foil ............................................................................. B.6.28
7 Hickey catcher ....................................................................................................................... B.6.29
7.1 Removing hickeys .......................................................................................................... B.6.29
8 Hand-held scanner with base station (Press Center 3/XL3 code reader with Ethernet
connection, option) ............................................................................................................... B.6.30
8.1 General .......................................................................................................................... B.6.30
8.2 Function/Task ................................................................................................................ B.6.30
8.3 Configuration on the machine ........................................................................................ B.6.31
8.4 Operation ....................................................................................................................... B.6.32
8.5 Faults ............................................................................................................................. B.6.38
8.6 Re-connecting hand-held scanner and base station ...................................................... B.6.40
8.7 Replacing the base station ............................................................................................. B.6.40
9 Requirements for the printing plate .................................................................................... B.6.42
9.1 Required size for edge-bent printing plates .................................................................. B.6.42
9.2 Technical printing plate requirements ........................................................................... B.6.43
10 AutoPlate ................................................................................................................................ B.6.46
10.1 Preparatory work for changing plates ............................................................................ B.6.46
10.2 Function of the printing unit guard on the delivery side ................................................. B.6.46
10.3 Removing the plate ........................................................................................................ B.6.47
10.4 Plate change .................................................................................................................. B.6.48
10.5 Mounting the plate ......................................................................................................... B.6.49
11 Positioning correction at the tail edge of print ................................................................... B.6.50
11.1 Overview and basic adjustment ..................................................................................... B.6.50
11.2 Positioning correction at the tail edge ............................................................................ B.6.50
12 Blanket cylinder .................................................................................................................... B.6.53
12.1 Coating the cylinder with a new chrome alloy ................................................................ B.6.53
12.2 Requirements on the cleaner ........................................................................................ B.6.53
12.3 Torque when tensioning the blankets ............................................................................ B.6.53
12.4 Preparing blanket .......................................................................................................... B.6.53
12.5 Gap cover ...................................................................................................................... B.6.54
12.6 Removing the blanket ................................................................................................... B.6.55
12.7 Preparing packing sheets ............................................................................................. B.6.57
12.8 Mounting the blanket ..................................................................................................... B.6.57
12.9 Measuring the packing thickness of the blanket ............................................................ B.6.64
B.6.2 SC.999.0020/01
Printing unit
13 Blanket washup device ......................................................................................................... B.6.65
13.1 Function and structure .................................................................................................. B.6.65
13.2 Removing the blanket washup unit (all PU except for PU 1) ......................................... B.6.66
13.3 Removing the blanket washup unit (PU 1) ..................................................................... B.6.67
13.4 Preparations for removing the blanket washup unit from a PU with interdeck dryer ..... B.6.68
13.5 Removing the used washup cloth ................................................................................. B.6.69
13.6 Preparing the cloth supply roll ....................................................................................... B.6.69
13.7 Mounting a new washup cloth ....................................................................................... B.6.71
13.8 Fitting the blanket washup unit (all PUs, except for PU 1) ............................................ B.6.75
13.9 Fitting the blanket washup unit (PU 1) .......................................................................... B.6.76
13.10 Fitting the blanket washup unit on a PU with interdeck dryer ........................................ B.6.77
14 Impression cylinder washup device .................................................................................... B.6.80
14.1 Function and design ...................................................................................................... B.6.80
14.2 Removing the washup unit ............................................................................................ B.6.81
14.3 Removing the used-up washup cloth ............................................................................ B.6.82
14.4 Preparing the cloth supply roll ....................................................................................... B.6.83
14.5 Mounting a new washup cloth ....................................................................................... B.6.86
14.6 Installing the washup unit .............................................................................................. B.6.88
15 Washing fluid container ....................................................................................................... B.6.90
15.1 Equipment and function ................................................................................................. B.6.90
15.2 Requirements on water / washing fluid ......................................................................... B.6.90
15.3 Bleeding the washing fluid container ............................................................................ B.6.90
15.4 Filling the washing fluid container ................................................................................. B.6.91
15.5 Draining and disposing cleaner / water .......................................................................... B.6.92
15.6 Water container cell accidentally filled with cleaner? ..................................................... B.6.93
15.7 Cleaning the entire washing system .............................................................................. B.6.93
16 Washup .................................................................................................................................. B.6.94
16.1 Manual washup/automated washup .............................................................................. B.6.94
16.2 Washup devices, general information ............................................................................ B.6.94
16.3 Washup devices, detailed information ........................................................................... B.6.95
16.4 Error messages during washing .................................................................................... B.6.96
17 Sheet-transferring cylinders and drums ............................................................................. B.6.97
17.1 Equipment ...................................................................................................................... B.6.97
17.2 Replacement of cylinder jackets ................................................................................... B.6.97
17.3 Automatically cleaning surfaces of impression cylinder with PerfectJacket/PerfectJacket
Blue ............................................................................................................................... B.6.97
17.4 Manual washup ............................................................................................................. B.6.99
SC.999.0020/01 B.6.3
Printing unit
17.5 Care instructions for all surfaces .................................................................................... B.6.99
17.6 Notes on PerfectJacket/PerfectJacket Blue/TransferJacket Blue ................................. B.6.99
17.7 Print-related notes .......................................................................................................... B.6.100
17.8 Super Blue system ......................................................................................................... B.6.101
17.9 General notes on straight printing and perfecting .......................................................... B.6.101
18 Air settings in the printing unit ............................................................................................ B.6.102
18.1 Air settings on the impression cylinder .......................................................................... B.6.102
18.2 Air-supported sheet guiding .......................................................................................... B.6.102
19 Malfunctions on the printing unit ........................................................................................ B.6.104
19.1 Error message: Drain oil from residual-oil reservoir ....................................................... B.6.104
B.6.4 SC.999.0020/01
Printing unit
1 Printing unit - safety instructions
SF.901.4000-000UTKENU_00
1.1 To be observed when performing work
Warning - Risk of injury from rotat-
ing rollers and cylinders!
When cleaning the rollers and cylin-
ders, the ball of your thumb must point
in the direction of the infeed gap and
your fingers in the direction of the out-
let gap. Select the corresponding di-
rection of rotation.
Warning - Risk of injury from rotat-
ing rollers and cylinders!
Use the gap covers of the blanket
cylinders, plate cylinders and coating
blanket cylinders in order to avoid in-
juries.
Warning - Explosion hazard due to
evaporating washing fluid!
Only use washing fluid with a flash
point of more than 55 °C. Fill the wash-
ing fluid container carefully and only
with approved cleaning agents. Do not
overfill the washing fluid container.
Keep sources of heat away from the
washing fluid container. Deal with
spilled fluids immediately and in the
correct manner.
Warning - Risk of injury from spilt
cleaners!
The washing fluid container is under
pressure. This pressure can lead to
cleaners being sprayed out of the con-
tainer. Switch off the compressed-air
supply hose and bleed the washing
fluid container before opening the lid.
Warning - Risk of injury from rotat-
ing parts!
There is a risk of injury when the guard
in front of the circumferential register
coarse adjustment device is open.
Close and lock the guard after you
have made your adjustments.
SC.999.0020/01 B.6.5
Printing unit
Warning - Risk of injury from mov-
ing parts!
Put the press on safe prior to perform-
ing any work in the area of the slide-in
opening for the washup module. Never
reach into the area of the slide-in open-
ing for the washup module. Use the
telescopic bar for handling the washup
module.
Warning - Risk of burning from hot
surfaces!
After dryer use, wait until all accessible
parts have cooled down and are no
more than lukewarm (approximate-
ly 40 °C).
Warning - Explosion hazard due to
evaporating solvents!
Before the use of cleaning agents, wait
until the cylinders and press compo-
nents to be cleaned have cooled down
and are just warm to the touch (ap-
proximately 40 °C).
Warning - Explosion hazard due to
evaporating solvents!
When using dryers, only use inks and
varnishes that do not create any ex-
plosive atmosphere when heated in
the dryer. This is specified in the cor-
responding safety data sheets.
Ensure that no solvents can enter into
the dryer area when using cleaners on
the press. Never use and store sol-
vents in the vicinity of the dryer.
When using an automatic washup de-
vice, set the wash program so that the
blankets and impression cylinders are
dry before you continue with the pro-
duction. This ensures that no solvent
can enter into the dryer area.
B.6.6 SC.999.0020/01
Printing unit
Warning - Danger of death from
electrical voltage!
Dryers work with very high operating
voltages. Ensure that the machine and
the dryers cannot be switched on be-
fore starting any maintenance work on
the dryer:
Switch the main switch to 0/Off and
lock it in this position with a padlock.
Leave a sign with the name of the per-
son authorized to switch on the main
switches.
Never touch any plugs of the electrical
connections or disconnect them when
the dryer is in operation. Protect all
plugs of electrical connections against
moisture, contamination and damage.
Faulty cables, plugs and insulation
should be repaired by skilled person-
nel only, using original spare parts.
Warning - Risk of injury from falling!
There is a risk of falling and thus suf-
fering serious bodily injuries when
climbing on or off in the area of the
white sheet metal.
Only step on the designated foot-
boards (gray bulb plate) from the drive
side.
Caution - Non-approved cleaners can
damage the gripper tips!
Depending on the press version, the
gripper tips are polyurethane-coated.
Non-approved cleaners attack the
polyurethane coating and consequently
cause malfunctions in the printing pro-
cess.
Use only approved cleaners when clean-
ing the gripper tips. There is a list of ap-
proved cleaners on the Internet sites of
FOGRA and Heidelberger Druck-
maschinen AG.
Caution - Damage caused by incor-
rect cleaners!
Never use cleaners (e.g. "paint strip-
pers") containing dichloromethane
(methylene chloride), trichloroethy-
lene or other chlorinated or halo-
genated carbon hydrides.
These washing fluids damage press
components, cylinder packings, rollers,
and blankets.
SC.999.0020/01 B.6.7
Printing unit
Caution - Damage to the press caused
by improper handling of the sheet
guide plates!
Never remove the sheet guide plates
near the transfer drums and impression
cylinders. The sheet guide plates must
only be removed and fitted by Heidel-
berg service staff. You can clean the
sheet guide plates if you inch the transfer
drums into a vertical position.
B.6.8 SC.999.0020/01
Printing unit
2 Printing-related notes on cylinder rolling
FS.901.0745-000UTKENU_07
2.1 Bearer-to-bearer presses
All Heidelberg sheet offset presses are bearer-to-
GX.901.0769-000GRAUND_00
bearer printing presses. This means that plate cylinder
and blanket cylinder have hardened steel disks (bear-
ers, Fig. 1/1) at their end faces that run under preten-
sion to each other.
The advantages of the bearer-to-bearer press concept
are:
1 1
● quiet, low-vibration press operation,
● sturdy rolling conditions,
● precise reproduction of the finest details during
the entire lifetime of the press.
The bearers serve as a reference during packing
height measurements.
Fig. 1 Plate cylinder blanket cylinder diagram Note
As the bearers run against each other
under pretension, they must always be
kept free of dirt and ink deposits. Clean
the bearers. You can find notes on this in
the "Maintenance and cleaning, cus-
tomer" manual.
The blanket cylinder and the impression cylinder do
not run bearer-to-bearer. The distance between the
two cylinders is variable and can be adjusted to print-
ing materials of different thicknesses.
2.2 Cylinder undercut
The surfaces of plate cylinder and blanket cylinder
GS.901.1357-000GRAUND_00
1 2 3 (Fig. 2/3) sit below the bearers (Fig. 2/1), with space for
printing plate, blanket and packings. The difference
between bearer and cylinder surface is called cylinder
undercut (Fig. 2/2).
Model line Plate cylinder Blanket cylin-
undercut der undercut
SX 52 0,03 mm 3,0 mm
SX 74 0,15 mm 2.3 mm
XL 75 0,12 mm 2.3 mm
Fig. 2 Cylinder undercut
CX 92 0,12 mm 2.3 mm
SM 102 0,12 mm 2.3 mm
SX 102
CD 102
CX 102
CX 104
XL 106 0,10 mm 2.3 mm
Tab. 1
SC.999.0020/01 B.6.9
Printing unit
2.3 Cylinder rolling
The cylinders are connected to one another with gear-
GX.901.0768-000GRAUND_00
wheels of equal size (Fig. 3/1), and run synchronously.
Rolling is the rolling behavior of plate, blanket and im-
pression cylinder surfaces during the printing process.
Fig. 3 Cylinder rolling
2.4 Packing, packing thickness
The term packing is used for everything that is mount-
ed on the blanket cylinder or the plate cylinder. The
blanket cylinder packing includes, for example, the
blanket and the underlay sheet.
The entire thickness of the packing is classed as the
packing thickness.
2.5 Consequences of incorrect packing height
There will be friction or insufficient printing pressure
between the surfaces when the packing thickness is
not adjusted to the specified values.
Possible consequences of too much packing: dou-
bling, slurring, dot gain and register faults.
2.6 Printing pressure
To transfer the ink onto the blanket, the cylinder sur-
faces must be "squeezed" against each other. The
printing pressure is specified in mm.
Plate cylinder and blanket cylinder run with bearer-to-
bearer pressure. The printing plate is 0.15 ... 0.20 mm
above the bearer, depending on the plate thickness.
Place packing underneath the blanket until you
achieve an optimal printing pressure of approx.
0.15 mm between the plate cylinder and the blanket
cylinder.
B.6.10 SC.999.0020/01
Printing unit
2.7 Influence of cylinder rolling
Why should the printing pressure be approx.
GX.901.1351-000GRAUND_00
0.15 mm?
1
The printing plate (Fig. 4/1) transfers the printed image
with printing pressure onto the blanket (Fig. 4/2). The
blanket is compressed under the pressure of the plate
cylinder.
Fig. 4 Printing plate and blanket
2.8 Measuring the packing thickness
You must check the calculated packing thickness by
GS.901.1943-000GRAUND_00
measuring it. The measurement is performed in the
same manner as with the blanket cylinder. See the
chapter "Blanket cylinder, measuring the packing
thickness".
Tip
To protect the plate, place a sheet of pa-
per onto the plate cylinder so that part of
it lies underneath the last inking form
roller. Throw on the inking form rollers to
hold the paper in place.
Fig. 5 Packing gauge
SC.999.0020/01 B.6.11
Printing unit
2.9 Packing thickness of the cylinders
1 Plate cylinder
GX.901.1651-000GRAUND_01
9 2 Printing plate
1
10 3 Plate/blanket printing pressure
2
4 Blanket
3 11
5 Packing sheet
4
12 6 Blanket cylinder
5
7 Printing pressure = impression pressure adjust-
ment + thickness of the printing material
6 8 Impression cylinder
9 Plate cylinder bearer
10 Plate cylinder undercut
11 Blanket cylinder undercut
5
12 Blanket cylinder bearer
4 13
13 Packing height
Fig. 6 Diagram of the cylinders with packings
Blanket cylinder packing
You have to underlay the blanket. Blankets may vary in
thickness.
Note
Be careful not to use too much packing
under the blanket, otherwise the pres-
sure between plate cylinder and blanket
cylinder will be too great.
You must correct the preset pressure
between the blanket and impression
cylinders manually at the control station.
The press control system assumes a
blanket height of 0.00 with respect to the
bearer. Differing packing heights must
be taken into account when the impres-
sion pressure between the blanket and
impression cylinders is adjusted.
Blankets can settle by up to 0.08 mm
during operation. Check the blanket
height after mounting. Adjust the blanket
height after approx. 5000 impressions
with suitable packing sheets.
B.6.12 SC.999.0020/01
Printing unit
3 Height adjustment of the gripper pads on the feed cylinder
SC.901.0611-000UTKENU_08
3.1 Feed cylinder
Sheet transport
CX.901.0200-001GRAUND_00
The gripper bar (Fig. 7/2) of the feed cylinder (Fig. 7/3)
takes the sheet from the transfer gripper (Fig. 7/1) and
transfers the sheet to the impression cylinder
2
(Fig. 7/4).
3
The gripper pads on the feed cylinder are height-ad-
justable.
1
Fig. 7 Feed cylinder
Sheet transfer
CX.901.0100-001GRAUND_00
1 The gripper (Fig. 8/3) holds the sheet (Fig. 8/1) onto
the gripper pad (Fig. 8/2). At the moment of sheet
transfer, the gripper pads (Fig. 8/2 and 4) are opposite
each other.
4 2 Ideally, the gap between the gripper pads opposite
each other should be the same as the sheet thickness.
In order to ensure good sheet transport when pro-
cessing printing materials of different thicknesses, the
height of the gripper pad (Fig. 8/4) can be adjusted on
3 the feed cylinder and on the transfer drum.
Fig. 8 Diagram of sheet transfer
3.2 Gripper pad height
When does it make sense to adjust the gripper pad
height?
If the stock thickness and the height of the gripper pad
differ by more than 0.3 mm, this results in severe de-
formation of the lead edge of sheet. This in turn can
lead to printing problems.
The gripper pad height can be adjusted to the stock
thickness when you change production from thin to
thick or from thick to thin printing materials.
SC.999.0020/01 B.6.13
Printing unit
Thin printing material
CX.901.0110-000GRAUND_00
A 1 2 A Deformation of the sheet if the gap be-
tween the gripper pads opposite each
other (Fig. 9/1) is larger than the stock
thickness.
3 2 1 Processing thin printing materials with too wide a gap
between the gripper pads opposite each other may
B 1 2 lead to tension in the sheet.
Thick printing material
B Deformation of the sheet if the gap be-
tween the gripper pads opposite each
3 2 1 other (Fig. 9/1) is smaller than the stock
thickness.
Fig. 9 Diagram of the gripper pads Processing thick printing materials with too small a gap
between the gripper pads opposite each other may
lead to marks/damage on the sheet in the area of the
gripper bite.
3.3 Setting ranges
Ideally, you should always set the height of the gripper
pads in relation to the stock thickness (e.g. scale value
"3" when stock thickness is 0.3 mm).
One scale line (Fig. 10/2) is equivalent to a gap dis-
tance of 0.1 mm.
To minimize the adjustment work, you can, for exam-
ple, work in one of the following areas depending on
the stock thickness.
Thickness of printing Dial reading
material
0.03 ... 0.3 mm 1
0.31 to 0.6 mm 4
Tab. 2
3.4 Adjusting the height of the gripper pads on the feed cylinder
The gripper pad height can be adjusted to the different
SG.901.5986-002GRAUND_00
stock thicknesses.
1 8 1. Select the control panel at the feeder.
The LED in the button Control panel selection
lights up.
2. Open the door below the feed table. Fold up the
1 feed table.
Note
2
This provides you with improved acces-
sibility.
3. Inch the press forward until the adjusting screw
(Fig. 10/1) is easily accessible.
4. Open the guard in front of the feed cylinder
Fig. 10 Adjustment device on the feed cylinder
B.6.14 SC.999.0020/01
Printing unit
5. Using a 17 mm socket wrench, set the adjusting
screw (Fig. 10/2 ) to the desired value.
Turning clockwise increases the gap (....8).
Turning counterclockwise decreases the gap (....
1).
The pointer (Fig. 10/2) indicates the current value
for the set gap. Each line on the scale corre-
sponds to 1/10 mm.
Note
In Position 1 an increased loosening
torque must be overcome.
Note
Compensate the thread play. Always set
the required gap from the larger to the
smaller value.
6. Close all guards
7. Deselect the control panel at the feeder again.
The LED in the button Control panel selection
goes dark.
SC.999.0020/01 B.6.15
Printing unit
4 Removing lost sheets
SX.901.0603-000UTKENU_01
4.1 Sheet travel monitor
For sheet travel monitoring purposes your press is
equipped with several monitoring systems. If sheets
are not grasped or scraps of paper are detected in
these areas, the corresponding error message is is-
sued on the control station.
Caution - Risk of damage to the
press!
Before you start up the press again, you
must remove all non-gripped sheets and
pieces of sheets.
Below is an itemized description of all error messages
and the corresponding troubleshooting measures for
clearing malfunctions.
● Sheet loss in the printing unit/coating unit.
○ Straight printing units
○ Printing units after the perfector
● Sheet loss in the perfector.
● Sheet loss on the sheet ascent of the delivery.
This monitoring is only active on machines with
perfector, coating unit and extended delivery.
4.2 Sheet loss in the printing unit/coating unit
What happens in the case of sheet loss?
● The press is stopped through an Emergency
stop.
● The feeder switches off.
● All printing units cease printing.
● The "Sheet loss, sheet travel monitor" error mes-
sage appears in the corresponding printing unit.
4.2.1 Straight printing units
Removing the non-gripped sheet
1. Open the cylinder guard and, if necessary, the
inking unit guard on the printing unit on which the
error message appears.
2. Check inside the printing unit whether the sheet
is sticking to the blanket cylinder or has run into
the inking unit.
3. Open the transfer guards between the printing
units.
● Transfer guard before the PU with the
"Sheet loss, sheet travel monitor" error
message. On presses with intermediate
units, open all guards up to the last PU be-
fore the intermediate units.
B.6.16 SC.999.0020/01
Printing unit
● Transfer guard after the PU with the "Sheet
loss, sheet travel monitor" error message.
4. Search for all non-gripped sheets and pieces of
sheets and remove them from the press.
Search for pieces of sheets, which got stuck on
the guide plate prongs, for example. Even small
scraps of paper can damage the sheet-guiding
cylinders and grippers.
Note
Try to inch the press as little as possible
for this purpose. If this is necessary, only
inch in the direction of sheet travel.
When inching, paper can be dragged
along. This means that the area in which
you can detect sheets or pieces of
sheets is extended.
Caution - Risk of damage to the
press!
If there are still sheets or pieces of
sheets in the press, you may only crank
the press backward in emergencies. The
existing sheets can damage sheet-
transferring cylinders and grippers when
the press is cranked backward.
5. Carefully check the sheet and scraps of paper.
Have you found and completely removed all
scraps of paper?
6. Close all guards
7. Do not put the machine into operation until you
have removed all sheets and sheet scraps.
4.2.2 Units after the perfector
Removing the non-gripped sheet
1. Open the cylinder guard and, if necessary, the
inking unit guard on the printing unit on which the
error message appears.
2. Check inside the printing unit whether the sheet
is sticking to the blanket cylinder or has run into
the inking unit.
Caution - Risk of damage to the
press!
Remove all non-gripped sheets and
pieces of sheets straight away before
you put the press back into operation.
3. Open the transfer guards between the printing
units.
● Transfer guard before the PU with the
"Sheet loss, sheet travel monitor" error
message. On presses with intermediate
units, open all guards up to the last PU be-
fore the intermediate units.
SC.999.0020/01 B.6.17
Printing unit
● Transfer guard after the PU with the "Sheet
loss, sheet travel monitor" error message.
4. Search for all non-gripped sheets and pieces of
sheets and remove them from the press.
Search for pieces of sheets, which got stuck on
the guide plate prongs, for example. Even small
pieces of sheets, which might crease up when
being moved along or gather together and be
moved along in a bunch can damage sheet-guid-
ing cylinders and grippers.
Note
Try to inch the press as little as possible
for this purpose. If this is necessary, only
inch in the direction of sheet travel.
When inching, paper can be dragged
along. This means that the area in which
you can detect sheets or pieces of
sheets is extended.
Caution - Risk of damage to the
press!
If there are still sheets or pieces of
sheets in the press, you may only crank
the press backward in emergencies. The
existing sheets can damage sheet-
transferring cylinders and grippers when
the press is cranked backward.
5. Carefully check the sheet and scraps of paper.
Have you found and completely removed all
scraps of paper?
6. Close all guards
7. Do not put the machine into operation until you
have removed all sheets and sheet scraps.
4.3 Sheet loss in the perfector
If the feeder shuts off during a production
run and this symbol appears in the Mal-
function/Printing unit menu, at least
one sheet has not been gripped during
the sheet reversing process.
Caution - Risk of damage to the
press!
Before you start up the press again, you
must remove all non-gripped sheets.
What happens in the case of one non-gripped
sheet
● The press stops with Stop.
● The feeder switches off.
● All printing units cease printing.
B.6.18 SC.999.0020/01
Printing unit
● The "Lost sheet in perfector" error message ap-
pears.
● The press stops as soon as all sheets are in the
delivery.
The press cannot go onto impression before the non-
gripped sheet has been removed from the press.
What happens in the case of several non-gripped
sheets
● The press is stopped through an Emergency
stop.
● The feeder switches off.
● All printing units cease printing.
● The "Lost sheet in perfector" error message ap-
pears.
● The press stops - emergency stop is active.
The press cannot go onto impression until all non-
gripped sheets have been removed from the press.
Removing one or several non-gripped sheets in
SX.901.0011-000GRAUND_00
the sheet reversing area
1. In the event that several sheets have not been
gripped:
There may be no sheets before or in the perfec-
tor. Transport all sheets to the area after the per-
fector in inching mode or at crawl speed.
Access to the area below the reversing drum is on O.S.
under the gallery.
2. Fold up the guard under the gallery (Fig. 11/1).
1 Slide the guard under the gallery toward the ma-
chine.
3. Pull the safety lock (Fig. 12/1) on the right-hand
side out of the support.
Fig. 11 Protection grid in front of the manhole on
O.S.
When the safety lock is open, the machine cannot be
SX.901.0010-000GRAUND_00
started up.
2 1
Fig. 12 Safeguard before manhole
SC.999.0020/01 B.6.19
Printing unit
4. Remove the non-gripped sheet from the press
FS.901.2039-000GRAUND_00
using the lost sheet pincers (Fig. 13/1). The lost
sheet pincers are included in the loose acces-
sories supplied.
5. Mount the safety device on the left-hand side
1 (Fig. 12/2) on the mounting bracket. Press the
safety device on the right-hand side (Fig. 12/1)
into the support.
6. Pull the guard (Fig. 11/1) under the gallery for-
ward again. Swing down the guard.
7. Start up the press.
Fig. 13 Lost sheet pincers
4.4 Sheet loss in sheet ascent of delivery
On straight printing/perfecting presses with a coating
SC.901.9905-001GRAUND_00
6 5 unit and extended delivery, sensors (Fig. 14/1,2) mon-
itor the sheet ascent. The sensors detect sheets not
gripped and the machine stops.
Removing the non-gripped sheet
1. Open the guard at the sheet ascent (Fig. 14/6).
3 4 2. Open the guard above the sprocket wheel shaft
(Fig. 14/3).
1 3. Check whether the sheet not gripped is located in
2 the sheet ascent of the delivery. Remove the
sheet and/or the scraps of paper if necessary.
Fig. 14 Sheet monitoring on sheet ascent
4. Close the open guards again.
5. Open the plate cylinder guard (Fig. 14/5) on the
coating unit.
6. Open the hinged guard (Fig. 14/4) on the coating
unit.
7. Check whether the sheet not gripped is located in
the coating unit. Remove the sheet and/or the
scraps of paper if necessary.
8. Carefully check the sheet and scraps of paper.
Have you found and completely removed all
scraps of paper?
9. Close the open guards again.
10. Start up the press.
B.6.20 SC.999.0020/01
Printing unit
5 Suction brush
SC.901.6501-000UTKENU_06
5.1 Utilization note
The suction brush is an optional piece of equipment.
Use the suction brush for printing material that pro-
duces a lot of dust, such as
● uncoated recycling paper
● uncoated paper
● paper with a very high filler content
● cardboard.
Note
The suction brush may damage the sur-
face of sensitive printing materials.
Check whether the suction brush can be
employed with the currently used print-
ing material.
If you need to remove the suction brush
because you are processing sensitive
printing materials, you must install the
collecting trough below the blanket
washup device in its stead. The collect-
ing trough is part of the loose acces-
sories.
5.2 Design and function
The suction brush consists of the following compo-
SG.901.6994-002GRAUND_00
1 nents:
● Suction brush (Fig. 15/2)
The rotating brush roller in the suction brush
loosens up the dust on the surface of the printing
material.
The suction brush is connected to the control
system via a plug-in connection (Fig. 15/3).
2 The exhaust air hose (Fig. 15/1) connects the
suction brush to the vacuum pump.
● Vacuum pump with dust filter and connections
(Fig. 15/4)
The vacuum pump sucks in the dust and collects
it in the dust filters.
3
4
Fig. 15 Delivered parts
SC.999.0020/01 B.6.21
Printing unit
Place of installation
SG.901.6995-002GRAUND_00
The suction brush (Fig. 16/1) is installed in the first
printing unit, between blanket washup device and feed
1 drum.
1. Swing up the guard (Fig. 16/1).
2. Swing down the swing frame (Fig. 16/2).
4 3 The suction brush (Fig. 16/3) is located beneath the
blanket washup device (Fig. 16/4).
2
Positions
The suction brush can be locked in the following po-
sitions:
● Working position
Fig. 16 Suction brush in the first printing unit The suction brush is switched on
or
● Neutral position
The suction brush is switched off.
Principle
SC.901.6002-002GRAUND_00
1 Suction brush
3 2 Brush roller in the suction brush
4
2 3 Blanket washup device
4 Blanket cylinder
1 5 Impression cylinder
6 Feed drum
5 6
Fig. 17 Side view of the suction brush installation
position
5.3 Removing the suction brush
The following preparations are required before you
can remove the suction brush from the printing unit.
B.6.22 SC.999.0020/01
Printing unit
1. If necessary, open the door (Fig. 18/1) under the
SC.901.6302-004GRAENU_00
PU 1 feed table.
3 2. Fold the feed table (Fig. 18/2) upward. This will
make the area more accessible.
3. Swing up the guard (Fig. 18/3).
4. Swing down the swing frame (Fig. 18/4) in front of
the blanket washup device (Fig. 18/5).
5. Release the rapid-action coupling of the air sup-
2 ply line.
4 6. Unlock the BWD.
7. Pull the blanket washup device on the adapter
5 guide rails out of the printing unit.
1
8. Remove the BWD from the adapter guide rails.
Fig. 18 Suction brush in the first printing unit Place the BWD in a clean, protected location.
Note
The assistance of a second person is
needed when removing the blanket
washup device.
9. The top of the suction brush is shaped like a
SG.901.6999-010GRAUND_00
trough. The trough collects washing fluid that
may drip down. Remove the washing fluid with an
2 absorbent cloth. Note the instructions in the
maintenance manual.
1 10. Inch the press until the gap of the impression
cylinder is in the suction brush area.
11. Release the plug-in connection (Fig. 19/1).
12. Pull the exhaust air hose (Fig. 19/2) out of the
side frame. To do so, bend the exhaust air hose
slightly toward you using one hand. Guide the
connection piece out of the side frame opening
with the other hand.
Fig. 19 Removing the suction brush
13. Unlock the suction brush. Release the spring bolt
SG.901.6995-010GRAUND_00
(Fig. 20/1) on the drive side and operator's side in
the direction of the arrow. Pull the suction brush
partially out of the printing unit.
Note
Ensure that you do not twist the suction
brush.
1 14. Remove the suction brush from the press.
Installing the collecting trough below the blanket
washup device
Fig. 20
SC.999.0020/01 B.6.23
Printing unit
1. Place the collecting trough (Fig. 21/2) onto the
SG.901.6997-000GRAUND_00
bearing surface (Fig. 21/3).
2. There are spring bolts (Fig. 21/1,4) on both sides
of the collecting trough.
3. Push the collecting trough (Fig. 21/2) into the
printing unit.
1 2 3 4 5 4. As you push in the trough, pull first the spring bolt
(Fig. 21/1) on O.S. and then the spring bolt
(Fig. 21/4) on D.S. The spring bolts (Fig. 21/1,4)
slide along the guide in the bearing surface
(Fig. 21/3).
5. Push in the collecting trough (Fig. 21/2) until it
reaches the stop (Fig. 21/5). The two spring bolts
(Fig. 21/1,4) snap into bores in the guide of the
Fig. 21 Collecting trough PU 1 bearing surface (Fig. 21/3).
Note
Make sure the spring bolts (Fig. 21/1,4)
are locked in place correctly.
Removing the collecting trough below the blanket
washup device
If you want to install the suction brush, you must first
remove the collecting trough.
1. If necessary, open the door (Fig. 18/1) under the
feed table.
2. Fold the feed table (Fig. 18/2) upward. This will
make the area more accessible.
3. Swing up the guard (Fig. 18/3).
4. Swing down the swing frame (Fig. 18/4) in front of
the blanket washup device (Fig. 18/5).
5. Release the rapid-action coupling of the air sup-
ply line.
6. Unlock the BWD.
7. Pull the blanket washup device on the adapter
guide rails out of the printing unit.
8. Remove the BWD from the adapter guide rails.
Place the BWD in a clean, protected location.
Note
The assistance of a second person is
needed when removing the blanket
washup device.
9. The collecting trough collects washing fluid that
may drip down. Remove the washing fluid with an
absorbent cloth. Note the instructions in the
maintenance manual.
10. Pull the spring bolts (Fig. 21/1,4) out of the guide
of the bearing surface (Fig. 21/3).
11. Lift the collecting trough (Fig. 21/2) out of the
printing unit.
B.6.24 SC.999.0020/01
Printing unit
5.4 Fitting the suction brush
1. Remove the blanket washup device, as de-
SG.901.6999-100GRAUND_00
scribed in 1.3.
2. Place the brush roller with the bearing pin
(Fig. 22/1) on D.S. and O.S. onto the guide
(Fig. 23/1).
3. Carefully push the suction brush into the printing
unit in the direction of sheet travel. Ensure that
the brush roller does not become twisted.
1 4. Pull the spring bolt on D.S. and O.S. inward.
Carefully push the brush roller further in the di-
rection of sheet travel.
2
5. Lock the brush roller in the home position.
6. Insert the air intake into the side frame opening
Fig. 22 Brush roller (Fig. 23/2).
SG.901.6999-002GRAUND_00 7. Connect the electrical plug-in connection.
8. If necessary, set the brush roller to the work po-
sition.
9. Fit the blanket washup device again. Fold the
feed table back into place. Close the door below
3 the feed table.
1
2
Fig. 23 Support for brush roller
5.5 Adjusting the suction brush with respect to the impression cylinder
Basic adjustment for printing material thickness of
SG.901.6189-001GRAUND_00
0.1 mm
1. To check the distance, push a strip of paper,
0,2 mm thick (Fig. 24/2) and at least 50 mm wide,
between the brush roller (Fig. 24/3) and the im-
pression cylinder (Fig. 24/1).
2. Turn the hollow screw (Fig. 25/1) on D.S. and on
2 O.S. to change the distance between the suction
brush and the impression cylinder.
Adjust the distance between the brush roller and
the impression cylinder over the entire width such
that the paper strip offers a slight resistance
when it is pulled out.
1 Note
One notch of the hollow screw corre-
3 sponds to an infeed of 0.1 mm.
Fig. 24 Basic setting
SC.999.0020/01 B.6.25
Printing unit
Adjusting the suction brush to the printing mate-
SG.901.6325-002GRAUND_00
rial
Caution - The brush roller can be-
come soiled if it comes into contact
with the impression cylinder.
When adjusting the suction brush en-
sure that the brush roller does not get in
contact with the cylinder surface.
1 1. The printing pressure depends on the printing
material.
Use the hollow screw (Fig. 25/1) to adjust the
suction brush to the printing material of the cur-
rent print job.
Fig. 25 Hollow screw
5.6 Adjusting operating position or home position
You can set the suction brush to two different posi-
SC.901.6000-003GRAUND_00
tions:
● Working position (Fig. 26/1)
The suction brush is close to the impression
cylinder. The brush roller rubs the printing mate-
1 2
rial.
● Rest position (Fig. 26/2)
The suction brush is switched off. The brush
roller does not touch the printing material.
Adjusting the working position
1. Pull out the spring bolts on the suction brush on
D.S. and on O.S.
Fig. 26 Adjusting operating position or home posi- 2. Push the suction brush fully home in the running
tion direction of the paper.
3. The spring bolts on the suction brush must en-
gage in the bores (Fig. 26/1) on D.S. and O.S.
Check the proper seat of the suction brush.
Adjusting the home position
1. Pull out the spring bolts on the suction brush on
D.S. and on O.S.
2. Pull the suction brush against the running direc-
tion of the paper until the spring bolts are at the
level of the bore (Fig. 26/2).
3. The spring bolts on the suction brush must en-
gage in the bores (Fig. 26/2) on D.S. and O.S.
Check the proper seat of the suction brush.
Note
With very stiff printing materials, the
brush roller can cause marks on the
sheet, even if the suction brush is in the
home position. Remove the suction
brush in this case.
B.6.26 SC.999.0020/01
Printing unit
5.7 Cleaning the dust filters in the vacuum pump
Note
SG.901.6475-001GRAUND_01
Clean the dust filters in the vacuum
3 pump at least once a day.
1. Open the four locks on the vacuum pump
(Fig. 27/1).
2. Remove the cover (Fig. 27/3).
3. Remove the dust filters (Fig. 27/2).
1 4. Empty the dust filters and shake them clean.
5. Re-install the dust filters.
6. Place the cover onto the vacuum pump.
1
7. Close the four locks (Fig. 27/1).
2
1
Fig. 27 Cleaning the dust filters
SC.999.0020/01 B.6.27
Printing unit
6 Plate cylinder
SC.B01.0706-000UTKENU_00
6.1 Gluing on the polyester underlay foil
Only for machines with Heidelberg instant register
SG.901.1300-001GRAUND_00
system
1. Wash the inking unit.
1 2. Pull off the old foil.
3. Clean and degrease the cylinder surfaces well.
4. Position the yellow inking form roller 13
(Fig. 28/1) closer to the plate cylinder with three
full rotations each of the adjusting screws
(Fig. 28/2) on D.S. and O.S..
5. Inch the machine forward up to the end of the
2 plate.
6. Engage the inking form rollers.
7. Pull off the protective film of the polyester foil ap-
prox. 15 cm.
Fig. 28 Inking form roller and adjusting screw 8. Lay on the underlay foil 1 mm before the milling
edge of the cylinder gap parallel to the edge,
centre it laterally, press it on and smooth it flat.
9. Inch the machine backward and pull off the pro-
tective film further. Smooth the underlay foil flat
from the centre outward
10. Inch the machine through again. Check the foil
for bubble-free seating.
11. Throw off the inking form rollers and adjust the
yellow inking form roller again in the normal po-
sition.
12. Clamp in the plate to prevent the freshly glued on
foil from separating.
Note
Check the foil weekly as soon as the
edges no longer adhere firmly to the
cylinder surface. Only glue on the foil
once.
B.6.28 SC.999.0020/01
Printing unit
7 Hickey catcher
SC.B01.0712-000UTKENU_00
7.1 Removing hickeys
Note
SG.901.0608-001GRAUND_00
The formation of hickeys is strongly re-
duced when the Vario effect is activated
in a press that is equipped with a Vario
2 1 dampening system.
Removing hickeys
1. Insert the hickey remover (Fig. 29/1) at the cor-
responding position of the scale (Fig. 29/3) into
the guide slot until it is in contact with the plate.
3 Setting the hickey remover
Caution - Risk of damaging the hickey
remover and the plate cylinder!
Fig. 29 Hickey remover
Adjust the hickey remover at standstill
only.
2. Open the screw (Fig. 29/2).
3. Insert the hickey remover (Fig. 29/1) into the
guide slot until it is in contact with the plate.
4. Tighten the screw.
SC.999.0020/01 B.6.29
Printing unit
8 Hand-held scanner with base station (Press Center 3/XL3 code reader with
SF.901.9573-000UTKENU_00
Ethernet connection, option)
8.1 General
The hand-held scanner (PowerScan 9501, scanner,
code reader Ethernet) can be procured directly from
the manufacturer or from retail.
Always follow the manufacturer's operating instruc-
tions when using the hand-held scanner.
Please contact Heidelberg Service for details on con-
nection and configuration of the hand-held scanner:
● The connection procedure requires some wiring
work.
● Configuration is required.
● The "Press Center 3/XL3 Code Reader" license
is required to operate the hand-held scanner.
The hand-held scanner functions are only available
SF.901.1908-000GRAUND_00
when the machine is switched on.
The display is available in English or German lan-
guage versions.
Fig. 30 Hand-held scanner
The base station makes a data connects between the
SF.901.1909-000GRAUND_00
hand-held scanner and the machine.
The hand-held scanner is also charged in the base
station.
Fig. 31 Base station
8.2 Function/Task
You can use the hand-held scanner to read a code on
a printing plate, a job folder or on a plate cart.
B.6.30 SC.999.0020/01
Printing unit
To improve production reliability, then hand-held scan-
ner can be used to check if, e.g. the printing plate in a
unit's loading compartment belongs to the job that is to
be set-up next. The related unit and the color code for
the printing plate are also shown.
The comparison of the printing plate with the job queue
is always conducted when scanning a code. The result
of the comparison is shown on the hand-held scan-
ner's display.
8.3 Configuration on the machine
Configuration on the machine is conducted on the user
interface on the Prinect Press Center in the
Heidelberg > Settings > Intellistart > Hand-held
scanner menu.
The description is available in the machine's "Prinect
Press Center" operating manual and in the user inter-
face context menu.
SC.999.0020/01 B.6.31
Printing unit
8.4 Operation
8.4.1 General
● If the machine is switched on, the AUX LED on
SF.901.1907-000GRAUND_00
the base station lights up yellow.
● If the machine is switched off, the AUX LED
blinks in yellow.
● Once the hand-held scanner is switched on and
connected to the base station, 3 acoustic signals.
Fig. 32 LEDs on base station
B.6.32 SC.999.0020/01
Printing unit
8.4.2 Buttons on hand-held scanner
1 Activation
SF.901.1912-000GRAUND_00
4 Printing and holding the activation button acti-
3 vates the hand-held scanner's target laser. Once
the hand-held scanner has read in a code (green
dot shown), the target laser is deactivated again.
2 If you release the activation button without read-
ing in a code, the target laser is automatically de-
activated.
The hand-held scanner issues feedback in
acoustic and visual form.
2 F2
Switching background lighting on and off
1
3 F1
Without function
4 Up and Down
Without function
Fig. 33
8.4.3 Activation of hand-held scanner in standby mode
1. Press the activation button on the hand-held
scanner.
Wait until activation of the hand-held scanner has
completed (3 acoustic signals).
The hand-held scanner is now ready to scan a code.
8.4.4 Scanning a code
Procedure
SF.901.1913-000GRAUND_00
1. Hold the hand-held scanner at the code to be
scanned (Fig. 34)
2. Press and hold the Activation button.
The target laser is activated.
3. Move the target laser onto the code.
Once the code is successfully read-in, the target laser
is deactivated and a green laser dot is shown briefly.
An acoustic signal (optional) is also sounded.
The result is shown on the hand-held scanner's dis-
play.
Fig. 34 Example: Code on printing plate
SC.999.0020/01 B.6.33
Printing unit
8.4.5 Examples of depictions on the hand-held scanner's display after scanning a code
The display on the hand-held scanner is explained be-
low with the aid of examples.
The display is dependent on the setting on the user
interface on the Prinect Press Center, Heidelberg >
Settings > Intellistart > Hand-held scanner menu.
Example 1:
Setting in user interface on Prinect Press Center,
Heidelberg > Settings > Intellistart > Hand-held
scanner menu:
● Configuration for one-time scanning of a code:
Comparison of code with job queue
● Configuration for two-time scanning of a code:
Off
Scan the code on a printing plate.
The hand-held scanner displays the test result
SF.901.1914-000GRAUND_00
(Fig. 35):
The printing plate was identified for the next job
change.
Line 1 (top line): Blank
Line 2: Display of job queue position - Printing plate
belongs to job at position 1.
Line 3: Printing plate belongs to loading compartment
of unit 1, with color code B for black.
Line 4: Blank
Color signal: Green
Fig. 35
or
The hand-held scanner displays the test result
SF.901.1915-000GRAUND_00
(Fig. 36):
The printing plate was not identified for next job
change.
Line 1 (top line): Message "Wrong job"
Line 2: Display of job queue position - Printing plate
belongs to job at position 2.
Line 3: Printing plate belongs to loading compartment
of unit 1, with color code B for black.
Line 4: Blank
Color signal: Red
Fig. 36
or
B.6.34 SC.999.0020/01
Printing unit
The hand-held scanner displays the test result
SF.901.1923-000GRAUND_00
(Fig. 37):
A job with this printing plate was not found in the job
queue.
Line 1 (top line): Blank
Line 2 and 3: Message "Job not found"
Line 4: Blank
Color signal: Red
Fig. 37
Example 2
This function requires Prinect version P2020.10 or
higher.
Setting in user interface on Prinect Press Center,
Heidelberg > Settings > Intellistart > Hand-held
scanner menu:
● Configuration for one-time scanning of a code:
Comparison of code with job queue and fil-
tering of job memory
● Configuration for two-time scanning of a code:
Off
Scan the code on a printing plate.
The hand-held scanner displays the test result
SF.901.1916-000GRAUND_00
(Fig. 38):
The related job for the scanned printing plate is already
in the job queue. A matching job is in the job memory.
Line 1 (top line): Blank
Line_2: Display of job queue position - Printing plate
belongs to job at position 1.
Line 3: Printing plate belongs to loading compartment
Fig. 38 of unit 1, with color code B for black.
Line 4: Number of jobs that were filtered in the job
memory (1 job) / number of jobs that are already in the
job queue (1 job).
or
The hand-held scanner displays the test result
SF.901.1924-000GRAUND_00
(Fig. 39):
The related job for the scanned printing plate is not in
the job queue. A matching job is in the job memory.
Line 1 (top line): Message "Not in queue"
Line 2: Number of jobs that were filtered in the job
memory (1 job).
Line 3: Number of jobs already in the job queue
Fig. 39 (0 jobs).
SC.999.0020/01 B.6.35
Printing unit
Line 4: Blank
Example 3:
This function requires Prinect version P2020.10 or
higher.
Setting in user interface on Prinect Press Center,
Heidelberg > Settings > Intellistart > Hand-held
scanner menu:
● Configuration for one-time scanning of a code:
Comparison of code with job queue
● Configuration for two-time scanning of a code:
Release of jobs in job queue
Scan the code on a printing plate.
The matching job for the scanned printing plate is not
in the job queue.
SF.901.1917-000GRAUND_00
First scan of code
The hand-held scanner displays the result after the
first scan (Fig. 40):
Line 1 (top line): Message "Not in queue"
Line 2: Number of jobs that were found in the job
memory (1 job). No filtering in the job memory of the
user interface (Press Center).
Line 3: Number of jobs already in the job queue
Fig. 40 (0 jobs).
Line 4: Blank
Second scan of code
SF.901.1925-000GRAUND_00
The hand-held scanner displays the result after the
second scan of the same code (Fig. 41):
Line 1 (top line): Blank
Line 2: Number of jobs that were found in the job
memory (1 job).
Line 3: Number of jobs that are released/added suc-
cessively in the job queue (1 job).
Fig. 41
Line 4: Blank
Exception: If the matching job for the scanned printing
plate is in the job queue, a release is not made.
Example 4:
This function requires Prinect version P2020.10 or
higher.
Setting in user interface on Prinect Press Center,
Heidelberg > Settings > Intellistart > Hand-held
scanner menu:
● Configuration for one-time scanning of a code:
Comparison of code with job queue and fil-
tering of all jobs for a plate cart in job memory
● Configuration for two-time scanning of a code:
Release of all jobs for a plate cart in job queue
Scan the code on a printing plate.
B.6.36 SC.999.0020/01
Printing unit
First scan of code
SF.901.1926-000GRAUND_00
The hand-held scanner displays the result after the
first scan (Fig. 42):
Line 1 (top line): Message "Not in queue"
Line 2: Number of jobs that were filtered in the job
memory (3 jobs).
Line 3: Number of jobs already in the job queue (1 job).
Fig. 42 Line 4: Blank
Second scan of code
SF.901.1927-000GRAUND_00
The hand-held scanner displays the result after the
second scan of the same code (Fig. 43):
Line 1 (top line): Blank
Line 2: Number of jobs that were filtered in the job
memory (3 jobs).
Line 3: Number of jobs that are released/added suc-
cessively in the job queue (2 jobs).
Fig. 43
Line 4: Blank
Example 5:
This function requires Prinect version P2020.10 or
higher.
Setting in user interface on Prinect Press Center,
Heidelberg > Settings > Intellistart > Code Reader
Ethernet menu:
● Configuration for one-time scanning of a code:
Comparison of code with job queue and fil-
tering of job memory
● Configuration for two-time scanning of a code:
Release of jobs in job queue
Scan the code on a plate cart or on a job ticket.
First scan of code
SF.901.1928-000GRAUND_00
The hand-held scanner displays the result after the
first scan (Fig. 44):
Line 1 (top line): Blank
Line 2: Number of jobs that were filtered in the job
memory (6 jobs).
Line_3: Number of jobs already in the job queue
(2 jobs).
Fig. 44
Line 4: Blank
Second scan of code
SF.901.1929-000GRAUND_00
The hand-held scanner displays the result after the
second scan of the same code (Fig. 45):
Line 1 (top line): Blank
Line 2: Number of jobs that were filtered in the job
memory (6 jobs).
Line 3: Number of jobs that are released/added suc-
cessively in the job queue (4 jobs).
Fig. 45
Line 4: Blank
SC.999.0020/01 B.6.37
Printing unit
8.4.6 Messages on display of hand-held scanner when scanning printing plates (comparison of
printing plate code with job queue)
Task:
X = Unit
Y = Color code
German version English version Signal color Job for printing plate
Job Queue 1 Job Queue 1 Green Job is in job queue position 1.
Werk X - Y Unit X - Y or
Job is in job queue position 1 and also at 2…
Auftrag falsch Wrong Job Red Job is in job queue position 3.
Job Queue 3 Job Queue 3 or
Werk X - Y Unit X - Y Job is in job queue position 3 and also at 4…
Auftrag nicht Job not found Red Job not in job queue.
gefunden
Job Queue 2 Job Queue 2 Green Job is in job queue position 2 and position 1 is set-
Werk X - Y Unit X - Y up
Auftrag falsch Wrong Job Red Job is in job queue position 2 and position 1 is not
Job Queue 2 Job Queue 2 set-up.
Werk X - Y Unit X - Y
Auftrag falsch Wrong Job Red Job already set-up.
Maschine Machine => Printing plate must be mounted already.
Werk X - Y Unit X - Y
Maschine Machine Green Job is already loaded but not set-up.
Werk X - Y Unit X - Y => Printing plate not yet mounted.
Tab. 3
Summary of hand-held scanner feedback:
● Green LED lights up, long (approx. 3 seconds)
and short acoustic signal: Code check was suc-
cessful.
● Red LED lights up, long (approx. 3 seconds) and
short acoustic signal: Code check error.
8.5 Faults
8.5.1 Error message on hand-held scanner's display when scanning a code
German version English version Signal color Cause of malfunction Troubleshooting
FEHLER: ERROR: Red Code not known Scan a valid code (print-
EINGELESENER INVALID CODE ing plate code, job folder
CODE IST code, plate cart code).
UNGÜLTIG
Warten... Wait... - First scan of a code after Scan the code again.
switching on hand-held
scanner.
B.6.38 SC.999.0020/01
Printing unit
German version English version Signal color Cause of malfunction Troubleshooting
Fehler Error Red Workplace Interface er- Check the network con-
Abfrage nicht Request not possible ror nection in the in-house
moeglich network.
Check the functional ca-
pability of the Workplace
Interface.
No active "Workplace In- Set-up the data memory
terface" data memory. on the Prinect Press
Center at Settings > Set-
up network.
Tab. 4
8.5.2 Malfunctions on hand-held scanner and base station
Malfunction Cause Troubleshooting
Permanently blinking green LED Scanner not connected to base sta- Is the yellow AUX LED on the base
tion station on?
● If not, check the connections on
the base station (power supply
and Ethernet connection).
● If it is, connect the hand-held
scanner to the base station again
(see section "Re-connecting
hand-held scanner and base sta-
tion").
Short low acoustic signal and green Weak signal to base station Reduce the distance between the
LED blinks briefly hand-held scanner and the base sta-
tion.
As result of a scan: No active connection from the scan- Check whether the press is switched
Chirping signal and 4 "high-low-high- ner to the application on and started-up:
low" acoustic signals (and "brief" ● If yes, check if the licensing (Press
green LED) Center 3/XL3 Code Reader) pro-
cess was conducted:
○ If yes, notify Heidelberg Ser-
vice.
AUX LED on base station blinking fast No connection between base station Start up the press once more.
in yellow and machine
Tab. 5
8.5.3 Error messages on the Prinect Press Center
Error message Cause of malfunction Remedy
Intellistart sequence - Check job At least one job to be loaded could not Check the sequence of the Intellistart
queue: The hand-held scanner was be found or it was already in the job queue and acknowledge the error
unable to add at least one job to the job queue or on the machine. message.
Intellistart job queue.
SC.999.0020/01 B.6.39
Printing unit
Error message Cause of malfunction Remedy
The sequence in Intellistart job queue
may therefore not match the planned
sequence.
Hand-held scanner not connected. The base station of the hand-held Please notify Heidelberg Service.
Notify Service. scanner is not connected with the
control system.
Tab. 6
8.6 Re-connecting hand-held scanner and base station
Following replacement of a device, the hand-held
scanner and the base station have to be connected to
each other again.
1. Switch on the hand-held scanner by pressing the
Activation button.
2. Press and hold the button on the base station
SF.901.1918-000GRAUND_00
(Fig. 46/1) for at least 5 seconds.
Fig. 46
3. Use the hand-held scanner to read-in the code
SF.901.1919-000GRAUND_00
(Fig. 47).
4. Wait for approx. 10 seconds and then place the
hand-held scanner onto the base station.
The connection is then made automatically.
The connection process takes approx. 20 seconds.
Fig. 47
8.7 Replacing the base station
If the base station is defective, it may have to be re-
placed. The existing hand-held scanner can still be
used.
B.6.40 SC.999.0020/01
Printing unit
Procedure
1. Replace the base station. Connect the new base
station (power supply and connection through
Ethernet cable) to the Prinect Press Center.
2. Switch on the hand-held scanner.
3. Use the hand-held scanner to read-in the code
SF.901.1919-000GRAUND_00
(Fig. 48).
4. Wait for approx. 10 seconds and then place the
hand-held scanner onto the base station.
The connection is then made automatically.
The connection process takes approx. 20 seconds.
Fig. 48
5. Use the hand-held scanner to read-in the config-
SF.901.1906-000GRAUND_00
uration code (Fig. 49).
After approx. 3 seconds the scanner is connected
again to the base station (3 acoustic signals).
Note
When scanning the configuration code
for the first time, the settings are not all
transferred. This is why the configuration
code has to be read-in again.
6. After a waiting period of approx. 15 seconds, use
the hand-held scanner to read-in the configura-
tion code (Fig. 49) again.
After approx. 3 seconds the scanner is connected
again to the base station (3 acoustic signals).
Fig. 49 Configuration code
SC.999.0020/01 B.6.41
Printing unit
9 Requirements for the printing plate
SC.B01.0705-000UTKENU_00
9.1 Required size for edge-bent printing plates
SG.901.6978-000GRAUND_00
B.S. A.S.
11 mm
4 mm
4 mm
11 mm
O.S. D.S.
C.S. C.E.
L.S. L.I.
L.M. L.V.
12"0,1 mm 10,00)0,036 mm
780"0,1 mm
772,66)0,2 mm
1030"1 mm
772,66)0,2 mm
0,3 mm
7"1 mm
Fig. 50 Specification sheet - edge-bent printing plates
B.6.42 SC.999.0020/01
Printing unit
9.2 Technical printing plate requirements
Plate (Fig. 51/1)
FS.901.6353-000GRAUND_00
Max. convexity limit h max. (Fig. 51/2)
Note
The plates have to fulfill the following re-
1
quirements to ensure that the plate
2 2 change sequence runs smoothly. Plates
which do not fulfill the following require-
ments must be mounted and removed
manually.
Flatness/convexity limit
The clamping action only works correctly if the plate
Fig. 51 Convexity limit lies flat and has not warped. Fig. 51 shows the maxi-
mum permissible convexity limit. For this reason you
should only use new plates if you wish to mount plates
automatically. You can use the plate for a repeat job,
but in that case you need to mount it manually.
Convexity limit
Only use plates which do not exceed a maximum con-
vexity limit of hmax. 35 mm (Fig. 51/2).
Material
With the plate changer it is only permitted to use alu-
minum plates with a thickness of 0.24 mm to 0.30 mm
which comply with the specified dimensions.
Plates made from other materials (bimetal plates,
trimetal plates, polyester-based printing plates) and
aluminum plates which do not comply with the speci-
fied dimensions must be mounted and removed man-
ually. The same applies to the use of archived plates.
SC.999.0020/01 B.6.43
Printing unit
SG.901.0085-000GRAUND_00
B.S. 2 A.S.
O.S. D.S.
C.S. C.E.
L.S. L.I.
L.M. L.V.
1
6
4
Fig. 52 Damage to the printing plate
Perfect condition
FS.901.5617-001GRAUND_00
The plate must be punched and the edges folded cor-
rectly. Make sure that the plate is not damaged and
placed down on a flat surface. Plates exhibiting any of
the illustrated damage below are not suitable for au-
tomatic plate changes.
● Plate edge deformed at end of print run
(Fig. 52/1).
● Rear edge of plate deformed (Fig. 52/2).
● Register punching on D.S. deformed (Fig. 52/3).
● Lead edge of plate deformed (Fig. 52/4).
Fig. 53 Register punching ● Film punching deformed (Fig. 52/5).
● Plate edge deformed at lead edge of print
(Fig. 52/6).
● Register punching on O.S. deformed (Fig. 52/7).
● Register punching deformed in base of slot
(Fig. 53/arrow).
● Rear edge of plate bent upward, e.g. through
carrying or plate is curved.
B.6.44 SC.999.0020/01
Printing unit
● Plate is not flat, but curved or wavy (e.g. if the
plate was baked).
● Gumming residue on the edges of the punchings
and rear of the plate. This can cause malfunc-
tions during plate detection.
SC.999.0020/01 B.6.45
Printing unit
10 AutoPlate
SG.901.0601-000UTKENU_12
10.1 Preparatory work for changing plates
The rear plate clamp consists of three sections
C4.901.0304-002GRAENU_00
(Fig. 54).
1 1 1
Prerequisites for changing a plate with AutoPlate:
2 2 2 ● Open the gap of the rear plate clamp. To do this,
turn the six locking screws (Fig. 54/1) and the six
adjusting screws (Fig. 54/2) anti-clockwise up to
the stop. Tighten them lightly only ("zero posi-
tion").
● On the left and right section of the plate clamp,
D.S. 3 O.S. turn the hexagon-head screws such that the
marking (borehole) points upwards (Fig. 54/3).
Fig. 54 Sections of the rear plate clamp ● The front edge of the plate must not be bent.
● After coarse adjustment of the circumferential
register, the machine must turn at least one rev-
olution at crawl speed.
● The circumferential register must be at zero.
10.2 Function of the printing unit guard on the delivery side
The printing unit guard on the delivery side (Fig. 55/3)
SG.901.0679-001GRAUND_00
also serves as a device for feeding the printing plate.
For this, you must fold the hinged frame of the printing
unit guard (Fig. 55/1) upward.
Folding up the hinged frame
1 1. Grasp the hinged frame (Fig. 55/1) in the middle
of the lower edge. Fold up the hinged frame.
To fold it up, you must first overcome the retain-
ing power of the magnets (Fig. 55/2).
2. When the hinged frame is vertical, it descends by
approx. 20 mm into the printing unit guard.
1
2 Folding down the hinged frame
1. Grasp the hinged frame (Fig. 55/1) in the middle.
Pull the hinged frame approx. 20 mm upward out
of the printing unit guard.
2. Fold the hinged frame downward by 180° in the
direction of the delivery.
3
Fig. 55 Printing unit guard closed
B.6.46 SC.999.0020/01
Printing unit
10.3 Removing the plate
1. Control panel selection: Press the Control panel
C4.901.0406-002GRAUND_00
1 selection button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
Note
1 The printing unit must remain selected
during the entire plate changing proce-
dure.
3
2
2. Press the Positioning button.
The plate cylinder turns to the removal position.
3. Move the printing unit guard (Fig. 56/3) on the
delivery side upward.
The hinged frame (Fig. 56/1) can be folded down
or up.
4. Press the Remove/mount plate button.
The rear clamping bar opens. The plate jumps
out.
5. Press the Positioning button.
The plate cylinder turns until it reaches the lead
Fig. 56 Printing unit guard opened
edge of the plate. In the process, hold the plate
(Fig. 56/1) and guide it out of the press. The front
clamping bar opens.
Note
The next printing plate should be mount-
ed immediately after the previous one
has been removed, since the front plate
clamp is in an ideal position at this mo-
ment.
If no new plate is to be mounted:
6. Close the printing unit guard.
7. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
SC.999.0020/01 B.6.47
Printing unit
10.4 Plate change
The printing unit guard is closed. The hinged frame is
SG.901.6986-002GRAUND_00
folded upward.
1
Mounting a plate - straight after plate removal
1. Insert the plate (Fig. 57/1) into the plate shaft
2 (Fig. 57/2) of the hinged frame/printing unit
guard. The lead edge of the plate is in contact
with the bottom stops (Fig. 57/3). The folded
edge of the plate points towards the feeder.
2. Open the printing unit guard and remove the last
plate used as described.
Note
Make sure that in infeed position, the
hinged frame is always folded upward.
Fig. 57 Printing unit guard closed
3. Set the printing unit guard to the snap-in infeed
SG.901.6910-001GRAUND_00
position (Fig. 58).
1
4. Slightly raise the center of the lead edge of the
plate, and release the locking device (Fig. 58/2).
You can hear a light click.
Insert the plate into the clamping gap of the plate
cylinder clamping bar (Fig. 58/4). The plate must
be positioned correctly at the register pins of the
plate clamp.
5. Press the Remove/mount plate button.
The front plate clamp closes.
6. Press the Positioning button.
The plate cylinder turns toward the rear clamping
2 bar. The rear edge of the plate is clamped auto-
matically.
7. Close the printing unit guard.
8. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
3
Fig. 58 Printing unit guard in infeed position
B.6.48 SC.999.0020/01
Printing unit
10.5 Mounting the plate
Mounting a plate - not straight after plate removal
SG.901.6910-001GRAUND_00
1. Fold up the hinged frame as in Fig. 55.
1
2. Insert the plate (Fig. 57/1) into the plate shaft
(Fig. 57/2) of the hinged frame/printing unit
guard. The lead edge of the plate is in contact
with the bottom stops (Fig. 57/3). The folded
edge of the plate points towards the feeder.
3. Control panel selection: Press the Control panel
selection button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
4. Set the printing unit guard to the snap-in infeed
position (Fig. 59).
5. Press the Positioning button.
2 The cylinder turns until it reaches the front edge
of the plate.
6. Press the Remove/mount plate button.
The front plate clamp opens.
7. Slightly raise the center of the plate, and release
the locking device (Fig. 59/2). You can hear a
3
light click.
Insert the plate into the clamping gap of the plate
Fig. 59 Printing unit guard in infeed position cylinder clamping bar (Fig. 59/3). The plate must
be positioned correctly at the register pins of the
plate clamp.
8. Let go of the plate.
9. Press the Remove/mount plate button.
The front plate clamp closes.
10. Press the Positioning button.
The plate cylinder turns toward the rear clamping
bar. The rear edge of the plate is clamped auto-
matically.
11. Close the printing unit guard.
12. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
SC.999.0020/01 B.6.49
Printing unit
11 Positioning correction at the tail edge of print
SG.901.0666-000UTKENU_00
11.1 Overview and basic adjustment
1. Open the gap of the rear plate clamp. Turn the six
SG.901.6980-001GRAUND_00
1 1 1 locking screws (Fig. 60/1) and the six adjusting
screws (Fig. 60/2) counter-clockwise up to the
2 2 2 stop. Tighten them lightly ("zero position").
2. On the left and right section of the plate clamp,
turn the hexagon-head screw so that the mark
(borehole) points upwards (Fig. 60/3).
3 3. After coarse adjustment of the circumferential
register, the printing press must turn at least one
revolution at crawl speed.
Fig. 60 Tail edge plate clamp
AutoPlate / AutoPlate Pro usually clamps the printing
plate in an optimum way. The printing plate can, how-
ever, sometimes show slight register inaccuracies
which have to be compensated. Positioning correc-
tions can be made at the tail edge of print.
Note
For a smooth plate change, the tail edge
plate clamp must be in its normal posi-
tion. If the plate clamp was readjusted for
positioning corrections, you may set an
electronic flag; see section "AutoPlate
Pro". When the indicator is activated, a
signal lamp indicates that the plate
clamp has been readjusted. Automatic
plate change is not possible under these
circumstances.
11.2 Positioning correction at the tail edge
Possible adjustment
SG.901.0671-002GRAENU_00
1 Each section of the plate clamp has:
● Two locking screws for clamping the printing
2 plate (Fig. 61/1).
● Two adjusting screws for pulling the printing plate
in the circumferential direction (Fig. 61/2).
D.S. O.S.
Fig. 61 Clamping and pulling the printing plate
B.6.50 SC.999.0020/01
Printing unit
In addition, the left-hand and the right-hand section of
SG.901.0670-002GRAENU_00
the plate clamp each contain a hexagon-head eccen-
1 tric screw (Fig. 62/1) with a mark (countersink). These
screws are used for stretching the printing plate to-
wards D.S. and/or O.S.
Some examples of the possible adjustments are pro-
vided below.
D.S. O.S.
Fig. 62 Stretching the printing plate
Stretching the plate towards O.S.
SG.901.0674-002GRAENU_00
1 2 2 1 1. Turn the two outer locking screws (Fig. 63/1)
clockwise from the "zero position" up to the stop,
and tighten them.
3 3 3
D.S. O.S.
Fig. 63 Adjusting screws and locking screws
2. Turn the hexagon-head eccentric screw
SG.901.0672-002GRAENU_00
(Fig. 64/1) clockwise as far as necessary, but no
1
more than 90°. This pulls the printing plate to-
wards O.S.
3. The remaining four locking screws and the six
adjusting screws may not be adjusted. They must
remain in the "zero position."
D.S. O.S.
Fig. 64 Pulling the printing plate towards O.S.
Stretching the plate towards D.S. and O.S.
SG.901.0674-002GRAENU_00
1 2 2 1 1. Turn the two outer locking screws (Fig. 65/1)
clockwise from the "zero position" up to the stop,
and tighten them.
3 3 3
D.S. O.S.
Fig. 65 Adjusting screws and locking screws
SC.999.0020/01 B.6.51
Printing unit
2. Turn the hexagon-head eccentric screw
SG.901.0675-002GRAENU_00
1 (Fig. 66/1) clockwise as far as necessary, but no
2
more than 90°. By doing this, the printing plate is
pulled towards O.S. as shown by the arrow in
Fig. 66.
3. Turn the hexagonal-head eccentric screw
(Fig. 66/2) counterclockwise as far as necessary,
but no more than 90°. By doing this, the printing
D.S. O.S. plate is pulled towards O.S. as shown by the ar-
row in Fig. 66.
4. The remaining four locking screws and the six
adjusting screws may not be adjusted. They must
Fig. 66 Pulling the printing plate towards D.S. or remain in the "zero position."
O.S.
Pulling the printing plate in circumferential direc-
SG.901.0676-004GRAENU_00
tion on O.S.
1 1
The following example describes the adjustment of the
plate clamp section facing the operator side O.S.
2
1. Turn the two locking screws (Fig. 67/1) clockwise
from the "zero position" up to the stop, and tight-
en them.
2. As required, turn one or both adjusting screw(s)
(Fig. 67/2) clockwise out of the "zero position". By
D.S. O.S. doing this, the printing plate is pulled in the cir-
cumferential direction as shown by the arrow
(Fig. 67).
Fig. 67 Pulling the printing plate in the circumferen-
tial direction Note
Should register deviations occur in the
area of the middle section or the section
of the plate clamp facing D.S., the re-
spective clamping and adjusting screws
must be adjusted as described above.
B.6.52 SC.999.0020/01
Printing unit
12 Blanket cylinder
SG.901.1302-000UTKENU_13
12.1 Coating the cylinder with a new chrome alloy
The new chrome alloy on the blanket cylinder is the
same as the current chrome coating in terms of its
function, but is significantly more environmentally sus-
tainable.
Note
After processing several million sheets,
a brown patina can develop on the blan-
ket cylinder. This patina has no influence
on the printing quality and does not indi-
cate damage. Repairs are not necessary
either. In case of need, you can remove
the patina with a cleaner such as "Quick
Print".
12.2 Requirements on the cleaner
The blanket cylinders are coated with a blue shimmer-
ing alloy on a zinc base. The alloy provides an in-depth
corrosion protection.
To preserve the protection against corrosion for a long
time, you should observe the following instructions for
handling, cleaning and maintenance.
Note
In order to avoid a (chemical or mechan-
ical) reaction of the cylinder surface with
the paper surface, never use the press
without a blanket.
Caution - Risk of machine damage!
Never use benzine of kerosine as wash-
ing fluid. Only use cleaners that are cer-
tified for Speedmaster machines dated
1995 or later.
Approved cleaners
1. Please observe the specifications documented in
the "General" chapter of the maintenance and
cleaning customer manual.
12.3 Torque when tensioning the blankets
A torque wrench is included in the supplied tool kit.
Use this torque wrench to tension the blankets. Ten-
sion the blankets evenly in all printing units. The rec-
ommended torque is 65 Nm.
12.4 Preparing blanket
Metal-backed blanket
Your press is fitted as standard with metal-backed
blankets:
SC.999.0020/01 B.6.53
Printing unit
This blanket has a steel bar at the lead edge of print
and one at the tail edge of print. It does not need any
specific preparation for the installation.
Conventional blanket
SG.901.1302-002GRAUND_00
You can convert your press from using metal-backed
blankets to using conventional blankets. Please con-
2 tact your Heidelberg agency for further information.
The conventional blanket must be mounted in a clamp-
ing bar at the lead edge of print and in a clamping bar
at the tail edge of print.
Note
1 Only ever use the clamping bars fitted as
standard on your press.
3
1. Push the blanket up to the stop into the clamping
bar such that it is centered (Fig. 68/1).
Fig. 68 Clamping bar for conventional blanket
2. Check the position of the blanket at the inspec-
tion holes (Fig. 68/2).
3. Use the screws (Fig. 68/3) to clamp the blanket
from the inside to the outside. Tighten the screws
securely.
12.5 Gap cover
The gap cover for the blanket cylinder is constructed
SG.901.0997-000GRAUND_00
as follows:
3 1 Retainer plate
4 2 Spring bolts on D.S.
5 3 Bolts on O.S.
4 Viewing hole for retainer plate
1 5 Inspection window for center bearing
Fig. 69 Gap cover on the blanket cylinder
B.6.54 SC.999.0020/01
Printing unit
12.6 Removing the blanket
Metal-backed blanket
SG.901.0996-000GRAUND_00
1. Press the retainer plate (Fig. 71/1) on D.S. down-
ward at the gap cover.
1 2. Press the gap cover against the spring bolts on
D.S. (Fig. 70/2) and lift up the gap cover on O.S.
(Fig. 70/3).
3 3. Remove the gap cover.
4. Use a socket wrench to undo the blanket on the
clamp shaft at the tail edge of print.
2 5. Release the locking device (Fig. 71/2): Press the
leaf spring on the D.S. and O.S. towards the cen-
ter of gap and pull the blanket out of the clamp
shaft at the tail edge of print (Fig. 71/1).
6. Inch backwards up to the clamp shaft at the print
Fig. 70 Gap cover on the blanket cylinder start. Hold blanket and packing sheets stretched.
Pull out the blanket and the packing sheet from
SG.901.1313-003GRAUND_00
the press.
7. Release the locking device (Fig. 71/2): Press the
leaf spring on the D.S. and O.S. towards the cen-
1 2 ter of gap and pull the blanket out of the clamp
shaft at the print start (Fig. 71/1).
Fig. 71 Metal-backed blanket
Conventional blanket
SG.901.0996-000GRAUND_00
1. Press the retainer plate (Fig. 72/1) on D.S. down-
ward at the gap cover.
1 2. Press the gap cover against the spring bolts on
D.S. (Fig. 72/2) and lift up the gap cover on O.S.
(Fig. 72/3).
3 3. Remove the gap cover.
4. Use a socket wrench to undo the blanket on the
clamp shaft at the tail edge of print.
2 5. Insert the short ends of two mandrels (Fig. 73/1)
into the holes of the clamping bar (Fig 73/2).
Press the clamping bar with the mandrels in the
direction of the gap center. Tilt the mandrels si-
multaneously towards the center of the gap and
remove the clamping bar from the clamp shaft
Fig. 72 Gap cover
(Fig. 73/3).
6. Inch backwards up to the clamp shaft at the print
start. Hold blanket and packing sheets stretched.
SC.999.0020/01 B.6.55
Printing unit
Pull out the blanket and the packing sheet from
SG.901.1309-002GRAUND_00
1 the press.
ÑÑÑÑ
ÏÏÏ 7. Using your thumb, press the clamping bar at the
ÑÑÑÑ
ÏÏÏ lead edge of print (Fig. 74/1) in the direction of the
2
ÑÑÑÑ
ÏÏÏ
gap and, at the same time, press it upwards with
your fingers. Pull out the blanket.
3
ÑÑÑÑ
ÏÏÏ
Fig. 73 Mandrel in clamp shaft
SG.901.1303-003GRAUND_00
Fig. 74 Clamping bar on the blanket
B.6.56 SC.999.0020/01
Printing unit
12.7 Preparing packing sheets
The blanket has to be 0.00 mm ... 0.05 mm below the
SG.901.6162-001GRAUND_00
bearer. Select the packing sheets accordingly.
The maximum size of the packing sheets is
735 x 1030 mm.
Note
Use only calibrated packing sheets.
When printing a large run length in a
small format, you should use packing
sheets that are slightly smaller than the
sheet format. This prevents marks and
ink/dust deposits on the blanket.
1. Punch the packing sheets on the plate punch for
printing plates. Set the punches for the register
scope pins.
4 2 3 1
2. Secure the punched sheet as shown in Fig. 75
between fitting strip (Fig. 75/1) and support rail
(Fig. 75/2).
Note
Install the end of the rail with the spring
(Fig. 75/4) on O.S.
3. Close the safety latch (Fig. 75/3). During instal-
Fig. 75 Fitting strip and support rail for packing
lation, the rail (Fig. 75/4) points towards the blan-
sheets
ket cylinder.
12.8 Mounting the blanket
Metal-backed blanket
SG.901.1306-004GRAUND_02
Note
Clean the blanket cylinder before you
engage the blanket. If necessary, lubri-
cate the cylinder undercut with acid-free
oil.
1 1. Inch the press until the clamp shaft at the lead
edge of print is accessible.
2. Plug the support rail with the packing sheets into
the boreholes of the cylinder gap (Fig. 76/1), first
on O.S., then on D.S.
3. Check the secure seat of the support rail.
Fig. 76 Borehole in the cylinder gap
SC.999.0020/01 B.6.57
Printing unit
4. Press the front edge of the blanket into the
SG.901.1313-003GRAUND_00
groove of the clamp shaft (Fig. 77/1).
The metal backing of the blanket must lock into
1 2 place in the locking device (Fig. 77/2).
5. Inch the press forward.
6. Mount the blanket with the packing sheets on the
blanket cylinder.
Note
Ensure that the blanket does not get
caught between the bearers of blanket
cylinder and plate cylinder.
Fig. 77 Inserting the front edge of the blanket
7. Press the rear edge of the blanket into the groove
SG.901.6007-002GRAUND_00
of the clamp shaft at the tail edge of print
1 (Fig. 78/1).
The metal backing of the blanket must lock into
place in the locking device (Fig. 77/2).
8. Finally, using the torque wrench, tension the
blanket first at the front, then on the rear clamp
shaft. Tension the blankets evenly in all printing
units. The recommended torque is 65 Nm. Both
clamping bars should have the same angle with
respect to the cylinder gap.
9. Compare the lateral distances between blanket
and bearers to check the correct position of the
blanket.
Fig. 78 Inserting the rear edge of the blanket
Caution - Risk of machine damage!
The blanket must not touch the bearers.
If necessary, use a mandrel to press
down the raised edge.
Note
Note that a new blanket settles after a
few hundred prints. Therefore you need
to re-tension the blanket (torque 65 Nm).
Re-stretch the blanket after a maximum
of approximately 10000 prints. Check
the packing thickness. If necessary, cor-
rect the packing thickness.
B.6.58 SC.999.0020/01
Printing unit
10. Fit the gap cover. Press the retainer plate on D.S.
SG.901.0996-000GRAUND_00
(Fig. 79/1) downward. Guide the spring bolts
(Fig. 79/2) into the boreholes in the bearer on
1 D.S. Press the gap cover against the spring bolts.
11. Guide the gap cover with the bolts (Fig. 79/3) into
the boreholes in the bearer on O.S. The align-
ment aid on O.S. (Fig. 80/1) helps you align the
3 bolts correctly.
Fig. 79 Gap cover on the blanket cylinder
SG.901.1306-004GRAUND_01
Fig. 80 Alignment aid on O.S.
12. Check the correct installation. When the gap cov-
SG.901.6847-001GRAUND_00
er is fitted correctly, you can see the center bear-
ing (Fig. 81/3) in the central recess (Fig. 81/1).
The retainer plate must sit flush against the view-
ing hole (Fig. 81/2).
2 1
Fig. 81 Center bearing
SC.999.0020/01 B.6.59
Printing unit
Conventional blanket
SG.901.1305-003GRAUND_01
2 3 1 Note
Clean the blanket cylinder before you
engage the blanket. If necessary, lubri-
cate the cylinder undercut with acid-free
oil.
1. Turn the "print start" (Fig. 82/1) and "tail edge of
print" (Fig. 82/2) clamp shafts to the position
shown in Fig. 82.
4
The rear edges of the clamp shafts (Fig. 82/4)
must line up with the markings (Fig. 82/3).
2. Inch the press until the clamp shaft at the lead
edge of print is accessible.
Fig. 82 Positioning the clamp shafts 3. Plug the support rail with the packing sheets into
the boreholes of the cylinder gap (Fig. 83/1), first
SG.901.1306-004GRAUND_02
on O.S., then on D.S.
4. Check the secure seat of the support rail.
Fig. 83 Borehole in the cylinder gap
5. Insert the clamping bar with the groove into the
SG.901.1307-003GRAUND_00
two spring-type holders (Fig. 84/1).
Fig. 84 Retaining spring
B.6.60 SC.999.0020/01
Printing unit
6. Press the clamping bar (Fig. 85/1) against the
SG.901.1308-002GRAUND_00
spring-type holder (Fig. 85/3) in the direction of
the gap and, at the same time, downwards. The
3 clamping bar must perceptibly engage in the
1
clamp shaft (Fig. 85/2).
2
Fig. 85 Engaging the clamping bar
7. Use a mandrel (Fig. 86/1) to check the correct
1 SG.901.1309-002GRAUND_00 position of the clamping bar with respect to the
ÑÑÑÑ
ÏÏÏ clamp shaft.
ÑÑÑÑ
ÏÏÏ Inserting the long end of the mandrel must be
2
ÑÑÑÑ
ÏÏÏ
possible.
3
ÑÑÑÑ
ÏÏÏ
Fig. 86 Position of the clamping bar with respect to
the clamp shaft
8. Turn the clamp shaft at the print start until the
SG.901.1310-000GRAUND_00
ÏÏÏÏ
3 ... 4 mm
ÑÑÑ
edge of the clamping bar is approximately
ÏÏÏÏ
ÑÑÑ
ÏÏÏÏ
3 ... 4 mm inside the safety area of the two bolts
(Fig. 87).
ÑÑÑ
ÏÏÏÏ
9. Inch the press forward.
ÑÑÑ
ÏÏÏÏ
10. Mount the blanket with the packing sheets on the
blanket cylinder.
ÑÑÑ Note
Ensure that the blanket does not get
caught between the bearers of blanket
cylinder and plate cylinder.
Fig. 87 Position of the clamp shaft
SC.999.0020/01 B.6.61
Printing unit
11. Insert the short ends of the mandrels on D.S. and
SG.901.1311-002GRAUND_00
O.S. into the clamping bar at the tail edge of print.
12. Insert the clamping bar into the spring-type hold-
ers.
13. Using the mandrels, press the clamping bar in the
direction of the gap center (Fig. 88/1).
In doing so pull the mandrel ends upward
(Fig. 88/2) so that the clamping bar rests flatly on
the clamp shaft and locks into place.
1
2
Fig. 88 Engaging the clamping bar
14. Use a mandrel (Fig. 89/1) to check the correct
SG.901.1312-002GRAUND_00
ÏÏÏ position of the clamping bar with respect to the
ÑÑÑÑ
ÏÏÏ
1 clamp shaft.
ÑÑÑÑ
ÏÏÏ Inserting the long end of the mandrel must be
ÑÑÑÑ
ÏÏÏ
possible.
ÑÑÑÑ
ÏÏÏ
Fig. 89 Checking the clamping bar position
15. Finally, using the torque wrench, tension the
blanket first at the front, then on the rear clamp
shaft. Tension the blankets evenly in all printing
units. The recommended torque is 65 Nm. Both
clamping bars should have the same angle with
respect to the cylinder gap.
16. Compare the lateral distances between blanket
and bearers to check the correct position of the
blanket.
Caution - Risk of machine damage!
The blanket must not touch the bearers.
If necessary, use a mandrel to press
down the raised edge.
Note
Note that a new blanket settles after a
few hundred prints. Therefore you need
to re-tension the blanket (torque 65 Nm).
Re-stretch the blanket after a maximum
of approximately 10000 prints. Check
the packing thickness. If necessary, cor-
rect the packing thickness.
B.6.62 SC.999.0020/01
Printing unit
17. Fit the gap cover. Press the retainer plate on D.S.
SG.901.0996-000GRAUND_00
(Fig. 90/1) downward. Guide the spring bolts
(Fig. 90/2) into the boreholes in the bearer on
1 D.S. Press the gap cover against the spring bolts.
18. Guide the gap cover with the bolts (Fig. 90/3) into
the boreholes in the bearer on O.S. The align-
ment aid on O.S. (Fig. 91/1) helps you align the
3 bolts correctly.
Fig. 90 Gap cover on the blanket cylinder
SG.901.2936-000GRAUND_00
Fig. 91 Alignment aid on O.S.
19. Check the correct installation. When the gap cov-
SG.901.6847-001GRAUND_00
er is fitted correctly, you can see the center bear-
ing (Fig. 92/3) in the central recess (Fig. 92/1).
The retainer plate (Fig. 92/2) must sit flush
against the viewing hole.
2 1
Fig. 92 Center bearing
SC.999.0020/01 B.6.63
Printing unit
12.9 Measuring the packing thickness of the blanket
An exact cylinder rolling requires the packing thick-
SG.901.1314-001GRAUND_00
ness to be measured very accurately. Even when the
packings were measured outside the press with a
plate micrometer, the packing thickness should be
checked again inside the printing press with the Hei-
delberg packing measuring device.
Note
With a new blanket, remember that the
blanket settles after a few hundred print-
ings. This requires a first re-stretching.
After around 10000 prints, tension the
blanket again (torque 65 Nm). and mea-
sure the packing thickness again. Cor-
rect the packing thickness if necessary.
1. Cover the blanket and the bearer with a sheet of
Fig. 93 Packing gauge paper.
2. Place the packing gauge parallel to the cylinder
shaft so that the feeler of the outer dial gauge is
positioned on the bearer (Fig. 93).
3. Press the measuring device down with the red
handle and set the pointers of the 3 dial indicators
to 0.
4. Slide the measuring device to the center of the
SG.901.1315-001GRAUND_00
blanket (Fig. 94).
With identical contact pressure, the two dial indicators
in the center and on the left (Fig. 94/, /1) still indicate 0.
1 2 The dial indicator on the right (Fig. 94/2) now indicates
the difference in height between the blanket and bear-
er.
Fig. 94 Packing gauge
B.6.64 SC.999.0020/01
Printing unit
13 Blanket washup device
SG.901.6300-000UTKENU_05
13.1 Function and structure
Function
SG.901.6300-002GRAUND_00
The blanket washup device cleans the blanket with a
washup cloth. The washup cloth is a consumable item.
The removable part of the blanket washup device is
the washup unit.
The washup cloth is unwound from the cloth supply roll
(Fig. 95/1) in the direction of the arrow. Metering tubes
apply water and washing fluid. A distributor bar dis-
tributes the washing fluid across the entire width of the
washup cloth. A pressing bar presses the washup
cloth onto the blanket. The soiled washup cloth is
1
wound onto a used-cloth roll (Fig. 95/2).
2
Fig. 95 Removed washup unit
Design
SG.901.6301-001GRAUND_00
2
1 Blanket washup unit support
1 2 Spindle for the used-cloth roll
3
3 Clamping rod for spindle for used-cloth roll
4 4 Washup cloth
5 Cloth supply spindle
5 Operation
The operation of the washup device is described in the
separate operating manual of the control station.
Please also observe the End of cloth / Wash cartridge
not available notes indicating that the washup cloth
should soon be changed.
Fig. 96 Design of the washup unit, view from O.S.
SC.999.0020/01 B.6.65
Printing unit
SG.901.6381-000GRAENU_00
PU 2-n PU 1
3
3 1 2
Fig. 97 Schematic diagram showing the place of installation of the washup device
The washup device (Fig. 97/3) is installed in front of the
blanket cylinder on the feeder side. In order to remove
the washup unit you either need to swing up the feed
table (Fig. 97/2) or the respective footboard (Fig. 97/1).
13.2 Removing the blanket washup unit (all PU except for PU 1)
1. Swing up the hinged footstep (Fig. 98/1) in front
SG.901.6382-000GRAENU_00
PU 2-n of the corresponding PU.
2. Swing down the swing frame (Fig. 98/2) in front of
1 the washup unit (Fig. 98/3).
3 2
Fig. 98 Sequence of removing/fitting the washup
unit
B.6.66 SC.999.0020/01
Printing unit
3. Unlock (Fig. 99/1) the washup unit in the direction
SG.901.6307-001GRAUND_00
indicated by the arrows.
2 Hold the cloth supply roll in place with one hand
so that the washup unit does not tilt.
1 4. Pull the washup unit (Fig. 99/2) evenly out of the
printing unit.
5. Lift the washup unit on O.S. Pull the washup unit
toward you on the swing frame.
6. Take the washup unit off the swing frame. Place
the washup unit in a clean, protected location.
Note
Remove the washup unit with the help of
a second person, if necessary.
Fig. 99 Sequence of removing/fitting the washup
unit
SG.901.6307-010GRAUND_00
Fig. 100 Pulling the washup unit out from the side
13.3 Removing the blanket washup unit (PU 1)
1. If necessary, open the door (Fig. 101/1) under the
SG.901.6384-001GRAENU_00
PU 1 feed table.
2. Fold the feed table (Fig. 101/2) upward. This will
make the area more accessible.
3. Swing down the guard (Fig. 101/3) in front of the
washup unit (Fig. 101/5).
4
4. Swing the guide (Fig. 101/4) down as indicated
by the arrows.
2 5. Unlock (Fig. 99/2) the washup unit as indicated
by the arrows.
3 Hold the cloth supply roll in place with one hand
5 so that the washup unit does not tilt.
1
6. Pull the washup unit on the guides out of the
Fig. 101 Sequence of removing/fitting the washup printing unit.
unit 7. Lift the washup unit off the guides and put it down
in a clean and safe place.
SC.999.0020/01 B.6.67
Printing unit
Note
Remove the washup unit with the help of
a second person, if necessary.
13.4 Preparations for removing the blanket washup unit from a PU with interdeck dryer
UV LED Interdeck Dryer
SG.901.6382-020GRAUND_00
1. Fold up the hinged footstep (Fig. 102/1) in front of
1 the PU.
2 2. Remove the UV LED dryer as described in the
manual DryStar UV LED dryer. The blanket
3 washup device is now accessible.
3. Move the flap (Fig. 102/4) in front of the washup
unit to a horizontal position. You can pull the
blanket washup unit out of the printing unit on a
guide that is mounted to the flap in front of the
4 washup unit.
4. Unlock (Fig. 99/2) the washup unit in the direction
indicated by the arrows.
Fig. 102 Removing the washup unit from a PU with
interdeck dryer Hold the cloth supply roll in place with one hand
so that the washup unit does not tilt.
UV interdeck dryer
SG.901.6382-025GRAUND_00
1. Open the dryer guard on D.S.
2 1 2. Pull the UV interdeck dryer (Fig. 103/1) toward
D.S. and out of the printing unit.
3 3. Fold up the hinged footstep (Fig. 103/2) in front of
the PU.
4. Move the flap (Fig. 103/4) in front of the washup
device into horizontal position. You can pull the
blanket washup unit out of the printing unit on a
4 guide that is mounted to the flap in front of the
washup unit.
Fig. 103 Removing the washup unit from a PU with
interdeck dryer
Removing the blanket washup unit
SG.901.6307-001GRAUND_00
1. Unlock (Fig. 104/2) the washup unit in the direc-
2 tion indicated by the arrows.
Hold the cloth supply roll in place with one hand
1 so that the washup unit does not tilt.
2. Pull the washup unit (Fig. 104/3) evenly out of the
printing unit.
3. Lift the washup unit out of the machine and put it
down in a clean and safe place.
Note
Remove the washup unit with the help of
a second person, if necessary.
Fig. 104 Sequence of removing/fitting the washup
unit
B.6.68 SC.999.0020/01
Printing unit
13.5 Removing the used washup cloth
Removing the cloth supply roll
SG.901.6304-001GRAUND_00
1. Push the latch (Fig. 105/1) down and to the right.
4 2. Pull out the bolt for locking the cloth supply spin-
dle (Fig. 105/2) slightly.
3. Remove the cloth supply roll.
1 Removing the used cloth roll
1. Push the latch (Fig. 105/1) down and to the right.
2. Pull out the bolt (Fig. 105/3) that secures the
2 used-cloth roll.
3 3. Rotate the washup unit horizontally by 180° as
indicated by the arrow (Fig. 105/4).
Fig. 105 Locked bolt, seen from O.S. 4. Remove the used-cloth roll.
FS.901.6319-001GRAUND_00 Pulling the spindle out of the used-cloth roll
1. Press the holding bracket (Fig. 106/1) against the
spring pressure (Fig. 106/2) out of the guide
groove.
1 3
2. Swivel the holding bracket 90°.
3. Pull the clamping rod (Fig. 106/3) out of the spin-
dle for used-cloth roll.
4. Pull the spindle for used-cloth roll out of the used-
cloth roll.
Note
Dispose of the used-cloth roll and the
2 used washup cloth in an environmentally
compatible way. Heed the local waste
disposal regulations.
Fig. 106 Holding bracket - used-cloth roll spindle
13.6 Preparing the cloth supply roll
Note
SG.901.6313-000GRAUND_00
Shop-made cloth supply rolls without
sufficient cloth tension produce loops
that cause malfunctions due to drawn-in
1 washup cloths.
Use fully-wound cloth supply rolls from
the Saphira range.
The sleeve of the cloth supply roll must be suitable for
the clamping device of the blanket washup unit. The
mandrels must enter into the sleeve. This is why ap-
propriate recesses must be provided on aluminum
sleeves, for example.
Note
Do not use cardboard cores or any made
of other soft materials. The holding
strength of these cores is insufficient.
Fig. 107 Cloth supply roll O.S.
SC.999.0020/01 B.6.69
Printing unit
Specification on cloth supply roll
SG.901.6643-000GRAENU_00
Washing side, outside
Heidelberg recommends using original washup cloths
from the Heidelberg Saphira program.
D.S. O.S. If you spool the cloth supply rolls yourself, pay atten-
tion to the following specifications:
● Adhere to the specified dimensions for the cloth
supply roll (Fig. 108) and the washup roll core
(Fig. 109).
● The cutting edge of the washup roll core must not
bulge and be free of burrs (Fig. 109/1).
● Stick a double-sided adhesive tape onto the
Fig. 108 Cloth supply roll washup roll core (Fig. 109/2) as follows:
SG.901.6641-000GRAUND_00
1 1 ○ Tesafix 4970 or equivalent, double-sided
adhesive tape with one or double-sided
overlapping cover.
○ Adhesive tape with overlapping cover on
one or both sides
○ True to edge final trimming
○ 2 strips offset by 180°.
● The direction of winding must conform to the di-
rection of winding shown in Fig. 108/1.
2
● Secure the wound-up roll against unwinding by
itself with a lightly sticking adhesive tape.
Fig. 109 Washup roll core
Inserting the spindle
SG.901.6313-000GRAUND_00
1. Insert the spindle of the cloth supply roll into the
new cloth supply roll. Ensure that the winding di-
rection is correct (see Fig. 110 and Fig. 111).
1
2. Tighten the knurled nut (Fig. 110/1). This causes
the arbors at the bearing (Fig. 111/1) to secure
the sleeve of the cloth supply roll.
Fig. 110 Cloth supply roll O.S.
B.6.70 SC.999.0020/01
Printing unit
The groove on the driver plate (Fig. 111/2) is on D.S.
FS.901.6313-001GRAUND_00
1 2
Fig. 111 Cloth supply roll D.S.
SG.901.6314-000GRAUND_00 Note
1 1 Make sure that the mandrels (Fig. 112/1)
penetrate fully into the cloth supply roll
sleeves. Tighten the knurled nut secure-
ly.
Fig. 112 Mandrels in the washup roll core
13.7 Mounting a new washup cloth
Inserting the cloth supply roll
SG.901.6315-001GRAUND_00
1. Place the driver plate of the cloth supply roll
(Fig. 113/1) on the bearing on D.S. (Fig. 113/2).
Align the groove and spring with one another.
1 2
Fig. 113 Inserting the cloth supply roll on D.S.
SC.999.0020/01 B.6.71
Printing unit
2. Push the latch (Fig. 114/1) down and to the right.
SG.901.6304-001GRAUND_00
4
2
3
Fig. 114 Releasing the bolt
3. Pull out the bolt (Fig. 115/1) on O.S. a little bit in
SG.901.6316-001GRAUND_00
order to insert the cloth supply role.
4. Align the cloth supply roll (Fig. 115/2) in relation
to the bolt on O.S.
1 2 5. Push in the bolt firmly.
Make sure that the bolt has locked in place prop-
erly.
Note
The bolt must be pushed in completely.
The washup unit cannot be installed and
locked if the bolt is not pushed in all the
way.
Fig. 115 Inserting the cloth supply roll on O.S.
Inserting the spindle for used-cloth roll
SG.901.6317-001GRAUND_00
Note
In order to remove the spindle for the
used-cloth roll you need to rotate the
2 washup unit horizontally by 180° as in-
1 dicated by the arrow (Fig. 114/4).
1. Place the driver plate of the spindle for used-cloth
roll (Fig. 116/1) on the bearing bolt on D.S.
(Fig. 116/2).
Align the groove and spring with one another.
Fig. 116 Bearing of the used-cloth roll spindle D.S.
B.6.72 SC.999.0020/01
Printing unit
2. Push the latch (Fig. 114/1) to the right.
SG.901.6318-001GRAUND_00
3. Pull out the bolt on O.S. (Fig. 117/1).
Align the groove (Fig. 117/2) and spring with one
another.
4. Push in the bolt firmly.
Make sure that the bolt has locked in place prop-
erly.
Note
1
When the bolts of the cloth supply roll
and the spindle for the used-cloth roll are
fully inserted, the latch (Fig. 114/1) en-
gages in the groove of the bolts. Only
then can the washup unit be installed
and locked.
Fig. 117 Spindle for used-cloth roll O.S.
Fastening the beginning of the cloth
SG.901.6319-010GRAUND_00
1. Rotate the spindle for used-cloth roll, until the
groove in the spindle is facing upwards.
2. Roll out approx. 20 to 30 cm of the washing cloth.
3. Pull the washup cloth tightly around the washup
unit. Align the washup cloth in such a way that it
1 protrudes the used-cloth roll spindle (Fig. 120/1)
by approximately 5 cm.
3
2
Fig. 118 Inserting the clamping rod
SG.901.6319-020GRAUND_00
Fig. 119 Inserting the clamping bar
SC.999.0020/01 B.6.73
Printing unit
SG.901.6319-001GRAUND_00
2 1
Fig. 120 Locking the clamping bar
4. Insert the clamping rod (Fig. 118/2) into the re-
ceptacle on D.S.
5. Starting at D.S., press the clamping bar into the
groove (Fig. 118/3) of the spindle for used-cloth
roll. The washup cloth is also clamped in position.
Ensure that the profile (Fig. 119/2) of the clamp-
ing bar is standing on its edge and the claw
(Fig. 119/1) is turned away from the end of cloth.
Tip
Installing the clamping rod is easy when
you press on the clamping rod and move
the holding bracket (Fig. 118/2) back
and forth.
6. Swivel the holding bracket on the clamping bar
(Fig. 120/3) until the holding bracket makes full
contact with the spindle for the used-cloth roll.
The holding bracket engages automatically in the
groove of the spindle for the used-cloth roll.
7. Make sure that the holding bracket has locked
into place correctly. The clamping bar is then se-
cured.
8. Turn the spindle for the used-cloth roll until at
least one layer of cloth is on the spindle. The
washup cloth must be tensioned so that it is prop-
erly taut and free of creases.
B.6.74 SC.999.0020/01
Printing unit
13.8 Fitting the blanket washup unit (all PUs, except for PU 1)
1. Place the washup unit (Fig. 121/3) in the correct
SG.901.6383-000GRAENU_00
PU 2-n position with one side on the swing frame
(Fig. 121/2).
1 Note
Ask someone to help, if necessary.
3 2
Fig. 121 Sequence of removing/fitting the washup
unit
2. Slide the washup unit toward D.S. on the swing
SG.901.6309-001GRAUND_00
3 1 frame. Place the washup unit on the swing frame.
Fig. 122 Sequence of removing/fitting the washup
unit
3. Push the washup unit into the printing unit until
SG.901.6309-010GRAUND_00
the locking bolt (Fig. 122/2) on O.S. is inside the
2 side frame (Fig. 122/3).
4. Hold the washup unit (Fig. 123/1) in position with
one hand. With the other hand, swing the locking
device (Fig. 123/2) inward in the direction of the
arrow. The locking device (Fig. 123/2) swivels by
approx. 20°.
1
Fig. 123 Sequence of removing/fitting the washup
unit
SC.999.0020/01 B.6.75
Printing unit
5. Slide the washup unit into the printing unit up to
SG.901.6309-020GRAUND_00
1 the stop. To do this, slide the washup unit
(Fig. 124/1) forward from the middle with your
2
thumb (Fig. 124/2) on the cloth supply roll and
your index finger (Fig. 124/3) on the cross bar.
The locking device engages audibly in the side
frames on D.S. and O.S.
Note
3
Make sure the washup unit is locked
properly. The locking bolts must lock ful-
ly into the side frame on D.S. and O.S.
6. Swing up the swing frame in front of the washup
unit (Fig. 121/2).
Fig. 124 Sliding in the washup unit 7. Fold down the hinged footstep (Fig. 121/1).
13.9 Fitting the blanket washup unit (PU 1)
SG.901.6385-001GRAENU_00
PU 1
2
3
5
1
Fig. 125 Sequence of removing/fitting the washup
unit
1. Place the washup unit (Fig. 126/1) in the correct
SG.901.6309-005GRAUND_00
2 position onto the guide rails (Fig. 126/4) on D.S.
and O.S.
Note
1
Ask someone to help, if necessary.
5
2. Push the washup unit into the printing unit until
3
the locking bolt (Fig. 126/3) on O.S. is inside the
side frame (Fig. 126/2).
3. Hold the washup unit in position with one hand.
With the other hand, swing the locking device
4
(Fig. 126/5) inward in the direction of the arrow.
Fig. 126 Sequence of removing/fitting the washup The locking device (Fig. 126/5) swivels by ap-
unit prox. 20°.
B.6.76 SC.999.0020/01
Printing unit
4. Push the washup unit (Fig. 127/1) into the print-
SG.901.6309-020GRAUND_00
1 ing unit up to the stop. To do this, slide the
washup unit forward from the middle with your
2
thumb (Fig. 127/2) on the cloth supply roll and
your index finger (Fig. 127/3) on the cross bar.
The locking device engages audibly in the side
frames on D.S. and O.S.
Note
3
Make sure the washup unit is locked
properly. The locking bolts must lock ful-
ly into the side frame on D.S. and O.S.
Fig. 127 Sliding in the washup unit
5. Swing up the guard (Fig. 125/3) in front of the
washup device.
The guides (Fig. 125/4) swivel up with it.
6. Fold the feed table (Fig. 125/2) downwards.
7. If necessary, close the door (Fig. 125/1) under
the feed table.
13.10 Fitting the blanket washup unit on a PU with interdeck dryer
UV LED Interdeck Dryer
SG.901.6382-030GRAUND_00
1. Place the washup unit (Fig. 128/3) in the correct
1 position onto the guide rails at the flap
2 (Fig. 128/4) in front of the washup unit.
Note
3
Ask someone to help, if necessary.
Fig. 128 Fitting the washup unit on a PU with inter-
deck dryer
2. Slide the washup unit into the printing unit up to
SG.901.6309-020GRAUND_00
1 the stop. To do this, slide the washup unit
(Fig. 129/1) forward from the middle with your
2
thumb (Fig. 129/2) on the cloth supply roll and
your index finger (Fig. 129/3) on the cross bar.
Fig. 129 Sliding in the washup unit
SC.999.0020/01 B.6.77
Printing unit
3. Lock the washup unit (Fig. 130/2). The locking
SG.901.6309-010GRAUND_00
device engages audibly in the side frames on
2 D.S. and O.S.
Note
Make sure the washup unit is locked
properly. The locking bolts must lock ful-
ly into the side frame on D.S. and O.S.
1 Note
The flap in front of the washup device
must be in horizontal position during the
operation of the UV LED dryer.
4. Install the UV LED dryer as described in the man-
ual DryStar UV LED dryer.
Fig. 130 Sequence of removing/fitting the washup
5. Fold down the hinged footstep (Fig. 128/1).
unit
UV interdeck dryer
SG.901.6382-035GRAUND_00
1. Place the washup unit (Fig. 131/3) in the correct
1 position onto the guide rails at the flap in front of
2 the washup device.
Note
3
Ask someone to help, if necessary.
Fig. 131 Fitting the washup unit on a PU with inter-
deck dryer
2. Slide the washup unit into the printing unit up to
SG.901.6309-020GRAUND_00
1 the stop. To do this, slide the washup unit
(Fig. 132/1) forward from the middle with your
2
thumb (Fig. 132/2) on the cloth supply roll and
your index finger (Fig. 132/3) on the cross bar.
Fig. 132 Sliding in the washup unit
B.6.78 SC.999.0020/01
Printing unit
3. Lock the washup unit (Fig. 133/2).
SG.901.6309-010GRAUND_00
2 The locking device engages audibly in the side
frames on D.S. and O.S.
Note
Make sure the washup unit is locked
properly. The locking bolts must lock ful-
ly into the side frame on D.S. and O.S.
1 4. Swing up the flap (Fig. 131/4) in front of the
washup device.
5. Slide the UV dryer (Fig. 131/2) from D.S. into the
printing unit.
6. Close the dryer guard on D.S.
Fig. 133 Sequence of removing/fitting the washup 7. Fold down the hinged footstep (Fig. 131/1).
unit
SC.999.0020/01 B.6.79
Printing unit
14 Impression cylinder washup device
SC.B01.0300-000UTKENU_01
14.1 Function and design
Function
CX.901.0300-000GRAUND_00
The impression cylinder washup device cleans the im-
pression cylinder (Fig. 134/1) with a washup cloth
(Fig. 134/3). The washup cloth is a consumable item.
The washup unit is the removable part of the impres-
1
sion cylinder washup device.
The washup cloth is wound from the cloth supply roll
(Fig. 134/5) to the used-cloth roll (Fig. 134/4). Metering
2
tubes (Fig. 134/6) apply water and washing fluid to the
washup cloth. A rubber lip (Fig.134/2) presses the
6 washup cloth against the impression cylinder. When
3 the press rotates, the washup cloth cleans the
residues off the impression cylinder.
4 5
Fig. 134 Principle of impression cylinder washup
device
Design of the washup module
SC.B01.0308-000GRAUND_00
● Support of the impression cylinder washup unit
(Fig. 135/1)
1
● Locking claw (Fig. 135/2)
● Spindle for used-cloth roll (Fig. 135/3)
● Cloth supply roll (Fig. 135/4)
● Cloth supply spindle (Fig. 135/5)
● Knurled nut (Fig. 135/6)
2
● Clamping bar for the used-cloth roll spindle
7 (Fig. 135/7)
Operation
The operation of the impression cylinder washup de-
3 vice is described in the operating manual of the control
6 station.
5
4
Fig. 135 Design of the washup module
B.6.80 SC.999.0020/01
Printing unit
14.2 Removing the washup unit
Fig. 3 shows lever positions 1 and 2 of the locking
SC.B01.0320-000GRAUND_00
lever.
Lever position 1 (operating position)
The locking lever (Fig. 136/1) is vertical.
The washup unit is installed in the printing unit and
locked (operating position).
Lever position 2 (removal/installation position)
The locking lever (Fig. 136/2) is turned approx. 150° to
the right.
The washup unit is unlocked. The washup unit can be
pulled out and pushed in on guide rails.
Fig. 136 Unlocking the washup unit
Removing the washup unit
SC.B01.0300-000GRAUND_00
1. Remove the guard below the O.S. gallery at the
appropriate printing unit. Now you can reach the
washup unit.
2. Turn the locking lever (Fig. 136/2) approx. 150° to
the right.
2 3. Use the locking lever to carefully pull out the
washup unit from under the printing unit until you
reach the first stop.
4. Disconnect the locking rod (Fig. 137/1) from the
1 claw (Fig. 137/2).
Note
Put down the locking rod in a safe place.
The locking rod must not become dam-
aged or bent. The washup unit will only
Fig. 137 Disconnecting the locking rod function if the locking rod is installed cor-
rectly.
5. Lift the washing unit lightly. Continue to pull until
the rear rollers of the washup unit stop at the stop.
SC.999.0020/01 B.6.81
Printing unit
Note
So that the washup unit does not jam,
pull it parallel to the guide rails until the
rollers stop at the stop.
6. Lift the washup unit off the guide rails and place it
on a clean, level surface.
14.3 Removing the used-up washup cloth
Removing the cloth supply roll
CX.901.0312-000GRAUND_00
1. Press the retainer plate (Fig. 138/1) down in the
1
direction of the arrow.
2. Pull out the pin (Fig. 138/3) on the cloth supply
spindle up to the stop.
3. First remove the cloth supply spindle on the side
with the pin. Then remove the cloth supply spin-
dle from the washup unit on the other side.
3 If you wind up washup cloths yourself, you can use the
empty core several times. Please note the section
"Specifications of the clean cloth roll".
Dispose of any empty cores that are no longer needed
in an environmentally compatible way.
Fig. 138 Bolt on the cloth supply spindle
Removing the used cloth roll
4. Turn the washup unit into a favorable position.
5. Press the retainer plate (Fig. 138/1) down in the
direction of the arrow.
6. Pull out the pin (Fig. 138/2) on the used-cloth
spindle up to the stop.
7. First remove the used-cloth spindle on the side
with the pin. Then remove the used-cloth spindle
from the washup unit on the other side.
B.6.82 SC.999.0020/01
Printing unit
Pulling the spindle out of the used-cloth roll
CX.901.0313-000GRAUND_00
● Holding bracket engaged (Fig. 139/1)
1 ● Press holding bracket against spring force (Fig.
139/2)
● Holding bracket swung (Fig. 139/3)
● Clamping bar (Fig. 139/4) pulled out
1. Press the holding bracket (Fig. 139/1) against the
spring pressure (Fig. 139/2) out of the guide
groove of the spindle for used-cloth roll.
2 2. Turn the holding bracket by 90° to the left
4 (Fig. 139/3).
3. Pull the clamping rod out of the used-cloth spin-
dle in the direction of the arrow (Fig. 139/4).
Tip
Hold the spindle vertically. Carefully tap
the spindle on the floor. The side on
which the clamping bar was pulled out
faces downward in the process.
4. Pull the used-cloth spindle out of the used used-
3 cloth roll.
Note
Dispose of the used-cloth roll and the
Fig. 139 Holding bracket for spindle for used-cloth
used washup cloth in an environmentally
roll
compatible way. Heed the local waste
disposal regulations.
14.4 Preparing the cloth supply roll
Note
CX.901.0316-000GRAUND_00
Shop-made cloth supply rolls without
sufficient cloth tension produce loops
that cause malfunctions due to drawn-in
washup cloths.
1 Use ready-made cloth supply rolls from
Heidelberg Saphira.
The sleeve of the cloth supply roll must be suitable for
the clamping device of the impression cylinder washup
device. The mandrels must enter into the sleeve. This
is why appropriate recesses must be provided on alu-
minum sleeves, for example.
Note
Do not use cardboard cores or any made
Fig. 140 Cloth supply roll O.S. of other soft materials. The holding
strength of these cores is insufficient.
SC.999.0020/01 B.6.83
Printing unit
Specifications of the clean cloth roll
CX.901.0314-000GRAUND_00
Heidelberg recommends using original washup cloths
from the Heidelberg Saphira program.
If you spool the cloth supply rolls yourself, pay atten-
Ø max. 72 mm tion to the following specifications:
● Adhere to the specified dimensions for the cloth
supply roll (Fig. 141) and the washup roll core
(Fig. 142).
● The washing side of the washup cloth must be on
the outside (Fig. 141/arrow).
4,5±1 mm
1040-3 mm
1049±1 mm
Fig. 141 Cloth supply roll
● The cutting edge of the washup roll core must not
CX.901.0315-000GRAUND_00
10±2 mm bulge and be free of burrs (Fig. 142/1).
2 ● Stick the double-sided adhesive tape onto the
2
washup roll core (Fig. 142/2):
○ e. g. Tesafix 4970 or equivalent
○ adhesive tape with overlapping cover on
one or both sides
○ with true to edge final trim
Ø25+0,3/-0,2 mm ○ 2 strips offset by 180°
● Secure the wound-up roll against unintentional
Ø18,5±0,2 mm unwinding with a lightly sticky adhesive tape.
1 1
1049±1 mm
Fig. 142 Washup roll core
B.6.84 SC.999.0020/01
Printing unit
Inserting the spindle
CX.901.0321-000GRAUND_00
1. Insert the spindle of the cloth supply roll into the
new cloth supply roll. Ensure that the winding di-
rection is correct (see Fig. 143 and Fig. 144).
1 The direction of winding differs for blanket and
impression cylinder washup devices.
2. Tighten the knurled nut (Fig. 143/1). This causes
the arbors at the bearing (Fig. 144/1) to secure
the sleeve of the cloth supply roll.
Fig. 143 Cloth supply roll D.S.
CX.901.0319-000GRAUND_00 The groove on the driver plate (Fig. 144/2) is on O.S.
2 1
Fig. 144 Cloth supply roll O.S.
Note
CX.901.0309-000GRAUND_00
1 1 Make sure that the mandrels (Fig. 145/1)
penetrate fully into the cloth supply roll
sleeves. Tighten the knurled nut secure-
ly.
Fig. 145 Mandrels in the washup roll core
SC.999.0020/01 B.6.85
Printing unit
14.5 Mounting a new washup cloth
Inserting the cloth supply roll
CX.901.0305-000GRAUND_00
2 1. Press the retainer plate (Fig. 146/1) down.
2. Pull out the bolts on the D.S. (Fig. 146/2).
3. Mount the cloth supply roll bearing onto the bear-
ing bolt on the O.S. (Fig. 147/2).
Align the groove and spring with one another.
Fig. 146 Bearing unit for cloth supply roll
4. Align the cloth supply roll to the pin on D.S.
CX.901.0304-000GRAUND_00
5. Press in the pin on D.S. (Fig. 146/2) again up to
2 1 the stop.
Fig. 147 Bolt on the cloth supply spindle
Inserting the spindle for used-cloth roll
CX.901.0306-000GRAUND_00
1. Swing the retainer plate up out of D.S.
(Fig. 148/1).
1 2. Pull out the pin (Fig. 148/2) on D.S.
3. Place the driver plate (Fig. 149/1) of the used-
cloth spindle on the bearing bolt on O.S.
(Fig. 149/2).
3 Align the groove and spring with one another.
4. Align the used-cloth spindle to the pin on D.S.
2
Fig. 148 Bearing of spindle for used-cloth roll
B.6.86 SC.999.0020/01
Printing unit
5. Press in the pin (Fig. 148/2) again completely.
CX.901.0301-000GRAUND_00
The retainer plate (Fig. 148/1) blocks the pin
1 against being pulled out accidentally.
Note
The retainer plate (Fig. 148/1) cannot
block the pin against being pulled out
accidentally until the pin of the cloth sup-
ply roll (Fig. 148/3) and the used-cloth
spindle (Fig. 148/2) are pressed in com-
pletely.
Fig. 149 Retainer plate
Note
The washup unit can only be installed if
the retainer plate is completely in the end
position.
Fastening the start of the used cloth
CX.901.0317-000GRAUND_00
1. Rotate the spindle for used-cloth roll, until the
3
groove in the spindle is facing upwards.
2. Roll out approx. 20 ... 30 cm of the washing cloth.
3. Feed the washup cloth - while taut - into the
2 washup device. Align the washup cloth such that
it protrudes approximately 5 cm over the spindle
for used-cloth roll (Fig. 150/2).
Fig. 150 Putting on the clamping rod
4. Insert the clamping rod (Fig. 151/1) into the hold-
CX.901.0302-000GRAUND_00
1 er on O.S.
5. Press the clamping bar into the groove of the
spindle for used-cloth roll starting on O.S. The
clamping bar also clamps in the washup cloth.
Tip
Installing the clamping rod is easy when
you press on the clamping rod and si-
multaneously move the holding claw
(Fig. 150/1) forward and backward.
Fig. 151 Used-cloth roll, insert clamping bar
SC.999.0020/01 B.6.87
Printing unit
6. Swivel the holding bracket on the clamping bar
CX.901.0318-000GRAUND_00
(Fig. 152/1) until the holding bracket makes full
contact with the spindle for the used-cloth roll.
7. The holding bracket engages automatically in the
groove of the spindle for the used-cloth roll.
8. Make sure that the holding bracket has locked
into place correctly. The clamping bar is then se-
cured.
9. Turn the used-cloth spindle (counterclockwise)
with an Allen key (Fig. 153/1) until at least 2 cloth
layers are wound onto the used-cloth spindle.
The washup cloth must be tensioned so that it is
1
properly taut and free of creases.
Fig. 152 Locking the clamping bar
SC.B01.0303-000GRAUND_00
Fig. 153 Winding up used-cloth spindle
14.6 Installing the washup unit
1. Remove the guard below the O.S. gallery at the
SC.B01.0301-000GRAUND_00
appropriate printing unit. This will give you ac-
cess to the guide rails for the washup unit.
2. Pick up the washup unit with the correct side fac-
1 ing forward. The locking claw must face away
from the press.
3. Insert the washup unit by placing the rear rollers
of the module (Fig. 154/2) exactly on the guide
rails (Fig. 154/2). Pay attention also to the roller
2 and guide rail on the other side.
4. Carefully push the washup unit under the gallery
and towards the printing unit. The washup unit
must remain aligned with the guide rails.
Fig. 154 Installing the washup unit
B.6.88 SC.999.0020/01
Printing unit
Note
SC.B01.0302-000GRAUND_00
Make sure the top of the washup unit
1 does not scrape against the underside of
the gallery.
5. Place the front rollers (Fig. 155/1) exactly on the
guide rail (Fig. 155/2). Pay attention also to the
roller and guide rail on the other side.
6. Fit the locking rod (Fig. 137/1) into the claw
(Fig. 137/2).
2
7. Use the locking rod to push the washup unit into
the printing unit up to the stop.
Fig. 155 Installing the washup unit
SC.B01.0320-001GRAUND_00 8. Turn the locking lever (Fig. 156/1) left into vertical
position.
The washup unit is locked.
9. Make sure the molded part (Fig. 156/2) fits ex-
actly into the recess in the metal plate.
Note
The impression cylinder washup device
will only function if the locking rod is in
the correct position.
10. Mount the guard below the O.S. gallery.
Fig. 156
SC.999.0020/01 B.6.89
Printing unit
15 Washing fluid container
SG.901.1352-000UTKENU_11
15.1 Equipment and function
The washing fluid container for water and cleaner sits
underneath the footboards on O.S. The washing fluid
container supplies the following washup devices:
● Inking unit washup device
● Blanket washup device
● Impression cylinder washup device, if there is
one fitted on your press.
Presses with seven or more printing units have two
washing fluid containers. You should top up, clean and
maintain both washing fluid containers.
15.2 Requirements on water / washing fluid
● Please observe the specifications documented in
the Customer Maintenance and Cleaning manual
in the General chapter.
● Do not mix UV washing fluids and standard
washing fluids.
● Do not use UV washing fluids to clean coated
machine parts or non-UV-resistant materials
(e.g. standard inking rollers and standard blan-
kets).
● Never use chloric washing fluids for UV presses.
● Do not store washup solutions containing chlo-
rine near your UV press.
15.3 Bleeding the washing fluid container
1. Lift up the plate (Fig. 157/1) slightly in front of the
SG.901.0177-000GRAUND_00
washing fluid container (Fig. 157/2). Remove the
plate (Fig. 157/1) from the fixture. Place the plate
at the side of the press (Fig. 157).
1
2
Fig. 157 Washing fluid container plate
B.6.90 SC.999.0020/01
Printing unit
2. Pull out the washing fluid container from under-
SG.901.6912-000GRAUND_00
neath the footboard on O.S.
2
3. Turn the control knob (Fig. 158/5) counterclock-
4 wise toward the drain connection piece.
3
1
1 The black dot on the control knob is pointing to-
ward the drain connection piece. The container is
5 then bled.
Caution - Damage can be caused by
improper use!
The lugs (Fig. 158/1) on the sides of the
washing fluid container (2 or 3 cham-
bers) are specifically for Heidelberg in-
ternal production purposes. Do not use
them under any circumstances to attach
anything or to transport, lift or suspend
6 the container.
Fig. 158 Washing fluid container
Pressure regulator with relief valve
SG.901.6011-002GRAUND_00
2 Caution - Risk of damage to the
washup device!
Do not tamper with the relief valve
(Fig. 159/1). The pressure regulator
1 (Fig. 159/2) has been set at the factory.
The setting of the pressure regulator
may only be altered by the Heidelberg
Service.
Fig. 159 Pressure regulator with relief valve
15.4 Filling the washing fluid container
Partitioning of the washing fluid container
Fig. 158/2: Cleaners for the inking roller washup de-
vice
Fig. 158/3: Cleaners for the blanket and impression
cylinder washup device
Fig. 158/4: Distilled or treated Water (blue rubber
ring around cover)
SC.999.0020/01 B.6.91
Printing unit
1. Open the screw cap of the washing fluid contain-
er (Fig. 158/2, 3 or 4).
Note
- Prior to filling the washing fluid contain-
er you must ensure that the sieves have
been installed in the filler necks. Re-
move the sieves for cleaning only.
- Use two separate vessels for filling up
the container cells for water and for
cleaner. The washup result deteriorates
and the metering tubes can clog up
when water and cleaner mix.
2. Be aware that the container cells must be filled
with different cleaners or water. Fill each con-
tainer cell so that roughly 2 cm of the sieve pro-
trudes beyond the fluid level.
3. Add the required quantity of Aquaclean into the
freshly filled water container.
Observe the specifications for disinfecting water
documented in the Customer Maintenance and
Cleaning manual.
4. Close the filler necks with the screw caps after
you have filled the container.
5. Turn the control knob (Fig. 158/5) clockwise in
the direction of the compressed-air hose.
The black dot on the control knob is pointing to-
ward the compressed-air hose.
6. Push the washing fluid container under the foot-
board.
7. Mount the plate (Fig. 157/1) into the fixture.
15.5 Draining and disposing cleaner / water
Caution - Damage to the level switch!
SG.901.6912-000GRAUND_00
A level switch is positioned in each con-
2
tainer cell. Do not slide a rinsing hose or
4 any similar cleaning aids into the con-
3 tainer cell.
1
1
Caution - The metering tubes can clog
5 up!
The washup result deteriorates and the
metering tubes can clog up when water
and cleaner mix.
Use separate collecting troughs for wa-
ter and cleaner.
1. Depressurize the washing fluid container. See
"Bleeding the washing fluid container".
6 2. Place a collecting trough underneath the drain
nozzle (Fig. 160/6).
3. Unscrew the Allen screw from the drain nozzle
Fig. 160 Washing fluid container (Fig. 160/6).
B.6.92 SC.999.0020/01
Printing unit
4. Allow the cleaner to run into the collecting trough.
If necessary, rinse the container cell again with
the drained liquid.
5. Insert the Allen screw with gasket into the drain
nozzle. Tighten the Allen screw again.
6. Dispose of the cleaner in an environmentally
compatible way.
15.6 Water container cell accidentally filled with cleaner?
You must empty and clean the container cell imme-
diately if you have accidentally filled cleaner into the
water container cell.
1. Place a collecting trough under the drain nozzle
for the corresponding cell.
2. Open the filler neck for the corresponding cell.
3. Remove the Allen screw from the drain nozzle for
the corresponding cell.
4. Let the soiled water mixture run into the collecting
trough.
Caution - Damage to the level switch!
A level switch is positioned in each con-
tainer cell. Do not slide a rinsing hose or
any similar cleaning aids into the con-
tainer cell.
5. Thoroughly rinse the water container cell with
distilled water.
There must be no cleaner residues left in the
container cell.
6. Insert the Allen screw with gasket into the drain
nozzle. Tighten the Allen screw again.
7. Fill the water container cell with distilled water.
Add once 2 - 3 tablets of Aquaclean into the
freshly filled water container.
8. Close the filler neck with the screw cap after filling
has been completed.
9. Dispose of the soiled water mixture in an envi-
ronmentally compatible way.
15.7 Cleaning the entire washing system
If any crystalline or slimy deposits begin to form, you
must empty and clean out the system. Please observe
the specifications documented in the Customer Main-
tenance and Cleaning manual.
SC.999.0020/01 B.6.93
Printing unit
16 Washup
SC.901.1301-000UTKENU_06
16.1 Manual washup/automated washup
There are also applications for presses with an auto-
matic washup device, which require manual washup.
When do you have to wash up manually?
You must remove stubborn dirt manually.
Procedure
1. Soften any accumulated coating with water.
2. Soften the ink piling with a suitable washing fluid.
When doing so, absorb the dirt with a cloth.
Using water
3. Completely absorb the remaining dirt with a wa-
ter-soaked cloth.
4. Clean the surface of remaining dirt and washing
fluid residues with a clean, water-soaked cloth.
Use a lint-free cloth.
Manual washup in the area of the UV dryer
● Switch off the UV dryer before washup. Allow the
UV dryer to cool down for 10 minutes before you
begin the washup.
● Explosive vapors are formed during washup in
the area of the UV dryer. Wait for 10 minutes after
washup until you put the press back into opera-
tion. The vapors must disperse first.
16.2 Washup devices, general information
The press is equipped with various automatic washup
devices. Some washup devices are optionally avail-
able and are not found on every press.
Note
To achieve good wash results, you must
check whether the metering tubes apply
sufficient washing fluid and water.
● Inking roller washup device (IRWD)
● Blanket washup device (BWD) with washup cloth
● Impression cylinder washup device (ICWD) with
washup cloth
You can activate and set the washup devices on the
control station.
Note
When using washing fluids and other
consumables, please observe the corre-
sponding safety regulations and specifi-
cations in the maintenance manual.
B.6.94 SC.999.0020/01
Printing unit
16.3 Washup devices, detailed information
Washing fluid container
The washing fluid container supplies all washup de-
vices with water and washing fluid. Depending on the
press model, there are 2 washing fluid containers from
a certain number of printing units. Depending on the
application, the washing fluid containers contain:
● Water
● Washing fluid for standard inks
● Washing fluid for UV inks
● Washing fluid for mixed application
Only use washing fluids approved for UV requirements
by FOGRA.
Please observe the specifications in the service man-
ual, chapter "A, General information/checklists".
Caution - Danger of damage to the
washup devices!
Washing fluids for standard inks and
washing fluids for UV inks react with one
another. They can block the washing flu-
id lines. Before changing the type of
washing fluid, you must completely emp-
ty the washing fluid containers and the
supply pipes of the washup devices.
● Washing fluid for deep cleaning the inking unit
Operating information on the washing fluid container
can be found in the "Printing unit" chapter. A message
appears on the control station when water or washing
fluid is running short.
Inking roller washup device (IRWD)
The rotating inking rollers are coated with water and
washing fluid and the dissolved ink is removed by a
doctor blade. The dirty water on each PU is collected in
the washup blade trough. Operating information on the
inking roller washup device can be found in the "Inking
unit" chapter, in the operating manual for the control
station and in the maintenance manual.
● Washup blades for UV inks
Only use washup blades that are suitable for UV
inks. Standard washup blades swell up in contact
with UV inks and damage the press.
Presses with mixed rollers are delivered ready for
operation with standard inks as standard. The
doctor blades for UV inks are delivered loose with
the press.
Note
Doctor blades for UV inks are destroyed
when used in normal operation and by
washing fluids containing oil. To clean
the doctor blades, use the inking roller
washing fluid used.
SC.999.0020/01 B.6.95
Printing unit
Blanket washup device (BWD) with washup cloth
The washup cloth is unwound from a cloth supply roll
and moistened with water or washup fluid by various
metering tubes. Depending on the press equipment,
additional metering tubes may also moisten the
washup cloth with UV washing fluid. A pressing bar
presses the washup cloth to the rotating blanket cylin-
der. A dirty washup cloth is then wound onto the used-
cloth roll.
Impression cylinder washup device (ICWD) with
washup cloth
The washup cloth is unwound from a cloth supply roll
and moistened with water or washup fluid by various
metering tubes. Depending on the press equipment,
additional metering tubes may also moisten the
washup cloth with UV washing fluid. A pressing bar
presses the washup cloth to the rotating impression
cylinder. A dirty washup cloth is then wound onto the
used-cloth roll.
Tandem washup concept
The blanket washup device also washes the impres-
sion cylinder due to the contact with the blanket cylin-
der. Presses with tandem washup concept have no
separate impression cylinder washup device. Due to
the design, you must absorb washing fluid and water in
the impression cylinder channel with a cloth after the
washup procedure has been completed.
Note
On presses with UV basic equipment,
the blanket and impression cylinder
washup devices are designed so that
they can be used with standard and UV
washing fluids.
16.4 Error messages during washing
Troubleshooting information can be found in the help
text on the control station and in the operating manual
for the control station.
B.6.96 SC.999.0020/01
Printing unit
17 Sheet-transferring cylinders and drums
LS.901.7010-000UTKENU_12
17.1 Equipment
The cylinder surfaces of your printing press are sur-
face-coated to protect them against corrosion. During
the printing process, the sheet-transferring cylinders
sometimes come into contact with the freshly printed
side of the sheet. This is especially the case for press-
es equipped with perfector. All impression cylinders
and transfer cylinders that can come into contact with
a freshly printed side of the sheet are therefore
equipped with special jackets.
● Configuration variants for impression cylinders
after the perfector:
○ Smooth cylinder jackets
○ Surface-finished impression cylinder jacket.
○ PerfectJacket (silicone-finished surface).
○ PerfectJacket Blue (Solgel surface)
● Configuration variants for transfer cylinders:
○ Super Blue-System.
○ TransferJacket (silicone-finished surface).
○ TransferJacket Blue (Solgel surface)
17.2 Replacement of cylinder jackets
Note
The plates have sharp edges. Be partic-
ularly careful when handling the plates.
The plates are very susceptible to kinks
and bends. Take care not to kink or bend
the plates when removing or mounting
them and ensure that they are properly
mounted and sit flush across the entire
length.
Replacement of impression cylinder jacket
The impression cylinder jackets may only be replaced
by Heidelberg service staff. Heidelberg does not ac-
cept any warranty or other liability for damage caused
by incorrect handling or improper mounting of the jack-
ets.
Exception
For the product line XL 106, the replacement of the
impression cylinder jacket is possible using a feed
cassette. Observe the corresponding operating man-
ual for the Speedmaster XL 106 for this purpose.
17.3 Automatically cleaning surfaces of impression cylinder with PerfectJacket/PerfectJacket
Blue
1. Make sure that you have assigned the correct
impression cylinder surfaces to the correspond-
SC.999.0020/01 B.6.97
Printing unit
ing printing units. The assignment results in the
selection of the correct wash program for opti-
mum wash results.
The assignment is described in the manual
Prinect Press Center > Service >Machine Set-
tings > Paper Run Printing Unit.
2. Use the correct washup cloths.
Surface Washup cloth type Ink Advantage
PerfectJacket Saphira Wash-up Cloth white low-lint
Perfecting
PerfectJacket Blue Saphira Wash-up Cloth blue inexpensive
short wash time
low cloth consumption
low washing fluid consump-
tion
Tab. 7 Replacing washup cloth
3. Check the wash results.
Fibers of the washing cloth that remain on the
cylinder surface after automatic washup proce-
dures can get onto the sheet when printing again.
Remove any fibers with a cleaning cloth prior to
printing.
Possible causes for formation of fibers on
PerfectJacket
● Washup cloth too dry.
○ You have set too little water/washing fluid in
the wash program or individual spray noz-
zles are clogged.
○ You can check the spraying function on the
control station, Washing > Manual > Direct
operator control > Cloth wetting .
● The surface coating of PerfectJacket is heavily
worn.
○ Please notify Heidelberg Service.
● You have used the wrong washup cloth.
4. For fine optimization, you can coordinate the pro-
gram length and the degree of wetness on the
control station Washing > Settings > Edit .
Note
Use only washup cloths from the Saphi-
ra product range for the automatic
washup device. This reduces the forma-
tion of fiber particles, thus enabling an
optimum wash result and minimizing
wear on the impression cylinder jackets.
B.6.98 SC.999.0020/01
Printing unit
17.4 Manual washup
Clean manually once a day or shift
Clean the surfaces manually at least once a day (or
once every shift). Afterwards, wipe with a damp, clean
cloth. This also applies if the automatic washup de-
vices are otherwise used.
Procedure
1. Soften any accumulated coating with water.
2. Soften the ink piling with a suitable washing fluid.
When doing so, absorb the dirt with a cloth.
Using water
3. Completely absorb the remaining dirt with a wa-
ter-soaked cloth.
Note
The water must be distilled, fully desali-
nated or demineralized. The water can
be hardened again up to 10° dH.
4. Clean the surface of remaining dirt and washing
fluid residues with a clean, water-soaked cloth.
Use a lint-free cloth.
17.5 Care instructions for all surfaces
The right maintenance is vital in order to preserve the
ink-repelling properties as long as possible. The fol-
lowing basic rules apply to all surfaces:
Use only approved cleaning agents.
Please observe the specifications documented in the
separate Customer Maintenance and Cleaning man-
ual under General.
Caution - Damage to the cylinder sur-
faces!
Avoid any kind of mechanical strain on
the surfaces such as heavy pressure,
shocks, scratches, use of spatulas,
brushes, sponges, sandpaper or use of
abrasive washing fluids.
17.6 Notes on PerfectJacket/PerfectJacket Blue/TransferJacket Blue
Washing less frequently
The finished surface offers the advantage that
PerfectJacket/PerfectJacket Blue/TransferJacket
Blue must be washed up less frequently.
Only wash the surfaces of PerfectJacket/
PerfectJacket Blue with the automatic washup devices
if necessary. This procedure increases its service life.
SC.999.0020/01 B.6.99
Printing unit
17.7 Print-related notes
Visual appearance of the functional surface
The respective finishing process can cause visual col-
or deviations. However, these do not affect the printing
functionality.
No numbering, perforating or creasing!
● Numbering, perforating and imprinting is not pos-
sible with refined jackets or PerfectJacket/
PerfectJacket Blue/TransferJacket Blue as this
leads to lasting damage. Self-adhesive perforat-
ing rules, steel plates and die-cutting sheets can-
not be used due to the anti-adhesive surface
property.
Inks and varnishes
● Above all for double-sided varnish applications,
we recommend the Saphira inks and varnishes
tested and released by Heidelberg.
● Ask for inks that have been optimized for straight
printing and perfecting and the use of which im-
prove the ink splitting. The choice of ink has a
direct influence on the print quality that can be
achieved.
Sized packing sheets
● The use of sized packing sheets under the blan-
kets prevents damage caused by the edges of
the sheets.
Anti set-off powder
SG.901.0748-002GRAUND_00
● Use powder that is low in particulate matter (par-
ticulate matter = particle size < 10 μm).
● Keep the powder volume as low as possible.
● Use the finest powder possible (e.g. 20 µm).
● In case of powder build-up, clean the surface of
the PerfectJacket or PerfectJacket Blue manual-
ly.
● Please note the wear of the PerfectJacket that is
caused by each different powder type (mineral,
organic). Mineral powder may lead to greater
wear.
Fig. 161 Wear for powder grain size 30 µm
B.6.100 SC.999.0020/01
Printing unit
SG.901.6382-010GRAENU_00
Fig. 162 Wear for powder grain size 20 µm
17.8 Super Blue system
Caution - Risk of damage to the Super
Blue system!
Avoid any contact of the net with wash-
ing fluid and cleaners. Otherwise, the
ink-repellent layer will be destroyed.
If the effect of the ink-repellent coating starts to fade
and ink starts sticking to the net, you have to replace
the net with a new one.
17.9 General notes on straight printing and perfecting
An optimal paper run prevents smearing and scratch-
es in the printed image. Ensure that
● the front lays are parallel to each other on D.S.
and O.S.,
● the pull lay pulls correctly,
● the gap distance between the transfer drums is
set correctly,
● the air guidance is set correctly.
SC.999.0020/01 B.6.101
Printing unit
18 Air settings in the printing unit
SC.901.0612-000UTKENU_06
18.1 Air settings on the impression cylinder
The first printing unit of the CD/CX 102 has two blow-
SC.901.0620-002GRAUND_00
ing devices or, if equipped with a suction brush, only
one. The subsequent printing units each have three
blowing devices:
3
1 The cardboard blast tube
2 The cardboard blast tube improves the sheet
travel of cardboard sheets. At a pressure of
< 50 mbars, the sheet travel of low grammages
(e.g. lightweight papers) is improved, too. There
1 is no cardboard blower tube on the first printing
unit.
2 The paper blast tube
The paper blast tube improves the sheet travel in
front of the print nip with critical types of paper. If
Fig. 163 Blast tubes and blower bar the first printing unit is equipped with a suction
brush, it does not have a paper blower tube.
3 The printing nip blower bar
It optimizes sheet travel and prevents critical
printing materials from touching the blanket
washup device and the blanket cylinder.
The air jets from the three blowing devices can be set
SC.901.6753-000GRAUND_00
individually via the control panel on D.S. Adjustments
are made using the control knobs and can be checked
using the corresponding manometers. The numbering
in Fig. 163 correspond to the numbering in Fig. 164.
This means that the left-hand control knob (Fig. 164/1)
controls the cardboard blast tube (Fig. 163/1), etc.
1 2 3 Printing units with one or two blowing devices have
correspondingly fewer control panels.
Fig. 164 Blast air settings
18.2 Air-supported sheet guiding
General notes
For a non-contact transport of the sheet through the
press, there are six fans per printing unit under the
sheet guide plates. These fans produce an air cushion.
With a stock thickness of up to and including 0.3 mm,
the fans are automatically preselected via the Preset
adjustments, and are switched on when the press
starts up. With thicker printing material, the fans can
manually be switched on during production, or be pre-
selected in the Preset adjustments.
B.6.102 SC.999.0020/01
Printing unit
The fans can be switched on and off during operation
even if the fault display is flashing. Preselected fans
which were switched off manually will be switched
back on during the next production run. When a new
stock thickness is selected (Preset), the fans are au-
tomatically preselected or deselected (as described
above).
When the Emergency stop palm button is pressed all
the fans are immediately switched off. They will not
restart automatically after releasing the Emergency
stop button.
SC.999.0020/01 B.6.103
Printing unit
19 Malfunctions on the printing unit
SC.901.6400-000UTKENU_00
19.1 Error message: Drain oil from residual-oil reservoir
The bearings on O.S. are lubricated with oil at inter-
vals. The residual oil is collected in a residual-oil reser-
voir. This container needs to be emptied when the lev-
el sensor detects the malfunction.
Note
The error message does not interrupt
press operation. If you ignore the error
message, there is a risk that the residu-
al-oil reservoir might overflow.
19.1.1 Emptying the residual-oil reservoir
SC.A04.0070-001GRAUND_00
1 Residual-oil reservoir
2 Level sensor
2 3 Oil supply hose rapid-action coupling
1 Remedy
1. Secure the press against being switched back
on: Press the Emergency stop button on the
nearest control panel.
3 2. Open the lateral guard (Fig. 165/4) below the
footboard on O. S.
3. Carefully pull out the residual-oil reservoir from
below the footboard.
4. Drain the residual oil using a commercially avail-
4 able suction pump.
Note
Take care of environmentally safe dis-
Fig. 165 Residual-oil reservoir
posal of the lubricant!
5. Slide the residual-oil reservoir back into its posi-
tion below the footboard again. Close the lateral
guard (Fig. 165/4) below the footboard on O. S.
B.6.104 SC.999.0020/01
Plate changer
Plate changer
changer
Plate
1 Plate changer - safety instructions ..................................................................................... B.7.3
1.1 Safety instruction for the plate changer ......................................................................... B.7.3
2 AutoPlate Pro ........................................................................................................................ B.7.4
2.1 Overview ....................................................................................................................... B.7.4
2.2 Usable printing plates ................................................................................................... B.7.4
2.3 Special features of presses with AutoPlate Pro ............................................................ B.7.4
2.4 Positions of the plate changer ....................................................................................... B.7.6
2.5 Method of functioning .................................................................................................... B.7.8
2.6 Plate change ................................................................................................................. B.7.10
3 AutoPlate Pro - manual plate change .................................................................................. B.7.12
3.1 Overview ........................................................................................................................ B.7.12
3.2 Removing the plate ....................................................................................................... B.7.12
3.3 Mounting the plate ........................................................................................................ B.7.13
4 Notes on troubleshooting .................................................................................................... B.7.15
4.1 Basic knowledge and conduct of operator ..................................................................... B.7.15
4.2 10 Troubleshooting rules ............................................................................................... B.7.15
5 Error message: "General malfunction: automatic plate change" or "Finger protecting
bar/protective device" or emergency stop or "DWBA movement lock main drive" ....... B.7.17
5.1 Error message: "General malfunction: automatic plate change" .................................. B.7.17
5.2 Malfunctions from power failure during the plate change .............................................. B.7.18
5.3 Momentary triggering of the finger protecting bar .......................................................... B.7.18
5.4 Interruption of the automatic plate change due to a time-out ........................................ B.7.19
5.5 Brief lifting of the deflector plate on the delivery ............................................................ B.7.19
6 Error before the start of the plate change .......................................................................... B.7.20
6.1 Error: Plate change cannot be started .......................................................................... B.7.20
7 Malfunctions when removing the plate ............................................................................... B.7.22
7.1 Error message: "Malfunction: Plate rear edge sensor, PU x" ....................................... B.7.22
7.2 The error message "Malfunction: Plate ejection, printing plate end position" ............... B.7.23
7.3 Error message "Malfunction: Printing plate ejection in PU x" ....................................... B.7.24
7.4 Aborting the automatic plate changing procedure ........................................................ B.7.25
8 Malfunctions in data transmission ...................................................................................... B.7.29
8.1 Error message: "Fault on data transmission sensor - Remove plate in PU x" .............. B.7.29
9 Plate loading faults ............................................................................................................... B.7.30
9.1 Error message: "Malfunction: Front edge sensor D.S./O.S. - Remove plate PU x" ...... B.7.30
SC.999.0020/01 B.7.1
Plate changer
B.7.2 SC.999.0020/01
Plate changer
1 Plate changer - safety instructions
SF.901.1500-000UTKENU_01
1.1 Safety instruction for the plate changer
Warning - Risk of injury from rotat-
ing rollers and cylinders!
Press the Emergency stop button on
the printing unit before removing the
maintenance cover.
If you want the feeding rollers and
guide rollers to be turning so that they
can be cleaned, release the Emergen-
cy stop button again.
Fit the maintenance cover before start-
ing up the press again.
SC.999.0020/01 B.7.3
Plate changer
2 AutoPlate Pro
SG.901.0663-000UTKENU_01
2.1 Overview
Caution - Risk of damaging the plate
SG.901.0638-004GRAUND_00
changer!
1 Never walk or stand on the plate chang-
er. Do not use the openings on the top of
the plate changer as handles.
Possible applications
The plate changer (Fig. 1/1) offers the following func-
tions:
● Automatic plate change.
● Automatic plate loading only.
● Automatic plate ejection only.
It is also possible to change the plate without using the
plate changer (as on a conventional AutoPlate press).
Fig. 1 Plate changer
2.2 Usable printing plates
AutoPlate Pro permits new or used printing plates to
be changed.
The dimension requirements for the printing plates are
listed in chapter: "Printing press, printing unit, Auto-
Plate Pro - checking and adjusting".
2.3 Special features of presses with AutoPlate Pro
Blade trough for the inking unit washup device
SG.901.6386-000GRAENU_00
Use the following procedure to remove the blade
trough:
1. Move the roller guard upward.
1 2. Unlock the blade trough using the levers
(Fig. 2/1) on D.S. and O.S.
3. Remove the blade trough.
Fig. 2 Locking the blade trough
B.7.4 SC.999.0020/01
Plate changer
Electronic flag for manual adjustment of the tail
SG.901.0266-004GRAUND_00
edge plate clamp
Requirement
For a smooth plate change, the manual
clamping mechanism on the clamping
1 3 bar needs to be open.
2
An electronic reminder can be set if the clamping bar
4 has been manually clamped for positioning correc-
tions. While the indicator is set, automatic plate
change is not possible. See chapter "AutoPlate Pro -
manual plate change".
Press the Plate removal/mounting button (Fig. 3/9) for
5 7 more than two seconds. The button lights up to indi-
6 cate that manual adjustment has been carried out. Af-
ter the clamping bar has been reset to its normal po-
sition, press the button again for more than two sec-
8 14
onds. The light in the button goes out.
Note
The electronic flag may also be switched
9 15 on or off in the control station service
10
display. The light in the button goes out
when the press runs at more than 3,000
11 12 impressions/h. The flag remains set,
however. The button lights up when the
speed drops below 3,000 impressions/h.
13
Fig. 3 Printing unit control panel
Prerequisite for setting the third and fourth inking
SG.901.6977-003GRAUND_00
from roller
Requirement
The upper guard (roller guard) of the
plate changer is open.
1
The adjusting screws for the third and fourth inking
form roller (Fig. 4/1 ... 3) can be reached using the
2 Allen key with ball end. The Allen key with ball end is
included in the delivery.
● Fourth inking form roller, adjustment relative to
3 the printing plate (Fig. 4/1).
● Third inking form roller, adjustment relative to the
printing plate (Fig. 4/2).
● Fourth inking form roller, adjustment relative to
the ink distributor (Fig. 4/3).
Requirement
In order to adjust the third inking form
Fig. 4 Adjusting screws for inking form roller roller to the ink distributor you need to
open the cylinder guard.
SC.999.0020/01 B.7.5
Plate changer
2.4 Positions of the plate changer
You can move the plate changer to three positions.
Working position
SG.901.0471-001GRAUND_00
The working position (Fig. 5) is the standard position of
1 the plate changer. Printing and automatic plate chang-
ing operations can only be carried out when the plate
changer is in this normal position.
Fig. 5 Plate changer in working position
Maintenance position (roller guard open)
SG.901.0471-002GRAUND_00
1
In the maintenance position (roller guard open)
(Fig. 6/1) it is possible to inch the press with travel lim-
itation. The wash-up blade can be cleaned. The inking
rollers can be removed or adjusted.
Fig. 6 Plate changer in maintenance position
(roller guard open)
B.7.6 SC.999.0020/01
Plate changer
Maintenance position (cylinder guard open)
SG.901.0471-000GRAUND_00
In the maintenance position (cylinder guard open)
1 (Fig. 7) it is possible to inch the press without travel
limitation and in crawl speed. Manual plate change is
also possible.
2
Fig. 7 Plate changer in maintenance position
(cylinder guard open)
Opening/closing the plate changer
SG.901.0472-000GRAUND_00
1. When pressing the Open/close roller guard but-
ton (Fig. 8/1) while the guard is closed, the roller
guard will automatically move upward and re-
main in the maintenance position.
When pressing the Open/close roller guard but-
ton (Fig. 8/1) while the guard is open, the roller
guard will automatically move downward.
2. When pressing the Open/close cylinder guard
button (Fig. 8/2) while the guard is closed, the
cylinder guard and the roller guard will automat-
ically move upward and remain in the mainte-
nance position.
8When pressing the Open/close cylinder guard
button (Fig. /2) while the guard is open, the cylin-
der guard and the roller guard will automatically
move downward.
Note
1
You can only move the roller guard and
cylinder guard if the ink fountain is en-
gaged or if the ink fountain is in the lock-
2 in position.
You can only move the roller guard if
there is no plate in the loading compart-
ment.
Fig. 8 Section of the printing unit control panel
SC.999.0020/01 B.7.7
Plate changer
2.5 Method of functioning
The following processes execute automatically before
the plate change:
● The lateral and diagonal registers move to the
center position (zero).
● Impression is engaged.
Plate ejection
SG.450.0101-002GRAUND_00
The plate is ejected in a backward movement without
the press stopping. At certain angle positions, the fol-
lowing operations run automatically.
● The swing arm (Fig. 9/6) moves in plate ejection
position.
● The tail edge plate clamp (Fig. 9/4) opens. The
2
plate jumps out. It rests on the guide plate of the
3 swing arm (Fig. 9/6).
● The sensor (Fig. 9/4) in the guide plate checks
whether the plate was released properly. The tail
1 edge plate clamp closes.
6 5
Fig. 9 Removing the printing plate
B.7.8 SC.999.0020/01
Plate changer
● The plate cylinder turns backward until it reaches
SG.450.0101-007GRAUND_00
5 the position for removing the lead edge of plate.
The plate is ejected.
4 ● The sensor (Fig. 10/4) in the ejection compart-
ment checks whether the plate was ejected cor-
rectly. The lead edge plate clamp (Fig. 10/6)
3 opens.
● The transport rollers (Fig. 10/3) pull the plate out
the of lead edge plate clamp (Fig. 10/5).
● The swing arm (Fig. 10/2) swings in the direction
of the plate changer (cylinder guard) (Fig. 10/1).
● The plate is ready for removal.
2
6
Fig. 10 Removing the printing plate
Plate loading
SG.450.0101-010GRAUND_00
● The plate is inside the loading compartment
ready for loading. A register pin on D.S. prealigns
the plate. A sensor (Fig. 11/7) checks whether
the plate is ready for loading.
● The plate cylinder (Fig. 11/5) turns to the position
for mounting the lead edge. The lead edge plate
clamp (Fig. 11/6) opens.
● The swing arm (Fig. 11/3) in the cylinder guard
swings in the direction of the plate cylinder.
4 ● The transport rollers (Fig. 11/2) transport the
plate into the clamping bar (Fig. 11/6). The
5 clamping bar closes.
3 ● The plate cylinder turns forward. The plate is
6
mounted on the plate cylinder. The impression
2 pressure adjustment between plate cylinder and
blanket cylinder is active.
Fig. 11 Mounting a printing plate
SC.999.0020/01 B.7.9
Plate changer
● The plate cylinder (Fig. 12/4) stops in the rear
SG.450.0101-008GRAUND_00
edge clamping position. The tail edge plate clamp
(Fig. 12/5) opens.
● The pressing roller (Fig. 12/2) moves into contact
with the plate cylinder (Fig. 12/4). The plate
(Fig. 12/6) is pressed inside the rear edge plate
clamp.
● The tail edge plate clamp (Fig. 12/5) closes. The
pneumatic trolley moves away from the plate
cylinder.
● The swing arm (Fig. 12/3) moves back into its
3 starting position in the cylinder guard (Fig. 12/1).
The plate change in several printing units takes place
2 in succession in a path-optimized sequence. The se-
4 quence depends on the angular positions of the plate
5 cylinder.
6
1
Fig. 12 Mounting a printing plate
2.6 Plate change
Prerequisites
Observe the following points before you start a plate
change:
Printing plates
● The plates must be properly punched and
beveled.
● The plate edges must not be bent.
Plate changer
● Transport rollers must be clean.
● The ejection compartment must be empty.
Plate and blanket cylinder
● The rear edge plate clamp must not be clamped
manually. If necessary, open the plate clamp
manually.
● The blanket must be on the blanket cylinder.
Ink fountain
● The ink fountain must be engaged or in the lock-
in position.
Press
● The feed table is swiveled down and locked.
● There must be no paper in the printing units and
in the delivery gripper system.
B.7.10 SC.999.0020/01
Plate changer
● The pressing roller for the printing plate must be
installed.
● The press must be ready to run.
● The suction air compressor must be ready to run.
● The register servo-drives must be ready to run.
Preparing the plate change
C4.901.0304-001GRAUND_00
1 1 1 ● Open the gap of the rear plate clamp. Turn the six
locking screws (Fig. 13/1) and the six adjusting
2 2 2 screws (Fig. 13/2) counterclockwise up to the
stop, and tighten them lightly ("zero position").
● Close all guards
● Only put one plate inside the loading compart-
ment.
A.S. 3 B.S.
Fig. 13 Locking screws and adjusting screws
Inserting a plate into the loading compartment
SG.901.4922-000GRAUND_00
● Insert the new plate in the loading compartment,
with the emulsion side facing the delivery side.
1
The punched plate edge (Fig. 14) points down-
wards.
Note
The Positioning button on the printing
unit control panel lights up if the plate
has been inserted correctly.
Note
Do not prepare a new plate for loading
during a changeover process. You must
wait until the active plate change has
been completed.
Starting the automatic plate changing process
3 ● Start the automatic plate changing process on
the control station.
The press executes the plate changing process auto-
2 matically. In this process, the old plates are transport-
ed into the ejection compartments.
Fig. 14 Inserting a plate into the loading compart-
ment ● When the plate changing process has been com-
pleted: Remove the old plates from the ejection
compartments.
SC.999.0020/01 B.7.11
Plate changer
3 AutoPlate Pro - manual plate change
SG.901.0664-000UTKENU_00
3.1 Overview
This section describes the process of performing a
SG.901.6980-001GRAUND_00
1 1 1 manual "AutoPlate" plate change on presses with Au-
toPlate Pro.
2 2 2
Preparing a manual plate change:
Note
The front edge of the plate must not be
3 bent.
1. Open the gap of the rear plate clamp. Turn the six
locking screws (Fig. 15/1) and the six adjusting
Fig. 15 Tail edge plate clamp screws (Fig. 15/2) counter-clockwise up to the
stop. Tighten them lightly only ("zero position").
2. On the left and right section of the plate clamp,
turn the hexagon-head screw so that the mark
(borehole) points upwards (Fig. 15/3).
3. After coarse adjustment of the circumferential
register, the printing press must turn at least one
revolution at crawl speed.
3.2 Removing the plate
1. Control panel selection: Press the Control panel
SG.901.0625-003GRAUND_00
selection button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
Note
The printing unit must remain selected
1 during the entire plate changing proce-
dure.
2. Press the Open/close cylinder guard button. The
plate changer (Fig. 16/1) moves upward into the
upper end position (maintenance position).
3. Press the Positioning button.
The plate cylinder turns to the initial position.
4. Press the Remove/mount plate button.
The tail edge plate clamp opens. The printing
plate springs out.
5. Press the Positioning button.
Fig. 16 Removing the plate
The plate cylinder turns until it reaches the lead
edge of the plate. Support the printing plate dur-
ing the movement. The lead edge plate clamp
opens.
6. Guide the plate at the rear edge out of the press.
B.7.12 SC.999.0020/01
Plate changer
If no new plate is to be mounted:
7. Press the Open/close cylinder guard button. The
plate changer (Fig. 16/2) moves downward into
the operating position.
8. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
3.3 Mounting the plate
Mounting the plate immediately after removing the
SG.901.0626-004GRAUND_00
old plate
Caution - Risk of damaging the print-
ing plate by bending it!
Support the printing plate with your hand
1 during the clamping procedure.
3
1. Insert the printing plate (Fig. 17/1) up to the stop
(Fig. 17/2) into the lead edge plate clamp. The
printing plate must be positioned exactly above
the register pins of the plate clamp.
2. Support the printing plate with your hand.
3. Press the Remove/mount plate button. The lead
edge plate clamp closes.
4. Press the Positioning button.
The plate cylinder turns towards the tail edge
plate clamp. Continue supporting the printing
3 plate during the movement. The rear edge of the
plate is clamped automatically.
5. Press the Open/close cylinder guard button. The
plate changer (Fig. 17/3) moves downward into
the operating position.
6. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
1 no more than 0.5 seconds). The LED goes out.
Fig. 17 Mounting the plate
SC.999.0020/01 B.7.13
Plate changer
Mounting the plate not immediately after removing
SG.901.0626-004GRAUND_00
the old plate
Caution - Risk of damaging the print-
ing plate by bending it!
Support the printing plate with your hand
1 during the clamping procedure.
3
1. Control panel selection: Press the Control panel
selection button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
2. Press the Open/close cylinder guard button. The
plate changer (Fig. 17/3) moves upward into the
upper end position (maintenance position).
3. Press the Positioning button.
The plate cylinder turns until it reaches the
clamping position.
4. Press the Remove/mount plate button. The lead
3 edge plate clamp opens.
5. Insert the printing plate (Fig. 18/1) up to the stop
(Fig. 18/2) into the lead edge plate clamp. The
printing plate must be positioned exactly above
the register pins of the plate clamp.
6. Support the printing plate with your hand.
7. Press the Remove/mount plate button. The lead
1
edge plate clamp closes.
8. Press the Position button.
The plate cylinder turns towards the tail edge
plate clamp. Support the printing plate with your
hand during this process. The rear edge of the
plate is clamped automatically.
2 9. Press the Open/close cylinder guard button. The
plate changer (Fig. 18/3) moves downward into
the operating position.
10. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
Fig. 18 Mounting the plate
B.7.14 SC.999.0020/01
Plate changer
4 Notes on troubleshooting
SG.901.6211-000UTKENU_00
4.1 Basic knowledge and conduct of operator
Caution - Risk of press damage!
Before you can start troubleshooting:
Make sure that the operator is familiar
with the following notes and observes
them. In the event of any erroneous be-
havior during the troubleshooting pro-
cess, it will take longer before the mal-
function is eliminated. If the operator
does not proceed with caution or if
he/she tries to rectify faults through "use
of force", the plate changer and the
press may be damaged.
SG.450.0101-006GRAUND_00 The automatic plate changer (Fig. 1 /1) is located on
the delivery side in front of the PU. It also serves as a
protective device and consists of an upper part
(Fig. 19/7), roller guard and a bottom part (Fig. 19/4),
cylinder guard. The upper and lower part of the plate
8
1 changer can be moved independently of one another.
2 The plate changing process is monitored by various
sensors. In the event of a fault, the following error
messages are issued by the corresponding sensors
on the control station:
7 ● Ink fountain not engaged (Fig. 19/1)
● Ink fountain not locked into place (Fig. 19 /2)
6
● Plate not in the loading compartment (Fig. 19/3)
● Rear edge of plate not released (Fig. 19/5)
● Ejection fault, plate not in end position (Fig. 19/6)
5
● Plate not in the ejection compartment (Fig. 19/8)
4
3
Fig. 19 Schematic diagram of the plate changer
4.2 10 Troubleshooting rules
1. Keep calm! When a malfunction occurs, wait until the press stops.
2. Check the control station! Go to the control station first. At the control station, go to the Plate change menu
and select the Status display submenu. Check which fault has occurred on which
printing unit. There may be faults on several printing units at once. The error
message will help you to determine which type of fault is involved.
3. Do not switch off! If possible, do not switch off the press until the automatic plate change has been
completed. Proceed with the functional sequence once the fault has been found
and rectified, using the production button.
SC.999.0020/01 B.7.15
Plate changer
4. Do not use force! Even when little time is available: Keep calm! If you are unsure about what to do
next, contact your local Heidelberg Service. Do not attempt to rectify a fault by
using force.
5. Observe all printing units! In the event of a malfunction the plate changing procedure may still be active in
several printing units.
Turning the press could result in serious damage to the press.
6. Rectify the fault. Rectify the fault (e.g. release the safety device, remove plate, support the plate
supply).
7. Close the clamping bar. On the repaired printing unit: Press the button on the control panel to close the
clamp and/or clamping bar.
8. Enable printing unit. In order to acknowledge that a fault has been eliminated you might need to fully
open and close the cylinder guard and the clamping bar once.
9. Rectify next printing unit. If a fault is pending at another printing unit: Repeat steps 6, 7 and 8.
10. Everything OK? Check! If no further faults are pending: Make sure, by means of a visual inspection, that
no-one is located in the press hazard area with its moving parts, in particular in the
vicinity of the delivery gripper bars. Proceed with the automatic functional se-
quence by pressing the production button.
Tab. 1
B.7.16 SC.999.0020/01
Plate changer
5 Error message: "General malfunction: automatic plate change" or "Finger
SC.901.6218-000UTKENU_01
protecting bar/protective device" or emergency stop or "DWBA movement
lock main drive"
5.1 Error message: "General malfunction: automatic plate change"
After an emergency stop has been triggered by an
SG.901.0108-001GRAUND_00
1 Emergency stop button, detection of whole body ac-
cess, opening of a guard etc., an error message "Gen-
eral malfunction: Automatic plate change" and the
cause of the fault (e.g. Emergency stop palm button)
are displayed on the control station.
Fig. 20 Emergency stop button
Error message: "General malfunction: automatic plate change"
Error message "DWBA movement lock main drive"
Problem Possible cause Remedy
The plate change is interrupted and A deformed plate is caught in the Monitor the faulty printing unit while
the press stopped. guide elements and briefly activates continuing the plate changing proce-
the finger protecting bar. The finger dure.
protecting bar is currently not active See detailed procedure in the table
anymore. below.
Protective device, e.g. emergency See detailed procedure in the table
stop for DWBA was triggered. below.
Tab. 2 Error message: "General malfunction: automatic plate change" or "Finger protecting bar/protective
device"
Note
If possible, do not perform a pile change
while a plate changing process is in
progress. It is not possible to deactivate
the DWBA while a plate mounting pro-
cess is taking place and it might trigger
an emergency stop.
Troubleshooting procedure
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Eliminate the malfunction (release the Emergency stop button, close the guard, unlock the DWBA, etc.).
3. Press the Production button. The automatic functional sequence is continued.
4. If it is not possible to resume the automatic plate change you need to continue the troubleshooting
procedure as described in the section Aborting the automatic plate change.
Tab. 3 "General malfunction: automatic plate change" troubleshooting procedure
SC.999.0020/01 B.7.17
Plate changer
5.2 Malfunctions from power failure during the plate change
Problem Possible cause Remedy
Press is de-energized. Main switch pressed or power failure. Restore the power supply. A horn will
sound. Eliminate the malfunction in
accordance with the table below.
Tab. 4 Error message "General malfunction: automatic plate change"
Troubleshooting after reestablishing the power supply
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Check on which printing unit which malfunction occurs.
3. Remove all printing plates that can be removed. Check whether the power failure has caused any dam-
age to the printing plates.
4. Open the cylinder guard on all printing units listed. Check whether the printing plate is in the printing unit.
Open/close clamping.
Close the cylinder guard.
Note: Several printing units may be affected at the same time. You must visually inspect each printing unit
to ensure that you do not cause any damage to the press during the troubleshooting process.
5. If a plate is damaged or if there is a plate inside the printing unit, continue the trouble shooting procedure
as described in the section Aborting the automatic plate change.
6. If there are no more faults pending, proceed with the automatic functional sequence by pressing the
Production button.
The main drive first rotates several revolutions in order to initialize the tachometer. It is possible for a rear edge that
is not mounted to make a noise by hitting against the rollers. The main drive moves forward to the position "Mount rear
edge of plate". The plate is mounted.
Check whether all rear edges have been clamped correctly. To do so, inch the press forward.
Tab. 5 Troubleshooting after reestablishing the power supply
5.3 Momentary triggering of the finger protecting bar
Error message: "General malfunction: automatic plate change"
Problem Possible cause Remedy
Finger protecting bar was triggered The finger protecting bar was trig- See table below
momentarily. The finger protecting gered momentarily by the rear edge of
bar is currently not triggered any- plate because the rear edge of plate
more. was not clamped.
Tab. 6 Error message "General malfunction: automatic plate change"
Remedy
1. Open the log window on the control station.
2. You can see in the list in which printing unit (location) the malfunction was triggered.
3. Open the cylinder guard on this printing unit.
4. Inch the press forward until the rear edge of plate is positioned above the pressing roller.
5. Inch the press backward while keeping the plate under light tension.
6. Inch the press backward until the clamping bar becomes visible.
B.7.18 SC.999.0020/01
Plate changer
Remedy
7. Open the clamping bar and remove the printing plate.
8. Close the clamping device and the protective devices.
Tab. 7 Error message "General malfunction: automatic plate change"
5.4 Interruption of the automatic plate change due to a time-out
No error message, automatic plate change is interrupted.
Problem Possible cause Remedy
The time allowed for an operation The plate adjustment at the front edge Continue the plate changing process
within the plate changing process was takes longer. by pressing the Production button.
exceeded.
Tab. 8 Error message "General malfunction: automatic plate change"
5.5 Brief lifting of the deflector plate on the delivery
Error message: "General malfunction: automatic plate change"
Problem Possible cause Remedy
The deflector plate at the delivery was The printer inadvertently lifted the de- Continue the plate changing process
briefly lifted. flector plate. by pressing the Production button.
Currently, the deflector plate is folded
back down.
Tab. 9 Error message "General malfunction: automatic plate change"
SC.999.0020/01 B.7.19
Plate changer
6 Error before the start of the plate change
SG.901.6214-000UTKENU_01
6.1 Error: Plate change cannot be started
The Setup processes with main drive button in the
SG.450.0101-006GRAUND_00
Plate change menu cannot be selected. The condi-
tions are checked by various sensors on the plate
changer before the plate changing process is started.
Potential malfunctions are displayed on the control
8
1 station.
2 ● The "Ink fountain disengaged" sensor (Fig. 21/1)
● The "Ink fountain not locked into place" sensor
(Fig. 21/2)
● The "Plate ready for loading" sensor (Fig. 21/3)
7
● Cylinder guard (Fig. 21/4)
6 ● Roller guard (Fig. 21/7)
● Ejection compartment (Fig. 21/8)
4
3
Fig. 21 Plate changer in basic position
Error message: A corresponding error message on the missing start condition is issued.
In the Plate change menu the button Setup processes with main drive is gray and cannot be selected.
Troubleshooting procedure
Eliminate the malfunction in accordance with the potential cause listed in the following.
Problem Possible cause Remedy
Plate change unable to be started. Ink fountain disengaged. Grasp the ink fountain by the handles
and close it until it is in its lock-in po-
sition.
Never engage the ink fountain to the
ink fountain roller without ink fountain
liner!
Plate(s) of a previous job are still in Remove plate(s) from ejection com-
the ejection compartment (Fig. 21/8). partment.
The plate (Fig. 21/3) is not ready for Remove the plate and check for dam-
loading. age. Insert the printing plate again
ready for loading.
If the plate is ready for loading, the
LED on the Positioning button is on. If
the LED on the button is not on, re-
move the plate and mount it manually.
Printing unit not preselected for Re- Preselect Remove or Mount.
move or Mount.
B.7.20 SC.999.0020/01
Plate changer
Error message: A corresponding error message on the missing start condition is issued.
In the Plate change menu the button Setup processes with main drive is gray and cannot be selected.
The automatic plate changing pro-
cess can only be started if at least one
PU has been selected.
Press not ready, main drive blocked. Close guard, release Emergency stop
(Open guard, Emergency stop button button, deselect control panels, re-
triggered etc.) lease detection of whole body access
etc.
The corresponding faults are signaled
on the printing unit and the control
station.
Electrical flag for clamp status in a If the trailing clamp is manually
printing unit set. clamped, release the clamp.
Reset electrical flag for manually-
clamped clamp (printing unit control
panel).
Sheets are still in the press/delivery. Rotate the press until all the sheets
have been delivered.
Cylinder guard (Fig. 21/4) not in end Move the cylinder guard downward.
position or coupling of the guards not Acknowledge the malfunction. Check
in basic position (check, index bolt the correct movement of the cylinder
malfunction) guard.
Plate clamping status not correct. Remove/mount plate in manual
mode.
The deflector plate on the delivery is Release the block.
not folded down. Heidelberg Service is required if this
occurs repeatedly.
If there are no more faults pending, proceed with the automatic functional sequence by pressing the Production
button.
Tab. 10 Plate change unable to be started.
SC.999.0020/01 B.7.21
Plate changer
7 Malfunctions when removing the plate
SG.901.6215-000UTKENU_00
7.1 Error message: "Malfunction: Plate rear edge sensor, PU x"
During the removal procedure the rear edge of plate
SG.450.0101-002GRAUND_00
(Fig. 22/1) is monitored by various sensors (Fig. 22/3,
4, 5). Malfunctions during the removal procedure are
detected by the respective sensors and displayed on
the control station.
1 Rear edge of plate
2 2 The "Printing plate end position" sensor
3 The "Plate buckled" sensor
3
4 Clamp (rear edge of plate)
5 The "Rear edge of plate released" sensor
1
6 5
Fig. 22 Removing the plate
Error message: "Malfunction: Plate rear edge sensor, PU x"
Troubleshooting procedure
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Check on which printing unit which malfunction occurs.
3. Open the cylinder guard.
4. Eliminate the malfunction in accordance with the potential cause listed in the following.
Problem Possible cause Remedy
Rear edge of plate (Fig. 22/1) is not The rear edge of the plate was Close the clamp. Release the me-
detected. clamped manually without setting the chanical clamping mechanism. Open
electronic flag. Rear edge of plate is the clamp.
still in the clamp (Fig. 22/4). The mechanical clamp bolts may only
be released when the clamp is
closed!
The plate is not released sufficiently Manually release the plate from the
from the opened clamp (Fig. 22/4). clamp.
This can be caused by damage or Clean clamp regularly.
soiling, for example.
No plate on the cylinder. Resume the automatic sequence as
described under step 6.
Sensor (Fig. 22/5) fails to detect the Clean the sensor (Fig. 22/5) in the
printing plate, even though the re- Ejection compartment guiding de-
moval procedure is executed correct- vice.
ly.
B.7.22 SC.999.0020/01
Plate changer
Error message: "Malfunction: Plate rear edge sensor, PU x"
Notify Heidelberg Service if this oc-
curs again.
Clamp (Fig. 22/4) does not open. Technical defect, such as defective Heidelberg Service required.
valve or rotary union. It is no longer possible to perform a
plate change on this printing unit.
5. After clearing the fault, the rear edge of plate should be released and positioned above the pressing roll.
6. Close the cylinder guard.
7. If there are no more faults pending, proceed with the automatic functional sequence by pressing the Production
button.
Tab. 11 Error message: "Malfunction: Plate rear edge sensor, PU x"
7.2 The error message "Malfunction: Plate ejection, printing plate end position"
SG.450.0101-004GRAUND_00 After the rear edge of plate (Fig. 23/1) has been re-
leased by the clamp (Fig. 23/7), the printing plate is
1
inserted in the ejection compartment (Fig. 23/2). The
transport of the printing plate inside the ejection com-
2 partment (Fig. 23/2) is monitored by various sensors
3 (Fig. 23/3, 5, 9). Malfunctions during the removal pro-
cedure are detected by the respective sensors and
4 displayed on the control station.
5 1 Rear edge of plate
11
2 Ejection compartment
10 3 The "Printing plate end position" sensor
4 Transport rollers / counter-rollers
6 5 The "Plate buckled" sensor
9 7
6 Clamping bar (lead edge of plate)
7 Clamp (rear edge of plate)
8 Finger guard spindle
8 9 The "Rear edge of plate released" sensor
10 Cylinder guard
11 Roller guard
Fig. 23 Ejecting the plate
Error message: "Malfunction: Ejection, plate not in end position (remove plate)"
Troubleshooting procedure
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Check on which printing units the error occurs.
3. Eliminate the malfunction in accordance with the potential cause listed in the following.
Problem Possible cause Remedy
Lead edge of plate (Fig. 23/1) is not The lead edge of plate (Fig. 23/1) is Try to remove the plate from the print-
removed correctly. not released because the clamping ing unit by lightly pulling at the rear
bar is soiled. edge of the plate.
SC.999.0020/01 B.7.23
Plate changer
Error message: "Malfunction: Ejection, plate not in end position (remove plate)"
The lead edge of plate (Fig. 23/1) is Try to remove the plate from the print-
not released because the lead edge of ing unit by lightly pulling at the rear
plate is damaged. edge of the plate.Pay attention to the
plate properties.
Transport rollers/counter-rollers Try to remove the plate from the print-
(Fig. 23/4) in the ejection compart- ing unit by lightly pulling at the rear
ment do not transport the plate. edge of the plate.Clean the transport
rollers/counter-rollers.
Notify Heidelberg Service if this oc-
curs again.
Plate buckled in the ejection compart- Open the roller guard (Fig. 23/11) on
ment (Fig. 23/2), end of the plate not the delivery side and remove the
visible. plate manually.
Rear edge of plate was clamped The rear edge of plate was clamped Remove the plate manually, close the
again after initiating the plate chang- again or fixed in place using adhesive clamping bar, close the guard.
ing procedure. tape in order to inch the press back-
ward in a controlled fashion.
4. If it is not possible to simply remove the printing plate and resume the automatic plate changing process, continue
the troubleshooting procedure as described under Aborting the automatic plate change.
5. Open the cylinder guard and check the printing unit. Close the clamping bar and the cylinder guard.
6. If there are no more faults pending, proceed with the automatic functional sequence by pressing the Production
button.
Tab. 12 Error message "Malfunction: Printing plate ejection, printing plate end position"
7.3 Error message "Malfunction: Printing plate ejection in PU x"
After the rear edge of plate (Fig. 24/1) has been re-
SG.450.0101-003GRAUND_00
leased by the clamp (Fig. 24/6), the printing plate is
inserted in the ejection compartment (Fig. 24/2). The
2 transport of the printing plate inside the ejection com-
partment (Fig. 24/2) is monitored by various sensors
(Fig. 24/3, 5, 10). Malfunctions during the removal pro-
3 cedure are detected by the respective sensors and
1 4 displayed on the control station.
5 1 Rear edge of plate
11 2 Ejection compartment
3 The "Printing plate end position" sensor
6 4 Transport rollers / counter-rollers
10
7 5 The "Plate buckled" sensor
6 Clamp (rear edge of plate)
7 Clamping bar (front edge of plate)
9 8 Finger guard spindle
8 9 Cylinder guard
10 The "Rear edge of plate released" sensor
11 Roller guard
Fig. 24 Ejecting the plate
B.7.24 SC.999.0020/01
Plate changer
Error message: "Malfunction: Printing plate ejection"
Troubleshooting procedure
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Check on which printing units the error occurs.
3. Eliminate the malfunction in accordance with the potential cause listed in the following.
Problem Possible cause Remedy
Sensor in the upper guard does not Plate does not touch the sensor. Pull out the plate manually. Close the
detect the plate. clamping bar.
Sensor does not detect the plate be- Pull out the plate manually. Clean the
cause it is soiled or defective. sensor in the ejection compartment.
Close the clamping bar.
Notify Heidelberg Service if this oc-
curs again.
4. If there are no more faults pending, proceed with the automatic functional sequence by pressing the Production
button.
Problem Possible cause Remedy
Plate is not fully ejected. A deformed plate is jammed in the Pull out the plate manually. Pay at-
guide elements. tention to the printing plate proper-
ties.
Damaged guide element blocks the Try to clear the blockage without hav-
plate. ing to open the roller guard. Once you
have cleared the blockage, you can
resume the automatic plate changing
process by pressing the Production
button. If it is not possible to clear the
blockage, see 6.
Notify Heidelberg Service if this oc-
curs again.
5. Remove all printing plates you are able to remove from the loading / ejection compartment without inching.
6. Abort the automatic plate changing procedure on the control station by pressing the Abort automatic plate
change button. Check whether a safety device has tripped or not and accordingly select the procedure no safety
device tripped, inching mode possible or safety device tripped, no inching mode possible, turn the press
forward using the crank handle to clear the fault.
Tab. 13 Error message: "Malfunction: Printing plate ejection"
7.4 Aborting the automatic plate changing procedure
No safety device tripped, inching mode possible
Troubleshooting procedure
1. Go to the Plate change menu and select the Status display submenu.Press the Abort the automatic
plate change button. Now you need to remove all plates that can be removed by hand one after the other.
If necessary, close the clamping bar. The printing unit control panels are now enabled for inching and
opening the protective devices on the delivery side. A safety prompt (pop-up) appears: "Caution! You
could trigger press movements that may damage the press."
2. Acknowledge this safety prompt and perform the following steps with great care.
3. In the Status display menu, the Remove plate manually, PU x,y,z entry appears.
SC.999.0020/01 B.7.25
Plate changer
No safety device tripped, inching mode possible
Troubleshooting procedure
4. The roller guard opens (Fig. 24/11) on those printing units on which the printing plate is already inside the
roller guard (Fig. 24/11).
5. On all other printing units, the cylinder guard (Fig. 24/9) needs to be fully opened.
6. Check whether the fault can be cleared simply by inching backward. If this does not work, continue with
(Tab. 15/3).
7. Start with the printing unit on which the printing plate has been pushed out the furthest. Inch the press
backward while keeping the plate under light tension.
8. Inch the press backward until the clamping bar (Fig. 24/7) just becomes visible.
9. Open the clamping bar (Fig. 24/7) and remove the printing plate.
10. Close the clamping bar (Fig. 24/7) and the protective devices (Fig. 24/9, 11).
11. Repeat the procedure (7-10) until all printing plates listed in the status display have been removed.
12. If there are no more faults pending, stop the automatic functional sequence by pressing the Production
button.
Tab. 14
Troubleshooting measures if inching mode is no
longer possible
Note
SG.450.0130-000GRAUND_00
When fixing the rear edge of plate, en-
sure that the press is subsequently
turned backward. The printing plate
must not work loose in an uncontrolled
manner. To prevent this, use a corre-
spondingly strong assembly tape.
2 1 Rear edge of plate
2 Adhesive tape
Fig. 25 Fixing the rear edge of plate with adhesive
tape
B.7.26 SC.999.0020/01
Plate changer
1 Rear edge of plate
SG.450.0131-000GRAUND_00
2 Adhesive tape
Fig. 26 Fixing the rear edge of plate with adhesive
tape
Safety device tripped, no inching mode possible, inch the press forward with the crank handle.
Troubleshooting procedure
1. Go to the Plate change menu and select the Status display submenu.Press the Abort the automatic
plate change button. Now you need to remove all plates that can be removed by hand one after the other.
If necessary, close the clamping bar. The printing unit control panels are now enabled for inching and
opening the protective devices on the delivery side. A safety prompt (pop-up) appears: "Caution! You
could trigger press movements that may damage the press."
2. Turn the press forward with the crank handle until the safety device is free again. Remove the crank
handle.
3. Inch the press forward until all plates are outside the guide devices.
4. Open the cylinder guards.
5. Use adhesive tape to fix all rear plate edges which are no longer held by the clamp. The sequence is
random here. Proceed as follows:
6. If necessary, clean the rear edge of plate to make the adhesive tape hold.
7. Fix the rear edge of plate as shown in Fig. 25 and inch the press forward until the adhesive tape is
wrapped once around the plate (Fig. 26). Stick the adhesive tape on top of itself and cut it off. In this way,
fix both the outer sides of the plate as well as the center of the plate.
8. After all rear plate edges are fixed in place you can remove the plates one after other by inching the press
backward. Proceed as follows:
9. Inch the press forward until the rear edge of plate becomes visible.
10. Detach the rear edge by cutting through the adhesive tape, for example. Inch the press backward while
keeping the plate under light tension.
11. Inch the press backward until the clamping bar just becomes visible.
12. Open the clamping bar and remove the plate.
13. Close the clamping bar and the protective device (Fig. 24/9, 10).
SC.999.0020/01 B.7.27
Plate changer
Safety device tripped, no inching mode possible, inch the press forward with the crank handle.
Troubleshooting procedure
14. Repeat the procedure (9-13) until all plates have been removed.
15. If there are no more faults pending, stop the procedure by pressing the Production button.
Tab. 15
B.7.28 SC.999.0020/01
Plate changer
8 Malfunctions in data transmission
SG.901.6219-000UTKENU_00
8.1 Error message: "Fault on data transmission sensor - Remove plate in PU x"
Error message: "Fault on data transmission sensor - Remove plate in PU x".
Troubleshooting procedure
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Check on which printing unit which malfunction occurs.
3. Eliminate the malfunction in accordance with the potential causes listed in the following.
Problem Possible cause Remedy
Plate position detection module Technical defect, e.g. transmission Mount the plate manually.
(PRM) cannot be initialized. system defective. Automatic mounting is no longer pos-
sible.
Heidelberg Service required.
4. Remove the plate from the compartment.
5. Close the clamping bar.
6. Check on the control station whether there are more malfunctions. If there are, repeat steps 4 to 6. You have to
remove all plates which cannot be mounted automatically.
7. If there are no more faults pending, proceed with the automatic functional sequence by pressing the Production
button. (The blue LED remains lit up as long as the press is performing an automatic functional sequence.)
8. Mount the removed plates manually.
Tab. 16 Error message: "Data transmission sensor - Remove plate on PU x"
SC.999.0020/01 B.7.29
Plate changer
9 Plate loading faults
SG.901.6216-000UTKENU_00
9.1 Error message: "Malfunction: Front edge sensor D.S./O.S. - Remove plate PU x"
The mounting procedure is monitored by various sen-
SG.450.0101-005GRAUND_00
sors. Malfunctions during the mounting procedure are
detected by the sensors and displayed on the control
station.
1 Front edge sensor
2 Clamping bar
Fig. 27 Mounting a printing plate
Error message: "Malfunction: Front edge sensor D.S. / O.S. - Remove plate"
Troubleshooting procedure
1. At the control station, go to the Plate change menu and select the Status display submenu.
2. Check on which printing unit which malfunction occurs.
3. Eliminate the malfunction in accordance with the potential cause listed in the following.
Problem Possible cause Remedy
Lead edge of plate is not detected. Front edge sensor soiled. Press against the rear edge of plate.
If the clamping bar fails to close au-
tomatically after pressing onto the
rear edge of plate, remove the print-
ing plate and close the clamping bar
manually.
If this occurs repeatedly, clean the
front edge sensor (see maintenance
manual)
Deformation of the printing plate at the Remove the printing plate. Do not use
front edge, e.g. bent corner, bent reg- damaged printing plates. Close the
ister punching. clamping bar manually.
Polyester plate provided. Remove the polyester plates. Close
the clamping bar manually. Mount the
polyester plates manually.
B.7.30 SC.999.0020/01
Plate changer
Error message: "Malfunction: Front edge sensor D.S. / O.S. - Remove plate"
Technical defect. e.g. defective front Remove the plate. Close the clamp-
edge sensor, clamping bar does not ing bar manually. Manually mount the
open. plates. Notify Heidelberg Service if
this occurs again.
4. If there are no more faults pending, proceed with the automatic functional sequence by pressing the Production
button.
5. Mount the removed printing plates manually.
Tab. 17 Error message: "Malfunction: Front edge sensor D.S. / O.S. - Remove plate"
SC.999.0020/01 B.7.31
Plate changer
B.7.32 SC.999.0020/01
Inking unit
Inking unit
unit
Inking
1 Inking unit - safety instructions ........................................................................................... B.8.3
1.1 To be observed when performing work .......................................................................... B.8.3
2 Manual adjustment of the lateral distribution .................................................................... B.8.5
2.1 General notes ................................................................................................................ B.8.5
2.2 Changing the distribution travel .................................................................................... B.8.5
2.3 Changing the start of distribution .................................................................................. B.8.6
2.4 Lateral clearance of the inking form rollers ................................................................... B.8.8
3 Inking unit temperature control ........................................................................................... B.8.9
3.1 Method of functioning ..................................................................................................... B.8.9
3.2 Regulating the flow rate at the ink fountain roller .......................................................... B.8.9
4 Removing and installing the inking rollers ......................................................................... B.8.11
4.1 Roller diagram ............................................................................................................... B.8.11
4.2 Overview and concise instructions ................................................................................ B.8.12
4.3 Preparations for the removal of the inking rollers ......................................................... B.8.16
4.4 Removing the inking rollers ........................................................................................... B.8.18
4.5 Installing and adjusting the inking rollers ...................................................................... B.8.22
4.6 Adjusting the inking form roller relative to the plate ....................................................... B.8.30
4.7 Final steps of inking roller installation ............................................................................ B.8.30
5 Template for roller adjustment ............................................................................................ B.8.33
5.1 Template - overview ....................................................................................................... B.8.33
5.2 How do you correct the contact area? ........................................................................... B.8.35
6 Removing and installing the ink vibrator ............................................................................ B.8.36
6.1 Removing the ink vibrator ............................................................................................. B.8.36
6.2 Installing and adjusting the ink vibrator ......................................................................... B.8.36
7 Selecting, servicing and storing inking rollers ................................................................... B.8.38
7.1 Selecting correct inking rollers ....................................................................................... B.8.38
7.2 Servicing and storing inking rollers ................................................................................ B.8.38
7.3 Detaching ball bearings from roller cores ...................................................................... B.8.39
7.4 Mounting ball bearings onto roller cores ........................................................................ B.8.40
8 Ink fountain ............................................................................................................................. B.8.41
8.1 Retightening and replacing the ink fountain liner .......................................................... B.8.41
8.2 Replacing the protective film over the metering elements ............................................. B.8.43
8.3 Cleaning the drip pan ..................................................................................................... B.8.45
8.4 Removing the drip pan for cleaning purposes ............................................................... B.8.45
8.5 Ink agitation system ....................................................................................................... B.8.45
SC.999.0020/01 B.8.1
Inking unit
9 Autoprotect - automatic application of roller protective agent ........................................ B.8.47
9.1 General .......................................................................................................................... B.8.47
9.2 System components ...................................................................................................... B.8.48
9.3 Changing canister ......................................................................................................... B.8.49
9.4 Commissioning ............................................................................................................. B.8.51
9.5 Preselecting the "Apply roller protective agent" operating mode .................................. B.8.51
9.6 Cleaning the inking rollers ............................................................................................. B.8.51
10 Ink mist suction removal ...................................................................................................... B.8.52
10.1 General .......................................................................................................................... B.8.52
10.2 Replacing the filtering mat ............................................................................................. B.8.53
B.8.2 SC.999.0020/01
Inking unit
1 Inking unit - safety instructions
SF.901.5500-000UTKENU_01
1.1 To be observed when performing work
Warning - Risk of injury from rotat-
ing rollers and cylinders!
When cleaning the rollers and cylin-
ders, the ball of your thumb must point
in the direction of the infeed gap and
your fingers in the direction of the out-
let gap. Select the corresponding di-
rection of rotation.
Warning - Risk of injury from rotat-
ing ink fountain roller!
Be careful with the rotating ink fountain
roller when working on the ink fountain
when it is engaged or swung down.
Clean the swung-down ink fountain
only when the ink fountain roller is at
standstill.
Warning - Risk of injury from rotat-
ing ink fountain roller!
Prior to removing or installing the ink
vibrator you must switch off the rota-
tion of the ink fountain roller (hit the
Emergency stop button on the printing
unit, for example).
Warning - Risk of injury from rotat-
ing parts!
There is a risk of injury when the guard
in front of the lateral distribution is
open. Close and lock the guard after
you have made your adjustments.
Warning - Risk of cutting on sharp
doctor blades!
Proceed with the utmost caution and
great care when removing and fitting
the blade equipment (e.g. chambered
blades, washup blades, blade holders)
and when changing the doctor blades.
Wear cut-resistant protective gloves
for all work on the blade equipment.
Only transport the blade equipment in
safe places and with the protective
bars on the doctor blade. Always take
other people into consideration when
handling the blade equipment.
SC.999.0020/01 B.8.3
Inking unit
Warning - Risk of injury from falling
screen roller!
Use the lifting device provided and a
crane. Also watch other persons dur-
ing installation and removal. Standing
or walking under suspended loads is
strictly forbidden.
Caution - Damage caused by incor-
rect cleaners!
Never use cleaners (e.g. "paint strip-
pers") containing dichloromethane
(methylene chloride), trichloroethy-
lene or other chlorinated or halo-
genated carbon hydrides. These
washing fluids damage press compo-
nents, cylinder surfaces, rollers, and
blankets.
B.8.4 SC.999.0020/01
Inking unit
2 Manual adjustment of the lateral distribution
SG.901.0802-000UTKENU_08
2.1 General notes
This section describes the manual adjustment of the
lateral distribution. This section only applies to ma-
chines without distributor roller remote control.
If your press features distributor roller remote control,
you can alter the settings directly on the control station.
The following can be set manually:
● The travel of the lateral distribution.
The displacement is not more than 35 mm. The
maximum setting is suitable for most jobs since
this grants the best distribution of ink in the inking
unit. For certain applications (such as several
inks in the ink fountain or greatly varying ink trap-
ping across the sheet width), it can be useful to
reduce the distributor roller travel or set it to zero.
● Timing of the lateral distribution.
Due to the movements of the vibrator roller and
other effects, a periodically recurring slight accu-
mulation of ink builds up in the inking unit. It is
printed with every sheet. Normally it is not visible,
but in sensitive print objects it may have an un-
desired effect. By changing the timing of the dis-
tributor roller, the position of the ink accumulation
can be shifted to an insensitive area.
2.2 Changing the distribution travel
The pin used for the adjustment is located behind a
SG.901.0855-002GRAUND_00
3 protecting cover in the D.S. side frame of the printing
unit.
2
1. Control panel selection: Press the Control panel
selection button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
2. Open the protecting cover.
3. The screw (Fig. 1/1) at the center of the pin has a
punched mark. Inch the press until the mark is
vertical to the imaginary axis and passes through
the joint rod (Fig. 1/2) as shown in the figure.
4. Slacken the locking nut (Fig. 1/3).
5. The entire hinge bolt can be slid up or down when
the printing press is positioned correctly.
● Sliding it up to the center of the graduated
disc: distribution travel is zero.
● Sliding it down to the edge: maximum dis-
tribution travel (35 mm).
1
Intermediate positions are possible.
6. Tighten the locking nut when the desired position
is reached. To do so, use the suitable T-wrench in
the press tool kit.
Fig. 1 Adjusting the distribution travel
SC.999.0020/01 B.8.5
Inking unit
7. Close the protecting cover.
8. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
2.3 Changing the start of distribution
The timing of the distributor roller is adjusted at the
SG.901.0655-003GRAUND_00
1
2 same hinge bolt as the distribution travel (protecting
cover in the D.S. side frame of the printing unit).
The scale below the hinge bolt (Fig. 2) is divided into
one white and one black section. Each section is num-
bered from 0 through 710. The sections are marked
with one white (Fig. 2/2) and one black arrow (Fig. 2/1).
The pin (Fig. 3/2) is positioned off-center and conceals
the scale at one point. This value is the timing of the
distributor roller. In Fig. 3, for instance, it is at
white 100.
The numerical value 100 does not indicate the position
of the accumulation of ink on the printed sheet. With
different subjects, the location of the ink accumulation
is at different positions.
1
Fig. 2 Scale for the start of distribution
Changing the timing of the distributor roller
SG.901.0662-002GRAUND_00
1. Control panel selection: Press the Control panel
selection button twice (with no more than 0.5 sec-
1 onds between presses). The LED lights up.
2. Open the protecting cover.
3. Inch the press until the hinge bolt (Fig. 3/1) is in its
lowest position.
4. Open the cover on D.S.
5. Slacken the lock nut (Fig. 3/2).
6. Inch the press to the desired new position. The
number concealed by the pin indicates the cur-
rent timing of the distributor roller.
7. Tighten the lock nut. To do so, use the suitable T-
wrench in the press tool kit.
8. Close the protecting cover.
9. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
2
no more than 0.5 seconds). The LED goes out.
Fig. 3 Adjusting the start of distribution
B.8.6 SC.999.0020/01
Inking unit
Examples of application
SG.901.0818-000GRAENU_00
The ex factory setting of the start of distribution is at
black 710. This setting is the correct one for most print
Position white 0
Ink coverage in % subjects. As described above, however, it can be use-
ful to shift the ink accumulation on the printed sheet for
Tail edge 97 certain sensitive motifs.
98
99 Example
There is a slight accumulation of ink in the center of a
100 print subject at the white 0 position.
99
98
First line of print 97
Fig. 4 Start of distribution at white 0
If the lateral distribution is set to white 200, the lateral
SG.901.0819-000GRAENU_00
distribution moves to the tail edge of print by around
200 mm.
Position white 200
Ink coverage in %
Rear edge 99
100
99
99
98
98
First line of print 97
Fig. 5 Start of distribution at white 200
SC.999.0020/01 B.8.7
Inking unit
If the lateral distribution is set to white 500, the ink ac-
SG.901.0820-000GRAENU_00
cumulation moves further by approximately 500 mm. It
then appears nearer to the front edge.
Position white 500
Ink coverage in % The drive on the lateral distribution is designed for half-
revolution. With one revolution of the plate cylinder,
Tail edge 97 the distributor rollers move from one side to the other.
97 With the second revolution they move back to the initial
98 position.
When changing over from a black figure to the same
99 white figure, the direction of the start of distribution is
99 reversed. The distributor moves from O.S. to D.S. in-
100 stead of from D.S. to O.S.
First line of print 99
Fig. 6 Start of distribution at white 500
2.4 Lateral clearance of the inking form rollers
Loosening the roller locks gives the rollers some lat-
SG.901.0842-003GRAUND_00
eral clearance. This enables you to counteract ghost-
ing problems.
2
Closer adjustment
1 1. Open the printing unit guard O.S.
2. Release the Allen screw (Fig. 7/1).
3. Pull out the knurled screw (Fig. 7/2) up to the
stop.
4. Tighten the Allen screw (Fig. 7/1).
Fig. 7 Loosening the roller locks
B.8.8 SC.999.0020/01
Inking unit
3 Inking unit temperature control
SG.901.1512-000UTKENU_04
3.1 Method of functioning
On presses with inking unit temperature control, the
SG.901.0849-000GRAUND_00
temperature of the ink fountain roller and ink distribu-
tors A, D, and C is controlled. During production, they
are usually cooled in order to counteract the temper-
ature rise in the inking unit. In this way the temperature
A
is kept at a constant level in the inking unit. Tempera-
ture control prevents that the viscosity of the ink varies.
D
C
Fig. 8 Inking unit
3.2 Regulating the flow rate at the ink fountain roller
When you open the printing unit guard on O.S.
SG.901.0850-003GRAUND_00
(Fig. 9/1), you will see the distributor for the tempera-
ture control fluid in the top right corner. On the distrib-
utor, there is the valve that regulates the flow rate
(Fig. 10/1). Use a screwdriver to adjust the valve.
1 Note
If the cooling is too severe due to the flow
rate being too great, condensation can
form on the ink fountain roller in condi-
tions of high humidity.
Fig. 9 Printing unit guard on O.S.
SC.999.0020/01 B.8.9
Inking unit
Use the following procedure to regulate the flow rate:
SG.901.0851-003GRAUND_00
1 1. Press the Control panel selection button twice.
2. Open the printing unit guard on O.S. (Fig. 9/1).
3. Use a screwdriver for slotted heads to regulate
the flow rate at the distributor:
● Screw slot (Fig. 10/1) in horizontal position:
maximum flow rate
● Screw slot (Fig. 10/1) in vertical position: no
temperature control takes place.
4. Close the printing unit guard.
5. Press the Control panel selection button twice.
Fig. 10 Regulating the flow rate
B.8.10 SC.999.0020/01
Inking unit
4 Removing and installing the inking rollers
SG.901.1500-000UTKENU_15
4.1 Roller diagram
SG.901.1500-006GRAUND_00
15
A 12
11
7
B
5
8
6 4
9 10
D 3
C
2 1
13
14
17
ZW
19
DW
16
FEAW
18
T
FR
Fig. 11 Roller diagram
Note
The roller designations 1 ...19 (remov-
able) and A ...D, FR (not removable) are
used repeatedly in the Inking unit and
Dampening system chapters. The
numbers 1 ...19 are binding for the in-
stallation sequence! The rollers FR and
16 ...19 are described in the "Dampening
system" chapter.
SC.999.0020/01 B.8.11
Inking unit
Fig. 11 Designation ø Color code Material / Remark
1 2nd inking form roller 72 mm blue rubber-coated
2 3rd inking form roller 66 mm red rubber-coated
3 Ink transfer roller 56 mm - plastic-coated
4 Ink transfer roller 80 mm yellow rubber-coated
5 Ink transfer roller 68 mm - plastic-coated
6 Ink transfer roller 72 mm blue rubber-coated
7 Ink transfer roller 56 mm - plastic-coated
8 Ink transfer roller 60 mm white rubber-coated
9 Ink transfer roller 66 mm red rubber-coated
10 Ink transfer roller 56 mm - plastic-coated
11 Ink transfer roller 80 mm yellow rubber-coated
12 Ink transfer roller 68 mm - plastic-coated
13 4th inking form roller 80 mm yellow rubber-coated
14 1st inking form roller 60 mm white rubber-coated
15 Ink vibrator 59 mm - rubber-coated
16/FEAW Dampening form roller 78 mm - rubber-coated
17/ZW Intermediate roller 56 mm - plastic-coated
18/T Water pan roller 108 mm - rubber-coated, crowned
19/DW Metering roller 98 mm - Stainless steel
A Ink distributor roller 85 mm - plastic-coated
B Ink distributor roller 85 mm - plastic-coated
C Ink distributor roller 85 mm - plastic-coated
D Ink distributor roller 85 mm - plastic-coated
FR Dampening distributor 85 mm - Chromium-plated
Tab. 1
4.2 Overview and concise instructions
If you are skilled in changing inking rollers, the follow-
ing diagrams show you the order in which sequence
the rollers must be removed and installed and how the
inking rollers are to be adjusted. You can find detailed
instructions in the sections "Removing inking rollers"
and "Installing and adjusting inking rollers".
Marker rings on the adjusting elements of the ink form
rollers and dampening form rollers facilitate the ad-
justment. The color allocation corresponds to the color
of the roller journals and/or the roller locks.
Adjusting element for Color
1st inking form roller white
2nd inking form roller blue
B.8.12 SC.999.0020/01
Inking unit
Adjusting element for Color
3rd inking form roller red
4th inking form roller yellow
Dampening form roller green
Tab. 2
All adjusting elements for roller adjustment are
SG.901.5564-000GRAUND_00
equipped with a hexagon socket (6 mm). Use the T-
wrench (Fig. 12) included in the press tool set for ad-
justment.
Removing the inking rollers
Tip
Fig. 12 T-wrench Mount a printing plate prior to removing
and fitting the inking rollers to prevent
damage on the plate cylinder.
Note
The rollers of the dampening system
16 ...19 must have been removed. All
parts are removed in the same way, fol-
lowing the same installation instructions
but in the reverse order!
1. Open the form roller locks.
2. Turn the adjusting screws two revolutions to dis-
engage the inking form rollers 13, 2, 1 and 14
from the ink distributors.
3. Remove the rollers 13, 8, 7, 6, 5, 4, 3, 2 and 1.
4. Remove the rollers 14, 12, 11, 10 and 9.
Width of contact area
SG.901.0870-000GRAUND_00
Note
Display of the setting values for the ink
stripe width:
4 +1 mm = The setting value is 4 mm.
You may exceed this setting value by
1 mm. However, you must not set any
value lower than 4 mm.
4 ±0,5 mm = The setting value is 4 mm.
You may deviate 0.5 mm above or below
this setting value.
4 -1 mm = The setting value is 4 mm.
You may set a value 1 mm below the
Fig. 13 Ink stripe width setting value. However, you must not set
any value greater than 4 mm.
SC.999.0020/01 B.8.13
Inking unit
Please use your ink stripe card for roller adjustment
SG.901.0871-001GRAUND_00
1 (Fig. 14) to measure the ink stripe width. The distance
between the limitation lines (Fig. 14/1) specifies the
2 upper tolerance value. The wide strip (Fig. 14/3) spec-
ifies the lower tolerance value. The specified distance
4 0,5
5+2
2,5+1
5 -1
4+1
5+1
6+1
4-1
+ +
-
(Fig. 14/2) in mm is displayed between the respective
3 limitation lines.
Note
The following setting values refer to a
Fig. 14 Roller adjustment aid, ink stripe card press with inking and dampening system
rollers at working temperature (directly
after completing a print job). If the press
is cold, you should set the rollers to the
lower limit of the tolerance range, since
the width of the contact area increases
when the rollers heat up.
Example: For a 4 ± 0.5 mm width of con-
tact area you should set the width of the
contact area to 3.5 mm.
From To Ink stripe width
Ink vibrator Ink fountain roller 4 ±0.5 mm
Ink vibrator Ink distributor A 5 +2 mm (for mechanical reasons)
Ink transfer roller, yellow Ink transfer roller 5 ±1 mm
Ink transfer roller, red Ink distributor B 4 ±1 mm
Ink transfer roller, red Ink transfer roller 4 ±1 mm
1st inking form roller, white Ink distributor C 4 +1 mm
2nd inking form roller, blue Ink distributor C 4 +1 mm
3rd inking form roller, red Ink distributor D 4 +1 mm
4th inking form roller, yellow Ink distributor D 4 +1 mm
1st inking form roller, white Printing plate 4 -1 mm
2nd inking form roller, blue Printing plate 4 -1 mm
3rd inking form roller, red Printing plate 4 -1 mm
4th inking form roller, yellow Printing plate 4 -1 mm
1st inking form roller, white Intermediate roller 3 +1 mm
Tab. 3
B.8.14 SC.999.0020/01
Inking unit
Installing and adjusting the inking rollers
SG.901.1534-006GRAUND_00
1. Grease the roller journals and journal boxes.
4 +0,5 mm
5 +2 mm
2. Install the rollers 1 ...8.
15 5 +1 mm
3. Install the red ink transfer roller 9. Use a paper or
mounting film strip (0.1 mm thick) to adjust it with
A 12 respect to ink distributor B.
11
4 +1 mm
4. Install ink transfer roller 10. Use a paper or
7 4 +1 mm mounting film strip (0.1 mm thick) to adjust it with
B
8
5 4 +1 mm respect to ink transfer roller 9.
6 4
9 10 5. Install the yellow ink transfer roller 11.
4 +1 mm D 3 6. Install ink transfer roller 12. Use a paper or
C
4 +1 mm 2 1 4 +1 mm
mounting film strip (0.1 mm thick) to adjust the
3 +1 mm
13
14 distance with respect to ink transfer roller 11.
4 -1 mm
17 7. Close the locks of rollers 13 and 14. The rollers
4 -1 mm 19 are not installed. Tighten the Allen screws.
16
4 -1 mm 4 -1 mm 8. Feed a bright ink, allow for even distribution and
18
stop the press.
FR
9. Adjust inking form rollers 1 (blue) and 2 (red) to
ink distributors C and D respectively. Ink stripe
width: 4 +1 mm.
10. Adjust the red ink transfer roller 9 to ink distributor
B. Ink stripe width: 4 ±1 mm.
Fig. 15 Installing the inking rollers
11. Adjust ink transfer roller 10 to the red ink transfer
roller 9. Ink stripe width: 4 ±1 mm.
12. Adjust ink transfer roller 12 to the yellow ink trans-
fer roller 11. Ink stripe width: 5 ±1 mm.
13. Install inking form rollers 13 (yellow) and 14
(white). Close the roller locks and tighten the
Allen screws.
14. Install the dampening system rollers.
15. Throw on the ink form rollers and dampening
form rollers. Engage intermediate roller 17.
16. Adjust inking form rollers 13 (yellow) and 14
(white) to ink distributors D and C respectively.
Ink stripe width: 4 +1 mm.
17. Adjust the inking form rollers with respect to the
plate. Ink stripe width: 4 -1 mm.
SC.999.0020/01 B.8.15
Inking unit
4.3 Preparations for the removal of the inking rollers
1. If your press is equipped with AutoPlate Pro:
SG.901.0471-002GRAUND_00
raise the roller guard (Fig. 16/1) of the plate
1
changer.
For presses without AutoPlate Pro: open the
printing unit guard (delivery side).
Fig. 16 AutoPlate Pro plate changer, roller guard in
maintenance position
2. Remove the blade trough (Fig. 17/2) to gain ac-
LS.901.4940-001GRAUND_00
cess to the inking rollers behind the inking roller
guard (Fig. 17/1).
2
1
Fig. 17 Inking roller guard and blade trough
B.8.16 SC.999.0020/01
Inking unit
3. Hold the inking roller guard on one of the two
LS.901.4307-002GRAUND_00
handles (Fig. 18/1), and swing it out of the print-
ing unit. The inking roller guard is secured in a
horizontal position. The front handle segment
hangs down.
Fig. 18 Handle on the inking roller guard
4. Swing the front handle segment (Fig. 19/1) to-
LS.901.6337-002GRAUND_00
ward the printing unit, beneath the horizontal ink-
ing roller guard. Magnets secure the front handle
segment in this position.
Now you have free access to the inking rollers.
Fig. 19 Handle on the inking roller guard, folded in
SC.999.0020/01 B.8.17
Inking unit
4.4 Removing the inking rollers
Engaging the inking form rollers
SG.901.1502-006GRAUND_00
1. On D.S. and on O.S. (Fig. 20/1), turn the adjust-
ing screws on the journal boxes of inking form
rollers 13 and 2, and 14 and 1 two revolutions to
the left. As a result, the rollers move away from
the ink distributor. They can be removed more
easily.
Fig. 20 Adjusting screws of the rollers 2 and 13 on
O.S.; roller 13 removed
2. Open the printing unit guard O.S.
SG.901.1501-006GRAUND_00
3. Remove the doctor blade.
3
4. To open the form roller locks, loosen the Allen
screws (Fig. 21/2).
5. Press the safety bushes (Fig. 21/1) inwards, and
2
1 pull out the knurled screws (Fig. 21/3) at the
same time.
6. Close the printing unit guard O.S.
Fig. 21 Roller locks from O.S.
Removing inking form roller 13 and ink transfer
SG.901.1503-006GRAUND_00
roller 8
7. Press the yellow inking form roller 13 (Fig. 22/1)
toward O.S. until the roller drops out of the journal
2
box on D.S.
8. Press the yellow inking form roller 13 toward D.S.
until the roller on O.S. drops out of the journal box
(Fig. 22/4).
9. Using both hands, roll out the yellow inking form
4 roller 13 (Fig. 22/1) over the guard (Fig. 22/3).
You need not remove the guard for this purpose.
10. Lift out the white ink transfer roller 8 (Fig. 22/2).
1
Fig. 22 Inking form roller 13 and ink transfer roller 8
B.8.18 SC.999.0020/01
Inking unit
Removing the ink transfer roller 7
SG.901.1504-007GRAUND_00
11. Remove ink transfer roller 7. To do this, press the
spring bolt (Fig. 23/1) on O.S. upwards. Remove
the roller on O.S. first.
Fig. 23 Spring bolt, ink transfer rollers 7 and 8 re-
moved
SG.901.1505-007GRAUND_00
Removing the blue ink transfer roller 6
12. Remove the blue ink transfer roller 6 (Fig. 24/1).
Fig. 24 Blue ink transfer roller 6
Removing the ink transfer roller 5
SG.901.1506-006GRAUND_00
13. Remove ink transfer roller 5 (Fig. 25/1).
Fig. 25 Ink transfer roller 5
SC.999.0020/01 B.8.19
Inking unit
Note
SG.901.1507-008GRAUND_00
To remove the rollers 4 ...1: Raise the
rollers from their installation position.
First insert the rollers into the recess
(clearance) in the side frame on D.S.
(Fig. 26/1). You can then remove the
rollers from the press more easily on
O.S.
Fig. 26 Free space above the spring bolt
SG.901.1508-006GRAUND_00
Removing the yellow ink transfer roller 4, ink
transfer roller 3, red inking form roller 2
14. Lift up the safety flaps (Fig. 27/1) and remove the
yellow ink transfer roller 4 (Fig. 27/2).
15. Remove ink transfer roller 3.
16. Push the red inking form roller 2 toward O.S.
17. Lift up the red inking form roller 2 on D.S. and
remove it.
1 2
Fig. 27 Safety flaps and yellow ink transfer roller 4
Removing the blue inking form roller 1
SG.901.1509-005GRAUND_00
18. Push the blue inking form roller 1 (Fig. 28/1) to-
ward O.S.
19. Lift up the blue inking form roller 1 on D.S. and
remove it.
Fig. 28 Blue inking form roller 1
B.8.20 SC.999.0020/01
Inking unit
Removing the white inking form roller 14
SG.901.1518-006GRAUND_00
You can access rollers 14, 12, 11, 10 and 9 from the
side of the printing unit facing the feeder.
20. Remove the metering and intermediate roller of
the dampening system. Please refer to the
"Dampening system" chapter.
21. Push the white inking form roller 14 (Fig. 29/1)
toward O.S. Pull the white inking form roller 14
out of the journal box on D.S. and lift it out.
Fig. 29 White inking form roller 14
SG.901.1510-007GRAUND_00 Removing the ink transfer roller 12
2 3 1 22. Loosen the adjusting screws (Fig. 30/2) and the
screw Fig. 30/3 on D.S. and on O.S. and swing off
the connecting link.
23. Remove ink transfer roller 12 (Fig. 30/1).
Fig. 30 Adjusting screws and ink transfer roller 12
Removing the yellow ink transfer roller 11
SG.901.1512-007GRAUND_00
24. Remove the yellow ink transfer roller 11
(Fig. 31/1).
Fig. 31 Yellow ink transfer roller 11
SC.999.0020/01 B.8.21
Inking unit
Removing ink transfer roller 10
SG.901.1513-006GRAUND_00
25. Loosen the adjusting screws (Fig. 32/1) and the
locking screw (Fig. 32/2) of the connecting link on
D.S. and on O.S., and swing off the connecting
3 link (Fig. 32/3).
4
2 26. Remove ink transfer roller 10 (Fig. 32/4).
Fig. 32 Adjusting screw and ink transfer roller 10
SG.901.1517-006GRAUND_00 Removing the red ink transfer roller 9
27. Remove the red ink transfer roller 9 (Fig. 33/1).
Fig. 33 Red ink transfer roller 9
4.5 Installing and adjusting the inking rollers
General notes
SG.901.1519-001GRAUND_00
Prior to installation, grease the roller journals and jour-
nal boxes.
The figures in the roller layout must be followed for the
installation sequence.
The following instructions always apply for adjusting
the inking rollers:
● Turning the adjusting screws clockwise in-
creased the pressure between the rollers.
● Turning the adjusting screws counterclockwise
decreased the pressure between the rollers.
Fig. 34 Roller journals
Using UV inks
Caution - Risk of press damage!
When using UV inks or for the alternate
processing of UV inks and conventional
inks, special roller types must be used.
Please note the roller manufacturer's
product information when using the
roller.
B.8.22 SC.999.0020/01
Inking unit
Using rollers for mixed operation
Tip
UV inks and conventional inks have a
different effect on the rollers in terms of
shrinkage and swelling. You should
therefore check the ink stripe width of the
rollers after changing the ink type.
To install the rollers 1 ...6: First insert the rollers into
the recess in the side frame on D.S. (Fig. 35/1). After
this, you can move the rollers to their installation po-
sition.
Insert the roller journals of inking form rollers 1, 2, 13,
and 14 into the journal boxes, first on O.S., then on
D.S. The corresponding roller lock must be open.
Installing inking form rollers 1 and 2 and ink trans-
SG.901.1520-005GRAUND_00 fer roller 3
1. Insert the blue inking form roller 1 into the journal
boxes (Fig. 35/2).
2. Secure the roller lock (blue) on O.S. by pressing
in the knurled screw and tightening the Allen
screw.
1 3. Insert the red inking form roller 2 into the journal
boxes (Fig. 35/3).
4. Secure the roller lock (red) on O.S. by pressing in
the knurled screw (Fig. 21/3) and tightening the
Allen screw (Fig. 21/2).
5. Place the ink transfer roller 3 (with lubricating
3 2 nipples) in the mounting fixtures between the red
inking form roller 1 and the blue inking form
Fig. 35 Journal box of rollers 1, 2, and 3 roller 2.
Installing ink transfer roller 4
SG.901.1521-006GRAUND_00
6. Move the yellow ink transfer roller 4 to the marked
position (Fig. 36/1).
Fig. 36 Position of the yellow ink transfer roller 4
SC.999.0020/01 B.8.23
Inking unit
Inserting ink transfer roller 5
SG.901.1522-006GRAUND_00
7. Insert ink transfer roller 5 (with guide roller,
Fig. 37/1). Ink transfer roller 5 must be in contact
with ink transfer roller 4 and its journal boxes
must rest on the stops.
1 2
Fig. 37 Ink transfer roller 5
SG.901.1505-007GRAUND_00
Installing the blue ink transfer roller 6
8. Move the blue ink transfer roller 6 (Fig. 38/1) to
the marked position (Fig. 37/2). Press it down-
1 ward until it comes into contact with ink transfer
roller 3. Lift up ink transfer roller 5 during this pro-
cess.
Fig. 38 Blue ink transfer roller 6
Fitting ink transfer roller 7
SG.901.1524-005GRAUND_00
9. To facilitate the insertion of roller 7: Press roller 5
lightly up into the printing press. This allows
roller 7 to slide in deeper and to rest on ink dis-
tributor D and roller 6.
10. Prior to inserting ink transfer roller 7, pull out the
spring bolt on D.S. (Fig. 39/1) up to the stop.
11. Insert the roller journal on D.S. first, so that it
2
reaches behind the retaining strap of the spring
1 bolt (Fig. 39/2).
Fig. 39 Spring bolt
B.8.24 SC.999.0020/01
Inking unit
12. During this process, position the anti-rotation el-
SG.901.1525-005GRAUND_00
ement of roller (Fig. 40/2) on the handle rod of the
1 spring bolt D.S. (Fig. 40/1) such that it encom-
passes the handle rod of the spring bolt.
2 13. Raise the spring bolt on O.S. and place the roller
journal behind the retaining straps. The brackets
fix the roller into position.
Fig. 40 Anti-rotation element of roller 7
Installing the white ink transfer roller 8
SG.901.1526-004GRAUND_00
14. Place the journal boxes of the white ink transfer
roller 8 (Fig. 41/1) onto the lateral supports. Apply
slight pressure to bring it to its end position.
Note
The rollers 3 ...8 are fixed by spring
1 force. Adjustment is not required.
Fig. 41 Fitting ink transfer roller 8
SC.999.0020/01 B.8.25
Inking unit
Installing the red ink transfer roller 9 and adjusting
SG.901.1527-005GRAUND_00
it to ink distributor B
1
15. Move the red ink transfer roller 9 to the marked
position (Fig. 42/2).
16. On D.S. and on O.S., place a paper or mounting
film strip (0.1 mm thick) between roller 9 and ink
2 distributor B (Fig. 42/1).
17. Using the adjusting screws (Fig. 42/3), adjust the
3 red ink transfer roller 9 to ink distributor B
(Fig. 42/1).
The adjustment is correct if the strip of paper or the
mounting film offers the same slight resistance on D.S.
and on O.S. when you pull it out from between ink
transfer roller 9 and ink distributor B.
Fig. 42 Red ink transfer roller 9
SG.901.1529-006GRAUND_00
Installing ink transfer roller 10 and adjusting it to
ink transfer roller 9
3 2 18. Insert the journals of ink transfer roller 10 (thin
roller) into the mounting fixtures (Fig. 43/1) on
4 D.S. and O.S.
19. On D.S. and on O.S., place a paper or mounting
5 1 film strip (0.1 mm thick) between roller 9 and
roller 10.
20. Swing the connecting link (Fig. 43/2) towards the
roller so that the adjusting screws (Fig. 43/4) on
D.S. and on O.S. dip into the borehole in the roller
journal when they are screwed in.
21. Secure the connecting link (Fig. 43/2) with the
self-locking screw (Fig. 43/5).
Fig. 43 Ink transfer roller 10
22. Use the adjusting screws (Fig. 43/4) to adjust ink
transfer roller 10 to ink transfer roller 9.
The adjustment is correct when the paper or mounting
film offers the same slight resistance on D.S. and on
O.S. when it is pulled out between ink transfer roller 9
and ink transfer roller 10.
23. Tighten the lock nuts (Fig. 43/3) after the adjust-
ment.
Inserting the yellow ink transfer roller 11
SG.901.1530-008GRAUND_00
1 2 3 24. Move the yellow ink transfer roller 11 to the
marked position (Fig. 44/1) between ink distribu-
tor A (Fig. 44/2) and ink distributor B (Fig. 44/3).
Fig. 44 Ink transfer roller 11
B.8.26 SC.999.0020/01
Inking unit
Inserting ink transfer roller 12 and adjusting it to
SG.901.1532-007GRAUND_00
ink transfer roller 11
25. Insert the journals of ink transfer roller 12 (thick
roller) into the mounting fixtures (Fig. 45/5).
4
26. Swing the connecting link (Fig. 45/3) towards the
5 roller so that the adjusting screws (Fig. 45/1) on
3 D.S. and on O.S. dip into the borehole in the roller
journal when they are screwed in.
2 1 27. Secure the connecting link (Fig. 45/3) with the
self-locking screw (Fig. 45/4).
28. Use the adjusting screws (Fig. 45/1) to adjust ink
transfer roller 12 to ink transfer roller 11. Check
whether a strip of paper or mounting film (0.1 mm
thick) offers the same slight resistance on D.S.
Fig. 45 Inserting ink transfer roller 12 and O.S. when it is pulled out between rollers 11
and 12.
29. Tighten the lock nuts (Fig. 45/2).
Fine adjustment of rollers
SG.901.1534-006GRAUND_00
Check the adjustment of the rollers 1, 2, 9, 10, and 12
4 +0,5 mm
that are already installed and of the rollers 13 and 14
5 +2 mm
that are to be installed later on the basis of the ink
15 5 +1 mm stripe width (Fig. 46).
A 12
To do so, carry out the steps described below.
11 1. Feed a bright ink.
4 +1 mm
7 4 +1 mm 2. Let the press run. When the ink is evenly dis-
B
8
5 4 +1 mm tributed, stop the press.
6 4
9 10 3. After a few seconds of waiting time, displaced ink
4 +1 mm D 3 produces an ink stripe at the contact point of the
C
4 +1 mm 2 1 4 +1 mm rollers.
3 +1 mm
13
14 4. Control panel selection: Press the Control panel
17 selection button twice (with no more than 0.5 sec-
4 -1 mm
19
onds between presses). The LED lights up.
4 -1 mm
16
4 -1 mm 4 -1 mm 5. Inch the press backwards until you can see the
18 ink stripe of the rollers to be adjusted. The ink
FR stripe must have the same width on D.S. and
O.S.
6. Use the adjusting screws on D.S. and on O.S. to
adjust the ink stripe.
● Turning the adjusting screws clockwise in-
Fig. 46 Adjustment values of the ink stripe creases the width of the ink stripe.
● Turning the adjusting screws counterclock-
wise reduces the width of the ink stripe.
To achieve a correct adjustment of the 1st inking form
roller 14, engage intermediate roller 17. The pressure
of the intermediate roller influences the ink stripe
width.
The adjustment of the inking form rollers to the plate
and the adjustment of the ink vibrator are described in
separate sections.
SC.999.0020/01 B.8.27
Inking unit
Fine adjustment of inking form rollers 1 and 2
SG.901.1533-006GRAUND_00
The adjusting screws for the adjustment of inking form
rollers 1, 2 (Fig. 47/1), 13 (Fig. 47/2) and 14 to ink dis-
tributors C or D are located on the underside of the
corresponding roller lock.
1. Adjust the blue inking form roller 1 to ink distrib-
utor C. Ink stripe width: 4 +1 mm.
2. Adjust the red inking form roller 2 to ink distributor
1 D. Ink stripe width: 4 +1 mm.
Fig. 47 Adjusting inking form rollers 2 and 13
Fine adjustment of ink transfer roller 9 with re-
SG.901.1527-006GRAUND_00
spect to ink distributor B
1
1. Adjust the red ink transfer roller 9 to ink distributor
B using the screw (Fig. 48/3). Ink stripe width:
4 ±1 mm.
2
Ink distributor B is positioned above ink transfer
roller 9. Inch the press forward so you can see the ink
stripe.
3
Fine adjustment of ink transfer roller 10 with re-
spect to the red ink transfer roller 9
2. Use the adjusting screws (Fig. 43/4) to adjust ink
transfer roller 10 to the red ink transfer roller 9. Ink
stripe width: 4 ±1 mm.
Check the adjustment of ink transfer roller 9 with re-
Fig. 48 Adjusting ink transfer roller 9
spect to ink distributor B again. Correct the adjustment
as needed.
3. Lock the adjusting screws.
Once the other rollers have been adjusted correctly,
the printing pressure of ink transfer roller 9 to ink dis-
tributor C is also correct. It need not be checked.
Fine adjustment of ink transfer roller 12 with re-
spect to the yellow ink transfer roller 11
4. Use the adjusting screws (Fig. 45/1) to adjust ink
transfer roller 12 to the yellow ink transfer roller
11. Ink stripe width: 5 ±1 mm.
5. Lock the adjusting screws.
B.8.28 SC.999.0020/01
Inking unit
Installing the yellow inking form roller 13
SG.901.1536-006GRAUND_00
1. Slide the yellow inking form roller 13 (Fig. 49/1)
over the guard (Fig. 49/2) into the press.
2. Insert the yellow inking form roller 13 (Fig. 49/1)
3 into the journal boxes (Fig. 49/3).
3. Secure the roller lock (yellow) on O.S. by press-
2 ing in the knurled screw and tightening the Allen
screw.
1 Installing the white inking form roller 14
4. Insert the white inking form roller 14 into the jour-
nal boxes.
5. Secure the roller lock (white) on O.S. by pressing
in the knurled screw and tightening the Allen
Fig. 49 Yellow inking form roller 13 screw.
Fitting the rollers of the dampening system
6. Fit the rollers of the dampening system. Please
refer to the "Dampening system, Removing and
fitting dampening rollers" chapter.
Adjusting inking form rollers 13 and 14 to the ink
distributors
7. Engage the inking form rollers with the plate us-
ing the Inking form rollers ON/OFF button.
8. Engage the dampening form roller with the plate
using the Dampening form roller ON/OFF button.
9. Engage intermediate roller 17 with inking form
roller 14 and dampening form roller 16.
10. Adjust the yellow inking form roller 13 with re-
spect to ink distributor D. Ink stripe width:
4 +1 mm.
11. Adjust the white inking form roller 14 with respect
to ink distributor C. Ink stripe width: 4 +1 mm.
SC.999.0020/01 B.8.29
Inking unit
4.6 Adjusting the inking form roller relative to the plate
Engage intermediate roller 17 before you start the ad-
SG.901.1556-007GRAUND_00
justment. The inking form rollers must first be disen-
gaged.
1. Press the Control panel selection button on the
desired control panel twice (with a max. interval
of 0.5 seconds). The LED in the button lights up.
2. Press the Positioning button. As a result, the ink-
ing rollers are not above the plate cylinder gap.
3. While the press is stopped, use the Inking form
rollers ON/OFF button to bring the inked inking
form rollers briefly into contact with the plate and
to disengage them again.
1 4. Inch the press forward and check the contact
area on the plate. Ink stripe width: 4 -1 mm.
Use the Allen screw (Fig. 50/1) to adjust the inking
form rollers to the plate.
Fig. 50 Adjusting the inking form roller relative to the
plate The four locks of the inking form rollers have colored
markings. The Allen screws belonging to the corre-
sponding roller are marked with the same color. Turn-
ing clockwise increases the contact pressure. Turning
counterclockwise reduces the contact pressure.
Check-up
Check the adjustment of the inking form rollers (inking
form rollers 1, 2, 13, and 14) to the plate at least week-
ly, or in the event of inking-up problems.
4.7 Final steps of inking roller installation
1. Fold out the handle segment (Fig. 51/1), which is
LS.901.6337-003GRAUND_00
secured by magnets, from underneath the guard.
Fig. 51 Handle segment on the inking roller guard
folded in
B.8.30 SC.999.0020/01
Inking unit
2. Swing the inking roller guard to the working po-
LS.901.4307-002GRAUND_00
sition. In its working position, the guard is
straightened and in contact with the printing
press (Fig. 52/1). The guard is closed.
Fig. 52 Inking roller guard in working position
3. Install the blade trough (Fig. 53/2).
LS.901.4940-001GRAUND_00
Note
Close the inking roller guard (Fig. 53/1)
behind the blade trough before moving
the AutoPlate Pro plate changer from
2 maintenance to work position.
1
Fig. 53 Inking roller guard and blade trough
SC.999.0020/01 B.8.31
Inking unit
4. If your press is equipped with AutoPlate Pro: low-
SG.901.0471-002GRAUND_00
er the roller guard (Fig. 54/1) of the plate changer.
1
For presses without AutoPlate Pro: close the
printing unit guard (delivery side).
Fig. 54 AutoPlate Pro plate changer, roller guard in
maintenance position
B.8.32 SC.999.0020/01
Inking unit
5 Template for roller adjustment
SX.901.8565-000UTKENU_00
5.1 Template - overview
Auxiliary function for roller adjustment
SX.009.0001-000GRAUND_00
Information on the correct way to create an evaluation
sheet and use the template can be found at the control
station in the associated operating manual.
Use the roller adjustment template to evaluate the
1 contact areas on a printed evaluation sheet.
How is the template constructed?
The template shows you the roller diagram of the ma-
chine (Fig. 55/1).
In the diagram below (Fig. 55/2) you see the width of
Roller Setup Gauge
2 the contact area between roller and roller or drum and
550
540 plate at the corresponding positions on the printed
evaluation sheet.
−2 −1 2.5 +1 +2
530
0−6
520
In the right margin of the table you see the assignment.
510
500
490
480 −2 −1 5 +1 +2
For example, 0-P means the contact area between the
470
0−5
dampening form roller and the plate (Fig. 55/3).
460
450
440
430
−2 −1 6 +1 +2
0−F
This symbol (Fig. 55/4) shows you the
420
410 3
400
390
optimum contact area width, here 4 mm (centre) on the
380
−2 −1 4 +1 +2
1−R third inking form roller toward the distributor roller. To
the right and left of the center, the deviations up to
370
360
350
340
−2 −1 5 +1 +2
0−P
+ 2 mm or up to - 2 mm from the reference value are
330 shown so you can evaluate the actual width of the
contact area.
−2 −1 3 +1 +2
320 1−6
310
300
Where can you get the template?
290
Position [mm]
280
The template is supplied with the machine.
270
260 −2 −1 4 +1 +2 −2 −1 4 +1 +2 1−P
2−R
If you have lost the template, you can get one for your
250
240 −2 −1 4 +1 +2
machine from the Heidelberg agency. Contact your
3−R
230
220
210 Heidelberg agency in this regard.
200
190
−2 −1 4 +1 +2
180 2−P
170
160
150
140
−2 −1 4 +1 +2
130 4−R
120
−2 −1 4 +1 +2
110 3−P
100
90
80
70 4
60
50 −2 −1 4 +1 +2
4−P
40
30
20
10 Print Start
71.009.001 Roller Setup Gauge SM102, CD102, SX102, CX102 © Heidelberg Druckmaschinen AG, 16−Jul−2012
0
4 3 2 1 0
Roller
Fig. 55 Roller adjustment template
SC.999.0020/01 B.8.33
Inking unit
Roller diagram and assignment
SX.009.0002-000GRAUND_00
In the roller diagram (Fig. 56) you can see the contact
points between the roller pairs or between the roller
and the plate.
Tab. 4 shows you an overview of the assignment of the
roller pairs and their corresponding contact area width.
Fig. 56 Roller diagram
Allocation Contact area between ... and ... Width
Color code mm
0-6 Intermediate roller 2.5
0-5 Dampening form roller Metering roller 5
0-F green Dampening distributor 6
0-P Plate 5
1-R Distributor roller 4
Inking form roller 1
1-P Plate 4
white
1-6 Intermediate roller 3
2-R Inking form roller 2 Distributor roller 4
2-P blue Plate 4
3-R Inking form roller 3 Distributor roller 4
3-P red Plate 4
4-R Inking form roller 4 Distributor roller 4
4-P yellow Plate 4
Tab. 4 Allocation
B.8.34 SC.999.0020/01
Inking unit
5.2 How do you correct the contact area?
Color code
DS.009.0004-000GRAUND_00
The dampening form roller/inking form rollers are la-
beled with a color code. This color code corresponds
2 to the roller diagram (Fig. 56) and the symbols
(Fig. 57/1) in the roller adjustment template.
Roller Color code
(Fig. 57/1)
Dampening form roller green
1
Inking form roller 1 white
Fig. 57 Color code, angle of rotation Inking form roller 2 blue
Inking form roller 3 red
Inking form roller 4 yellow
Tab. 5
Angle of rotation
Fig. 57/2 shows you how far you need to turn the ad-
justing screws of the corresponding roller in order to
correct the contact area by approximately 1 mm. In the
example this is approximately 180°.
In the chapter "Inking unit - Removing and installing
inking rollers" you will find the color-coded adjusting
screws and the correct procedure for adjusting the
rollers.
SC.999.0020/01 B.8.35
Inking unit
6 Removing and installing the ink vibrator
SG.901.1504-000UTKENU_08
6.1 Removing the ink vibrator
1. Control panel selection: Press the Select control
SG.901.1538-004GRAUND_00
1 2 3 4 panel button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
2. Inch the press until the ink vibrator can be turned
by hand.
3. Loosen the nut (Fig. 58/1). Next, swing the con-
necting link (Fig. 58/2) off the roller journal.
4. Raise the ink vibrator (Fig. 58/5) on O.S. Pull the
ink vibrator out of the bearing bore on D.S.
Caution - Risk of press damage!
5 Do not remove the connecting link
(Fig. 58/2)! When you remove it, there is
a risk that the connecting link drops into
Fig. 58 Removing the ink vibrator the printing press and damages the
printing press during start-up. After the
connecting link has been removed, only
Heidelberg Service is able to adjust is
correctly.
6.2 Installing and adjusting the ink vibrator
Note
SG.901.1538-004GRAUND_00
1 2 3 4 Check the adjustment of the ink vibrator
with respect to the ink distributor A if
there are any inking-up problems. Check
at least once weekly.
1. Insert the ink vibrator on D.S. into the bearing
bore.
2. Place the ink vibrator on O.S. into the bearing
shell.
3. Secure the roller: Swing the connecting link
5 (Fig. 59/2) over the roller end. Next, tighten the
lock nut (Fig. 59/1).
Fig. 59 Installing and adjusting the ink vibrator
4. Adjust the ink vibrator with respect to the ink
fountain roller: Inch the printing press forward un-
til the vibrator movement towards the ink fountain
roller is completed.
5. Tighten the adjusting screw (Fig. 59/3) on D.S.
and on O.S. by hand. The ink vibrator must be in
a light contact with the ink fountain roller. A par-
allel and evenly wide contact area of 4 ±0.5 mm
must form on the ink fountain roller.
● Turning the adjusting screw clockwise: The
contact area becomes wider.
● Turning the adjusting screw anti-clockwise:
The contact area becomes narrower.
B.8.36 SC.999.0020/01
Inking unit
6. Tighten the lock nuts when the adjustment is cor-
rect.
7. Adjusting the ink vibrator with respect to the ink
distributor A: Inch the press forward until the vi-
brator roller movement to the ink distributor is
completed.
8. Tighten the adjusting screw (Fig. 59/4) on D.S.
and on O.S. by hand. A parallel and evenly wide
contact area of 5 +2 mm must form on the ink
vibrator.
● Turning the adjusting screw clockwise: The
contact area becomes wider.
● Turning the adjusting screws anti-clock-
wise: The contact area becomes narrower.
Note
Adjust the ink vibrator only up to the nec-
essary intensity. Although a stronger
contrast has only a minimum influence of
the ink stripe width, it bears on rollers
and bearings.
9. Tighten the lock nuts when the adjustments are
correct.
10. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
SC.999.0020/01 B.8.37
Inking unit
7 Selecting, servicing and storing inking rollers
SG.901.1506-000UTKENU_08
7.1 Selecting correct inking rollers
Function
SG.901.1514-000GRAUND_00
1 Depending on the equipment of your press, conven-
tional inks or UV inks may be used. Make sure that you
2 use the correct inking rollers for each application.
There are inking rollers for:
3 ● Conventional ink
● UV ink
4
● both conventional ink and UV ink
These types of roller require special maintenance
and a specific cleaner. Please note the roller
manufacturer's product information when using
for the first time.
Design
● Ink roller coating (Fig. 60/1)
Fig. 60 Identification on inking roller ● Color coding for installation position of inking
roller (Fig. 60/2)
● Spacer ring (Fig. 60/3)
● Ball bearing (Fig. 60/4)
Note
If the inking roller is suitable for mixed
mode operation, a spacer ring is marked
in orange.
ink Color coding for spacer ring Remark
(Fig. 60/3)
Conventional Without
UV Without Red inking roller coating
Mixed operation Orange A spacer ring is marked orange.
The color marking for the installation
position is recognizable on the other
side of the roller.
Tab. 6 Inking roller selection
7.2 Servicing and storing inking rollers
Inking rollers may only be cleaned using suitable
washing fluids. Not suitable here are aromatic hydro-
carbons (e.g. benzene, toluene, ester, ketone) or chlo-
rinated hydrocarbons (e.g. trichloroethylene, per-
chloroethylene, methylene chloride).
B.8.38 SC.999.0020/01
Inking unit
Note
Observe the washing fluid recommen-
dations as provided by your Heidelberg
agency. Use only wash-up fluids that
have been tested by FOGRA and certi-
fied with regard to their material compat-
ibility and harmlessness to health.
Caution - Risk of press damage!
Wash-up solutions based on orange ter-
pene will corrode the rollers.
Mechanical damage in the sleeve can be rectified by
regrinding the surface. The rollers may only be re-
ground far enough to ensure that they can still be ad-
justed.
If one or more units of a press are not used for a job,
then the inking rollers on the printing units not used
must be protected against running dry with the aid of
print oil or acid-free grease.
Caution - Risk of press damage!
Print oil or acid-free grease corrode UV
rollers. For UV rollers, you must use a
suitable roller protection paste.
Store the inking rollers in their original packaging at
normal room temperature (not in the area of heaters)
and do not expose them to direct light.
The inking rollers should be stored on their journals to
ensure that the rubber surface is not damaged or de-
formed.
7.3 Detaching ball bearings from roller cores
An extractor (Fig. 61/1) is shipped with the press for
SG.901.1539-003GRAUND_00
detaching ball bearings.
1. Position the claws of the extractor on the spacer
ring behind the ball bearing (Fig. 61/2), not on
the bearing itself.
2
1
3 2
Fig. 61 Extractor
SC.999.0020/01 B.8.39
Inking unit
7.4 Mounting ball bearings onto roller cores
A press-fit device, angle (Fig. 61/3) with welded on
base plate, (Fig. 61/4) is included in the shipment for
mounting ball bearings.
1. Mount the spacer ring first and then the ball bear-
ing onto the roller core.
2. Place the rubber roller into the angle so that the
base plate (Fig. 61/4) of the special tool makes
contact with the ball bearing.
3. Press the ball bearing onto the spindle. Apply
light blows (rubber or wooden hammer) to the
base plate (Fig. 61/4). Make sure that the rubber
roller lies flat up against the sides of the angle
(Fig. 61/3), as otherwise the bearing may be tilt-
ed.
Note
Make sure that the angle does not dam-
age the rubber surface of the inking
roller.
B.8.40 SC.999.0020/01
Inking unit
8 Ink fountain
SG.901.1507-000UTKENU_13
8.1 Retightening and replacing the ink fountain liner
There is a screw (Fig. 62/1) in the middle of the foil
SG.901.1609-006GRAUND_00
clamping bar. Using this screw, you can pull back the
ink fountain liner by several millimeters. This ensures
that the contact area of the ink fountain liner on the ink
fountain roller is shifted and the service life of the ink
2 fountain liner is extended.
The foil clamping bar can continuously be adjusted
3 between the following two positions:
1 ● Basic position:
The screw is fully turned out (starting position af-
ter insertion of a new ink fountain liner).
● Pull position:
Fig. 62 Moving onward the ink fountain liner The screw has been fully turned into the foil
clamping bar. The ink fountain liner is pulled
back.
When process colors are used, the ink fountain liner
can remain in one position for a period that corre-
sponds to approximately 300,000 impressions. How-
ever, the durability may strongly diverge from this val-
ue, depending on the ambient conditions. Especially
when printing with special inks (bronze, white and UV
inks), you need to pull along or replace the ink fountain
liner at shorter intervals.
Moving onward the ink fountain liner
1. Loosen the knurled screws (Fig. 62/2) on the ink
fountain cheeks to pull along the ink fountain lin-
er.
2. Pull the ink fountain liner into the center position
or end position by turning the screw (Fig. 62/1) to
the right.
3. Tighten the knurled screws (Fig. 62/2) of the ink
fountain cheeks again.
The ink fountain liner must be replaced when it is at its
end position.
SC.999.0020/01 B.8.41
Inking unit
Replacing the ink fountain liner
SG.901.1610-006GRAUND_00
1. Secure the press against starting up again: Press
the Emergency-stop palm button on the next-
2 nearest control panel.
2. Empty the ink fountain.
3. Release the knurled screws (Fig. 62/2). Remove
the ink fountain dividers (Fig. 62/3).
4. Fold down the ink fountain completely.
1 5. Fold one end of the ink fountain liner in the ink
fountain over the other.
This prevents the metering elements and the ink
fountain holder from becoming soiled.
6. Remove the previously used ink fountain foil.
7. Fully unscrew the screw in the foil clamping bar
(Fig. 62/1) (normal position).
Fig. 63 Foil clamping bar 8. Hang the rear edge of the new ink fountain foil
into the fold in the foil clamping bar (Fig. 63/1).
● First insert the rear edge of the foil into the
fold above the screw.
● Center the ink fountain liner.
● Starting in the middle and moving outwards,
gently push the liner into the fold.
9. Hold the middle of the ink fountain liner in place
SG.901.1611-006GRAUND_00
with one hand. Insert the front edge of the foil
between ink fountain and ink fountain roller. At
the same time, press the ink fountain onto the ink
3 fountain roller.
10. Fold up the ink fountain with the levers.
Caution - Risk of press damage!
Never throw the ink fountain without ink
fountain foil on the ink fountain roller!
The ink fountain roller would destroy the
protective film over the metering ele-
ments. The metering elements can be
attacked and destroyed when the pro-
tective foil is defective.
11. Using the adjustment lever (Fig. 64/3), turn the
2 ink fountain roller until the ink fountain foil is fully
stretched and clamped between the ink fountain
1
roller and the ink fountain.
12. Insert the ink fountain dividers. Lightly push the
ink fountain cheeks against the ink fountain roller.
Tighten the rear knurled screw (Fig. 64/1).
Fig. 64 Replacing the ink fountain liner 13. Next, tighten the front knurled screw (Fig. 64/2)
until the ink fountain dividers are in contact with
the ink fountain roller and the scraping edge of
the hickey remover rests on the ink fountain
roller.
14. Release the Emergency stop button.
B.8.42 SC.999.0020/01
Inking unit
8.2 Replacing the protective film over the metering elements
The protective film (Fig. 65/2), the Tesa Moll strip
(Fig. 65/1) underneath it and the insulation strip
(Fig. 65/3) on D.S. and O.S. support the ink fountain
liner on the ink fountain roller. In the event of damage,
you need to replace these components.
Precautions
1. Secure the printing press against being put into
operation. Press the Emergency stop button on
the corresponding printing unit.
2. Empty the ink fountain.
3. Fold down the ink fountain completely.
4. Remove the two ink fountain cheeks and the ink
fountain liner.
SG.901.0014-000GRAUND_00 Pulling off the protective film, the Tesa Moll adhe-
sive strip and the insulation strip
Caution - Do not damage the cover
plate!
The cover plate can be distorted if you
pull off the protective film in the upward
direction. Pull off the protective film par-
3
2 allel to the cover plate.
1 1. Pull off the damaged protective film (Fig. 65/2).
2. If necessary, pull off the Tesa Moll strip
(Fig. 65/1).
3. Remove the insulating tape (Fig. 65/3) below the
ink fountain cheeks on both sides.
Fig. 65 Removing the protective film 4. Thoroughly remove any remains of the adhesive
layer. The adhesion surfaces must be clean and
grease-free.
Cleaning the metering elements
Caution - Washing fluids and cleaner
can gum up metering elements!
Clogged metering element may lead to
metering errors. Do not use any washing
fluid or cleaner for cleaning the ink
zones.
1. Clean the ink zones using a dry fluffless cloth in
the direction of the ink fountain roller.
Note
Cleaning the ink zones in the parallel di-
rection to the ink fountain roller may
cause residues to form that compromise
the function.
2. Lightly grease the cleaned metering elements
before you stick on the protective film. Use an
appropriate lubricant (e.g. Castrol Longtime
PD 2) for this. Ensure that there is no grease on
the splices.
SC.999.0020/01 B.8.43
Inking unit
Attaching a new Tesa Moll strip and insulation
SG.901.0039-000GRAUND_00
1 strip
1. Stick the testimonial strip (Fig. 67/1) onto the
edge of the cover plate in front of the metering
elements. Cut off any overlapping ends.
2. Stick one insulation strip (Fig. 66/2) on D.S. and
one on O.S. on the bar under the ink fountain
cheeks (Fig. 66/1).
● Begin exactly at the chamfer of the bar
2 (Fig. 66/arrow).
● Do not stick the insulating tape over the me-
tering elements.
Fig. 66 Insulating tape under the ink fountain divider
Affixing the protective film
SG.901.0015-000GRAUND_00
1. Hang the protective film (Fig. 67/2) with the fold in
the bar (Fig. 67/3).
2. The adhesive layer of the protective film is cov-
ered by protective paper. Peel off the protective
paper starting from one side all the way up to the
middle.
3. Starting from the middle of the ink fountain, stick
the protective film
● without folds
● and slightly pre-stretched
onto the cover plate (Fig. 67/4).
The Tesa Moll strip (Fig. 67/1) must become
1 slightly deformed in its cross-section when doing
so.
4 4. Pull the second half of the protective paper off the
adhesive layer toward the side. Stick the protec-
tive film onto the cover plate as described in the
previous step.
5. Release the Emergency stop palm button.
3
2
Fig. 67 Affixing the testimonial strip
B.8.44 SC.999.0020/01
Inking unit
8.3 Cleaning the drip pan
The drip pan collects ink residue. Clean the drip pan at
SG.901.1554-002GRAUND_00
1 regular intervals in order to prevent it from overflowing.
1. Secure the press against starting up again: Press
the Emergency-stop palm button on the next-
nearest control panel.
2. Empty the ink fountain.
3. Completely fold down the ink fountain at the han-
dles (Fig. 68/1).
2 4. Clean the drip pan (Fig. 68/2) with a cloth soaked
in cleaner.
5. Fold the ink fountain back again.
6. Release the Emergency stop button.
Fig. 68 Drip pan
8.4 Removing the drip pan for cleaning purposes
Note
SG.901.7605-000GRAUND_00
You can only remove the drip pan after
you have removed the ink transfer rollers
7 and 8.
Ensure that you do not damage the del-
icate roller coating when you remove the
drip pan.
To remove encrusted ink residue from the drip pan or
3 ink that has accumulated between the protective film
(Fig. 69/3) and the drip pan (Fig. 69/1), remove the drip
1 pan. For this purpose, first remove inking rollers 7 and
8 (Fig. 69/4, 5). For more information, refer to: "Re-
moving and installing the inking rollers".
4
2 To be able to access the fastening screws (Fig. 69/2),
you must reach underneath the cross bar and unscrew
5 the fastening screws with an Allen key, up to the stop.
1. Secure the press against starting up again: Press
Fig. 69 Ink fountain and drip pan (lateral) the Emergency-stop palm button on the next-
nearest control panel.
2. Remove the inking rollers 7 and 8 (Fig. 69/4, 5).
3. Slacken the fastening screws (Fig. 69/2) using an
Allen key. Unscrew the fastening screw up to the
stop.
4. Remove the drip pan from the press.
Proceed in the inverse sequence to reinstall the drip
pan.
5. Release the Emergency stop button.
8.5 Ink agitation system
The ink agitation system is a recommended accessory
for printing with UV inks. UV inks exhibit a high vis-
cosity and are likely to stagnate in the ink fountain. The
SC.999.0020/01 B.8.45
Inking unit
movement of the agitation system keeps the UV ink
fluid.
B.8.46 SC.999.0020/01
Inking unit
9 Autoprotect - automatic application of roller protective agent
SC.B01.7700-000UTKENU_00
9.1 General
Function
SC.B01.7700-000GRAUND_00
When roller protective agent is applied to non-ink-car-
rying inking rollers, these are protected from the con-
sequences of extended dry running.
A fourth metering tube (Fig. 70/1) in the inking unit
washup device is used to apply the roller protective
agent.
With the "Automatically apply roller protective agent"
function you can automatically apply roller protective
agent to preselected printing units and protect them.
1 During a job change the inking units with roller protec-
tive agent are automatically washed, if necessary, and
thus prepared for the next job.
Note
The automatic system will only function
properly if original Heidelberg Roller Pro-
tection Liquid (dyed red) from Heidel-
berg Saphira Consumables is used.
The Roller Oil product (clear) from Hei-
delberg Saphira Consumables can only
be used for manual application onto the
inking rollers.
Fig. 70 Diagram of inking unit with metering tube
Advantages of Heidelberg Roller Protection Liquid
SF.901.7705-001GRAUND_00
Using original Heidelberg Roller Protection Liquid of-
fers you a range of advantages, e.g.:
● it prevents dry running of inking rollers,
● it prevents wear and overheating of rollers,
● it increases the service life of rollers,
● it is easy to wash using an automatic wash pro-
gram,
● it maintains the roller surface,
● VOC-free,
● H1 approval (food safe).
Fig. 71 Heidelberg Roller Protection Liquid
What do you need to keep in mind when using
Roller Protection Liquid?
If you spill roller protective agent, mop it up thoroughly
from the floor. Dry the cleaned area. Dispose of the
cleaning cloth in an environmentally friendly manner.
Pay particular attention to the product specification
sheet for Roller Protection Liquid and the notes on
handling and disposal.
SC.999.0020/01 B.8.47
Inking unit
Location of the canister
SC.B01.7704-000GRAUND_00
The canister (Fig. 72/1) with Roller Protection Liquid is
located under the footboard on the O.S. in a separate
holding device next to the washing fluid container.
Depending on the given machine configuration, two
canisters with Roller Protection Liquid may be provid-
ed.
Fig. 72 Canister under the footboard on O.S.
9.2 System components
Components
SF.901.7706-001GRAUND_00
The system mainly consists of:
3 ● 5-liter canister with roller protective agent
(Fig. 73/2) (Roller Protection Liquid from Heidel-
berg Saphira Consumables, dyed red),
● Removable suction pipe (Fig. 73/3) with integrat-
ed screw cap,
2 ● Special holding device (Fig. 73/1) with symbol for
roller protective agent,
● Additional metering tube in inking unit.
Fig. 73 Holding device, canister and suction pipe
B.8.48 SC.999.0020/01
Inking unit
9.3 Changing canister
Preparing for the change
SF.901.7705-001GRAUND_00
You can easily replace an empty canister with a full
canister of roller protective agent.
Note
The suction pipe is fitted with a matching
screw cap. Use suction pipe with inte-
grated screw cap developed by Heidel-
berg only. The position of the screw cap
on the suction pipe is set to an exact lev-
el. To avoid any malfunctions, the posi-
tion of the screw cap on the suction pipe
must not be altered.
1. Remove the screen under the footboard.
2. Place a full canister with roller protective agent
(Fig. 74) next to the washing fluid container on
Fig. 74 Roller Protection Liquid the O.S.
Check for correct identification: Original Heidel-
berg Roller Protection Liquid is dyed red.
3. Unscrew the screw cap from the full canister.
Replacing canisters
SF.901.7707-001GRAUND_00
1. Pull the holder (Fig. 75/1) with the empty canister
out from under the footboard.
3
Ensure that neither the hose nor the electric ca-
ble is stretched too much. You do not need to
2 release the plug-in connection.
2. Firmly hold the suction pipe (Fig. 75/3) and un-
screw the screw cap (Fig. 75/2).
Note
When removing the suction pipe from
the canister, small amounts of roller pro-
tective agent may leak out of the suction
1 pipe.
3. Pull the suction pipe (Fig. 75/3) upwards out of
the canister.
Hold the suction pipe as upright as possible with
the suction opening facing downwards.
4. Collect any dripping roller protective agent using
Fig. 75 Canister and suction pipe a cloth.
SC.999.0020/01 B.8.49
Inking unit
On canister provided:
SF.901.7711-000GRAUND_00
5. Insert the suction pipe (Fig. 76/1) carefully, when
upright, from above into the full canister.
Fig. 76 Inserting suction pipe
6. Hold the suction pipe (Fig. 77/2) firmly and screw
SF.901.7712-000GRAUND_00
the screw cap (Fig. 77/1) onto the canister.
2 7. Check the suction pipe is correctly seated in the
canister.
1 8. Slide the holding device with the canister under
the footboard next to the washing fluid container.
Note
Ensure that the suction hose does not
become bent or damaged.
9. Mop up any spilled roller protective agent from
the floor and dry the cleaned area.
10. Hook in the screen under the footboard.
Fig. 77 Suction pipe in canister
B.8.50 SC.999.0020/01
Inking unit
9.4 Commissioning
If you are operating the roller protection system for the
SF.901.7701-000GRAUND_00
first time, you must fill the empty line system with roller
protective agent. This requires a specific procedure to
be followed.
Information about this is available on the control sta-
tion in the relevant operating manual.
Fig. 78 Control station
9.5 Preselecting the "Apply roller protective agent" operating mode
You can preselect the "Apply roller protective agent"
operating mode on the control station.
Information about this is available on the control sta-
tion in the relevant operating manual.
9.6 Cleaning the inking rollers
Prior to first use
If the inking rollers in your press have already been in
use for an extended period, clean them using the deep
cleaning function. More detailed information about this
is available in the chapter "Inking unit, double washing
fluid supply and deep cleaning".
Information about this is also available on the control
station in the relevant operating manual.
Automatic wash program
If you have protected one or more printing units with
Autoprotect and you wish to run these printing units
again with ink, the press control system automatically
starts the specified wash program.
Information about this is also available on the control
station in the relevant operating manual.
Washing fluid for manual cleaning
Clean inking rollers that are protected with roller pro-
tective agent, with washing fluid from Heidelberg
Saphira Wash Consumables. A list of suitable and
Roller Protection Liquid-compatible washing fluids can
be obtained from your Heidelberg agency or directly
from Heidelberg.
SC.999.0020/01 B.8.51
Inking unit
10 Ink mist suction removal
CX.901.0400-000UTKENU_01
10.1 General
The ink mist suction device is a standard feature of
presses with UV equipment. For other presses, the ink
mist suction device is optional.
Function
In the press, the ink mist suction device prevents any
ink mist from entering the pressroom through the pro-
tection grids. The ink mist is deposited in a filtering
mat. The filtering mat can be replaced.
Changeover intervals
The required changeover intervals are heavily depen-
dent on the layer thicknesses or the ink coverage, e.g.
opaque white or full surface back color. For these
kinds of print job, you should check the filtering mats
daily. The filtering mat must be changed if you can see
the ink on the back of the mat (the ink has penetrated
the mat).
You can find additional notes on this in the separate
"Maintenance and cleaning" manual.
Using UV inks
Wear suitable protective gloves and safety goggles
when cleaning the suction device and replacing the
filtering mat.
In particular, please refer to the chapter "Print-related
notes for using UV inks and UV varnishes".
Specification of the filtering mat
Use only genuine Heidelberg filtering mats (special
fiber mat for fine filtration). Genuine HEIDELBERG fil-
tering mats ensure the high availability of your press.
Commercially available filtering mats are not suitable
for the absorption of ink mist.
● If the dimensional accuracy is insufficient, ink
mist escapes into the pressroom.
● Heat builds up in the machine if there is not suf-
ficient ventilation, which can cause rust to form.
Disposal of consumable items
Dispose of used filtering mats in an environmentally
sound fashion. Observe the special regulations for
handling UV inks.
Cleaning
Information on maintaining and cleaning the ink mist
suction device can be found in the separate "Mainte-
nance and cleaning" manual.
B.8.52 SC.999.0020/01
Inking unit
Turning off ink mist suction removal temporarily
You can turn off ink mist suction removal temporarily in
order to refill ink, for example. If you press the Fans off
button (Fig. 79/2), the fans are switched off for 2 min-
utes. After the 2 minutes have elapsed, the fans switch
on again automatically. You can switch the fans back
on by pressing the Fans off button (Fig. 79/2) again
before the 2 minutes have elapsed.
10.2 Replacing the filtering mat
Opening the filter cassette
CX.901.0400-001GRAUND_00
1. Stop the press.
1
2. In case of UV inks: Wear protective gloves.
2
Work from the delivery side.
3. Open the inking unit guard at the top (Fig. 79/1) in
the direction of the arrow.
Fig. 79 Inking unit guard, top
The filter cassette (Fig. 80/1) is now easily accessible.
CX.901.0401-001GRAUND_00
4. Use the Allen key to undo the locking devices
(Fig. 80/2). Swing the bottom cover towards you.
2 The cover opens far enough for you to be able to
remove the filtering mat.
2
5. Remove the filtering mat.
1 Note
Dispose of the soiled filtering mat in an
environmentally friendly manner.
Fig. 80 Filter cassette in the printing unit
Inserting the filtering mat
6. Place the clean filtering mat into the filter cassette
the correct way around.
Ensure that the harder, more dense side is facing
toward the fans. The softer, more permeable side
faces toward the ink fountain roller.
7. Check to make sure that the filtering mat is prop-
erly inserted.
8. Swing the bottom cover closed again. Use the
Allen key to close the locking device (Fig. 80/2).
9. Close the inking unit guard at the top (Fig. 79/1).
SC.999.0020/01 B.8.53
Inking unit
B.8.54 SC.999.0020/01
Dampening system
Dampening system
system
Dampening
1 Dampening system - safety instructions ............................................................................. B.9.3
1.1 To be observed when performing work .......................................................................... B.9.3
2 Print-related notes ................................................................................................................ B.9.4
2.1 Settings .......................................................................................................................... B.9.4
3 Requirements for the dampening solution ......................................................................... B.9.6
3.1 Approved dampening solution additives ........................................................................ B.9.6
3.2 Preventing press damage .............................................................................................. B.9.6
3.3 High printing quality ....................................................................................................... B.9.6
3.4 Additive metering unit .................................................................................................... B.9.7
3.5 Metering of alcohol and dampening solution additives .................................................. B.9.7
3.6 Changing the dampening solution ................................................................................. B.9.7
3.7 Special requirements ..................................................................................................... B.9.8
4 Removing and installing dampening rollers ...................................................................... B.9.9
4.1 Overview ....................................................................................................................... B.9.9
4.2 Cleaning the dampening solution pan ........................................................................... B.9.10
4.3 Removing dampening rollers ........................................................................................ B.9.11
4.4 Installing and adjusting the dampening rollers .............................................................. B.9.13
5 Blower bar ............................................................................................................................... B.9.23
5.1 Setting the blower bar .................................................................................................... B.9.23
6 Cleaning the dampening system ......................................................................................... B.9.24
6.1 Manually cleaning water pan roller and metering roller ................................................ B.9.24
6.2 Notes on maintaining the dampening distributor ........................................................... B.9.24
SC.999.0020/01 B.9.1
Dampening system
B.9.2 SC.999.0020/01
Dampening system
1 Dampening system - safety instructions
SF.901.5600-000UTKENU_00
1.1 To be observed when performing work
Warning - Risk of injury from rotat-
ing rollers and cylinders!
When cleaning the rollers and cylin-
ders, the ball of your thumb must point
in the direction of the infeed gap and
your fingers in the direction of the out-
let gap. Select the corresponding di-
rection of rotation.
Caution - Risk of damage by cleaners
that contain chloride or silicone!
Do not use any cleaners that contain
chloride or silicone. They can damage
components of the dampening solution
supply system.
SC.999.0020/01 B.9.3
Dampening system
2 Print-related notes
XG.901.5024-000UTKENU_03
2.1 Settings
Dampening solution amount
As a rule, you should always print with as little damp-
ening solution as possible. Reduce the dampening so-
lution amount until you can observe color smearing in
the printed image. Then increase the dampening so-
lution amount slightly until the smearing disappears
again. You now have the ideal setting. The transferred
dampening solution amount is determined by:
● the speed of the water pan roller and metering
roller,
● the printing pressure between these two rollers.
The dampening system has speed compensation. The
speed is adjusted to the press speed.
Pay particular attention to the correct setting of the
dampening rollers to one another and the adjustment
of the contact areas.
Contact between the inking unit and dampening
system or intermediate roller ON/OFF
Depending on the roller configuration, the connection
between the inking unit and dampening system is es-
tablished via the intermediate roller or the dampening
form roller.
You can preselect the contact or separation of the ink-
ing unit and dampening system during production at
the control station. Press either the Contact/Separa-
tion button or the Intermediate roller ON/OFF button,
depending on the roller configuration of your press.
● The intermediate roller/dampening form roller
connects the inking unit and dampening system
The intermediate roller/dampening form roller con-
nects the inking unit and dampening system in order to
quickly achieve a stable ink-dampening solution bal-
ance.
● The intermediate roller/dampening form roller
does not connect the inking unit and dampening
system
In case of emulsification problems, forms with low ink
absorption and a simultaneously large ink film thick-
ness or with metallic pigment colors you can disen-
gage the intermediate roller from the inking unit. This
reduces the transfer of dampening solution to the ink-
ing unit.
● Position of the intermediate roller/dampening
form roller during washup, preinking, pre- and
post-dampening
During these operations, the control system controls
the intermediate roller/dampening form roller in accor-
dance with the selected program. The preselection
has no influence on this.
B.9.4 SC.999.0020/01
Dampening system
Overdampening
Requirement
The press is in production mode. The
guard in front of the dampening system
is closed.
With this function you can generate a brief excess of
dampening solution.
You can use the Overdampening button on the touch
screen of the delivery control panel or on the printing
unit control panel to overdampen the dampening sys-
tems. The water pan roller rotates at maximum speed
as long as the button is pressed.
Manual dampening roller washup
Requirement
The press is at standstill. The guard in
front of the dampening system is open.
Press the Overdampening/Manual dampening roller
washup button on the corresponding printing unit to
perform a manual washup procedure. The water pan
rollers and metering rollers then turn at washup speed.
SC.999.0020/01 B.9.5
Dampening system
3 Requirements for the dampening solution
LS.901.5503-000UTKENU_08
3.1 Approved dampening solution additives
Only use dampening solution additives approved by
Heidelberg. These can be found at the FOGRA Graph-
ic Technology Research Association website (when
printing this operating manual: www.fogra.org). If in
doubt, ask your Heidelberg agency.
Important note!
The use of damping solution additives not approved by
Heidelberg can result in damage to the machine (es-
pecially corrosion damage), the elimination of which
can cause costs to be borne by the customer!
3.2 Preventing press damage
In order to prevent damage to the press, the ready to
use dampening solution (including water and possibly
isopropyl alcohol) must not exceed the following limit
values.
Maximum increase in the conductance value of the wash- + 1700 µS/cm
water (difference between conductance value of wash-
water and conductance value of the ready to use damp-
ening solution)
Maximum anion content in ready to use dampening so- Halogenide (especially chloride and bromide): 25 mg/l
lution, corresponding to recommendations stipulated in Sulfate: 50 mg/l
BVD 1985
Nitrate: 20 mg/l
pH value, stabilized 4.8 to 9.2
Tab. 1
3.3 High printing quality
The dampening solution should comply with the fol-
lowing parameters in order to achieve a constantly
high printing quality and avoid problems with printing
plates related to dampening solutions.
Overall hardness 8 to 10 °dH
1° dH = 1.253° English hardness
1 °dH = 1.78° French hardness
1 °dH = 17.8 ppm
1 °dH = 0.1783 mmol/l
pH value 4.8 - 5.5
Dampening solution temperature 10 to 15 °C
Tab. 2
B.9.6 SC.999.0020/01
Dampening system
3.4 Additive metering unit
A separate operating and maintenance manual has
been provided for the dampening solution prepara-
tion accessories.
Requirements of the water
Water is the main component of the dampening solu-
tion. Standard tap water has to be processed before it
can be used. The water must be softened, sterilized
and filtered.
Poor water quality can cause the following problems:
● Limescale build-up in the inking unit and the blan-
ket,
● ink-carrying rollers become water receptive,
● ink splitting is adversely affected,
● the rollers can run bare,
● corrosion damage and damage in the line system
due to limescale.
The best solution is water which has been processed
using a reverse osmosis unit. An alternative is also to
use distilled water. The hardness of filtered or distilled
water must be brought to a constant level (approxi-
mately 8 to 10 °dH) by adding water softener.
3.5 Metering of alcohol and dampening solution additives
Meter these components precisely according to the
manufacturer's instructions. Many people tend to add
too much alcohol. This does not offer any printing ad-
vantages, is a burden on the environment and costs
money.
3.6 Changing the dampening solution
The dampening solution takes up ink and paper com-
ponents, such as paper dust, components of the coat-
ing and salts. This causes the dampening solution to
be soiled, which alters its chemical properties.
A part of the dampening solution penetrates into the
paper during the printing process and is replaced by
the dampening solution supply system. However, you
still have to change the dampening solution regularly.
Each week check the dampening solution and the fil-
ters in the dampening solution preparation and in the
intermediate tanks. Change the dampening solution
when required.
SC.999.0020/01 B.9.7
Dampening system
Note
If you use special filter units, you can use
the dampening solution for longer. How-
ever, you still have to change the damp-
ening solution as soon as the concen-
tration of the salts within it becomes too
great. One indicator that can tell you it is
necessary to change the solution is the
conductance measurement of the damp-
ening solution. If this conductance value
increases severely by approx. 1000
µS/cm due to components it has picked
up, you have to change the dampening
solution.
1. Each time you replace the dampening solution,
check the filters in the intermediate tank and in
the dampening solution preparation.
2. Dispose of the old dampening solution in an en-
vironmentally friendly manner in line with appli-
cable local regulations.
3.7 Special requirements
There are special dampening solution additives for
printing foils, for UV inks or when printing without al-
cohol. Get in touch with your supplier for more infor-
mation.
B.9.8 SC.999.0020/01
Dampening system
4 Removing and installing dampening rollers
SG.901.1601-000UTKENU_17
4.1 Overview
Using five rollers, the dampening system transfers the
SG.901.1600-003GRAUND_00
dampening solution from the dampening solution foun-
tain to the printing plate and - depending on the setting
- to the inking unit.
Note
17
Dampening distributor FR is not remov-
ZW
able. The roller designations 16 ... 19 are
19 binding for the installation sequence! Be-
16 fore you fit the rollers in the dampening
FEAW DW
system, you have to fit the rollers in the
18 inking unit. When removing, you first
T have to remove the rollers in the damp-
FR
ening system before you remove the
rollers in the inking unit. Please refer to
the "Inking unit, Removing and fitting ink-
Fig. 1 Roller diagram ing rollers" chapter.
The following points apply to any adjustment
work:
● When you reinstall the rollers, first adjust them
roughly, then to ink stripe width.
● The contact stripes on D.S. and O.S. must have
the same width.
Fig. 1 Designation Ø Material / Remark
16/FEAW Dampening form roller 78 mm Rubber-coated (Fig. 4/4)
17/ZW Intermediate roller 56 mm Plastic-coated (Fig. 4/3)
18/T Water pan roller 108 mm Rubber-coated, crowned (Fig. 4/1)
19/DW Metering roller 98 mm Stainless steel (Fig. 4/2)
FR Dampening distributor 85 mm Chromium-plated (cannot be removed)
Tab. 3
Width of contact area
SG.901.0870-000GRAUND_00
Display of the setting values for the ink stripe width:
● 4 +1 mm
The ideal setting value is 4 mm. You may exceed
this setting value by 1 mm. You may not fall below
this setting value.
● 4 ±0.5 mm
The ideal setting value is 4 mm. You may exceed
or fall below this setting value by 0.5 mm.
● 4 -1 mm
The ideal setting value is 4 mm. You may fall be-
low this setting value by 1 mm. You may not ex-
ceed this setting value.
Fig. 2 Ink stripe width
SC.999.0020/01 B.9.9
Dampening system
Please use your ink stripe card for roller adjustment
SG.901.0871-001GRAUND_00
1 (Fig. 3) to measure the ink stripe width. The distance
between the limitation lines (Fig. 3/1) specifies the up-
2 per tolerance value. The wide strip (Fig. 3/3) specifies
the lower tolerance value. The specified distance
4 0,5
5+2
2,5+1
5 -1
4+1
5+1
6+1
4-1
+ +
-
(Fig. 3/2) in mm is displayed between the respective
3 limitation lines.
Note
The following setting values refer to a
Fig. 3 Roller adjustment aid, ink stripe card press with inking and dampening system
rollers at working temperature (directly
after completing a print job). If the press
is cold, you should set the rollers to the
lower limit of the tolerance range, since
the width of the contact area increases
when the rollers heat up.
Example: For a 4 ± 0.5 mm width of con-
tact area you should set the width of the
contact area to 3.5 mm.
From To Ink stripe width
Inking form roller 1, white Plate 4 -1 mm
Inking form roller 1, white Intermediate roller 3 +1 mm
Dampening form roller Intermediate roller 2.5 +1 mm
Dampening form roller Plate 5 ±1 mm
Dampening form roller Dampening distributor FR 6 +1 mm
Dampening form roller Metering roller 5 +1 mm
Tab. 4
Caution - Do not place the end face of
SG.901.1601-002GRAUND_00
the intermediate roller on the roller
core!
Placing the removed intermediate roller
(Fig. 4/3) on the roller core at the end
face you can cause damage to the gear-
ing inside the roller that is responsible for
oscillation. Always rest the intermediate
roller on both journals.
1 2 3 4
Fig. 4 Removed rollers
4.2 Cleaning the dampening solution pan
You have to remove water pan roller 18 to clean the
dampening solution pan.
B.9.10 SC.999.0020/01
Dampening system
1. Remove water pan roller 18. For details on how to
do this, please refer to the "Removing the damp-
ening rollers" chapter.
2. Clean the dampening solution pan.
Please observe the specifications in the service
manual, chapter "A, General information/check-
lists".
Caution - Risk of press damage!
Only use cleaners that are certified for
Speedmaster machines dated 1995 or
later.
3. Fit water pan roller 18 again. For details on how to
do this, please refer to the "Fitting the dampening
rollers" chapter.
4.3 Removing dampening rollers
Dampening form roller 16 has to be disengaged from
SG.901.8912-001GRAUND_00
1 the plate cylinder.
2
Removing the water pan roller
1. Switch off the central dampening solution supply
3
at the control station.
4 2. Open the locking mechanism of the adjusting
screws by slackening the hexagon-head screw
(Fig. 5/1) on D.S. and O.S.
Tip
Use a pin wrench to move the hole in the
symbol disc (Fig. 5/3) downward. This
5 makes it easier to find the latest position
set.
Fig. 5 Water pan roller 3. Turn the adjusting screw (Fig. 5/2) on D.S. and on
O.S. back by 3 revolutions in the counterclock-
wise direction.
4. If the screw (Fig. 5/4) on the bearing shell is not
accessible, briefly press the Overdampening but-
ton.
The Allen key must make contact below the ad-
justing screw.
5. Slacken and remove the Allen screws (Fig. 5/4)
on the journals of water pan roller 18 on D.S. and
O.S.
Note
The Allen screws on D.S. and O.S. differ.
The Allen screw on D.S. has a high
head.
6. Press water pan roller 18 toward O.S. up to the
stop.
7. Grip water pan roller 18 by the recesses on the
side on D.S. and O.S. Roll water pan roller 18 out
SC.999.0020/01 B.9.11
Dampening system
of the dampening system over the edge of the
dampening solution pan.
8. Store water pan roller 18 in a protected place.
Removing the metering roller
SG.901.1604-007GRAUND_00
1. Release the screw on the journal on O.S.
(Fig. 6/1).
2. Slide metering roller 19 (Fig. 6/2) toward O.S. Lift
the roller journal on O.S.
3. Disengage the meshing of metering roller 19 on
D.S. Lift out metering roller 19.
1
Fig. 6 Removing the metering roller
Removing the intermediate roller
SG.901.8909-001GRAUND_00
1. Slacken the lock nuts on D.S. and O.S. (Fig. 7/1).
Fully unscrew the adjusting screws on the journal
box (Fig. 7/2) in the counterclockwise direction.
2. Take out intermediate roller 17.
1 Note
Removing intermediate roller 17
2 changes the adjustment with respect to
dampening form roller 16 and to the
first inking form roller 14. Readjust the
roller after reinstallation on the basis of
the contact areas.
Fig. 7 Removing the intermediate roller
B.9.12 SC.999.0020/01
Dampening system
Removing the dampening form roller
SG.901.1607-006GRAUND_00
1. Turn the adjusting screws (Fig. 8/2) on D.S. and
on O.S. 2 turns counterclockwise. This disen-
gages dampening form roller 16 from dampening
distributor FR.
2. Release the screw on the journal on O.S.
2 (Fig. 8/1). Remove the screw.
1 3. Slide dampening form roller 16 toward O.S.
4. Raise dampening form roller 16 on D.S. and re-
move it.
Fig. 8 Removing the dampening form roller
4.4 Installing and adjusting the dampening rollers
General notes
All adjusting screws have identical adjustment direc-
tions (exception: spring rod of the intermediate roller).
● Turning clockwise increases the width of the ink
stripe.
● Turning counterclockwise decreases the width of
the ink stripe.
All adjusting elements for roller adjustment are
equipped with a hexagonal recess. Use the T-wrench,
that is included in the scope of delivery of the printing
press, for adjustment.
First carry out a rough adjustment using strips of pa-
per. Next, check the result with bright ink via contact
areas.
Prior to the adjustment
● Printing plate is mounted on the plate cylinder.
● The inking form rollers have correctly been ad-
justed.
● Throw on the intermediate roller at the control
station. Diagonal register = 0.
● Grease all bearing points.
● Inch the press until the plate cylinder gap points
towards the delivery. If the gap is positioned un-
der the rollers, the adjustment result will be cor-
rupted.
Throwing on the dampening system
In order to obtain the same roller positions as in pro-
duction mode, you should adjust the rollers while the
dampening form rollers are thrown on.
1. Press the Throw dampening rollers on/off button
on the dampening system.
SC.999.0020/01 B.9.13
Dampening system
Inserting the dampening form roller
SG.901.1615-005GRAUND_00
1. Lay dampening form roller 16 (Fig. 9/1) into the
bearing shell on O.S. (Fig. 9/2) with the flattened
roller journal facing upward.
2. Insert dampening form roller 16 into the bearing
bore on D.S. up to the stop. Slide dampening
form roller 16 toward O.S. The screw thread must
1
correspond with the borehole in the roller journal.
2 3. Screw the roller journal to the bearing shell.
Tighten the Allen screw on O.S. (Fig. 9/3).
3
4. Use strips of paper for the adjustment.
Fig. 9 Dampening form roller
Roller adjustment with paper strip
SG.901.1623-001GRAENU_00
Smooth roller
1. At each side (D.S. and O.S.), place two paper
strips between the rollers to be adjusted.
Insert a strip of paper, approximately 5 cm wide,
towards the rubber roller, and another strip of pa-
per, approximately 2 cm wide, towards the
smooth roller/plate (Fig. 10). Both strips of paper
should have a total thickness of 0.10 mm.
2. Pull at the narrow strip of paper to determine
whether the adjustment is the same on D.S. and
on O.S.
Rubber roller
Fig. 10 Roller adjustment with paper strip
Adjusting the dampening form roller to the damp-
SG.901.8903-002GRAUND_00
ening distributor
1. Insert the strips of paper between dampening
form roller 16 and dampening distributor E (wide
strip pointing toward the dampening form roller).
FEAW
2. Adjust dampening form roller 16 to dampening
16 distributor FR using the adjusting screws
(Fig. 12/1).
FR When they are pulled out, the strips of paper must offer
the same slight resistance on D.S. and on O.S.
3. Remove the strips of paper. You should now be
Fig. 11 Dampening form roller and dampening dis- able to turn the roller easily by hand.
tributor 4. Turn the adjusting screws on both sides clock-
wise by 1.5 to 2 turns.
B.9.14 SC.999.0020/01
Dampening system
SG.901.1624-007GRAUND_00
1
Fig. 12 Adjusting screw for adjustment
SG.901.8907-002GRAUND_00 Adjusting the plate dampening roller relative to the
plate
1. Insert the strips of paper (wide strip pointing to-
ward the dampening form roller) between damp-
ening form roller 16 and the plate (with normal
packing thickness).
FEAW
16 2. Engage dampening form roller 16 with the plate
cylinder.
FR
Fig. 13 Adjustment dampening form roller - plate
3. Use the adjusting screw (Fig. 14/1) to adjust
SG.901.1626-006GRAUND_00
dampening form roller 16 to the plate. The ad-
justing screws on D.S. and on O.S. are self-lock-
ing. You need not lock the adjusting screws.
● Turning the screws clockwise increases the
pressure between dampening form roller 16
and the plate.
● Turning the screws counterclockwise re-
duces the pressure between dampening
form roller 16 and the plate.
1 When they are pulled out, the strips of paper must offer
the same slight resistance on D.S. and on O.S.
4. Remove the strips of paper.
Note
Fig. 14 Adjusting screw
In a subsequent step, the adjustment is
set to the exact distance of 5 ±1 mm us-
ing ink and ink stripe.
SC.999.0020/01 B.9.15
Dampening system
Installing the intermediate roller
SG.901.8908-002GRAUND_00
C Prior to inserting intermediate roller 17, adjust damp-
ening form roller 16 and the first inking form roller 14 to
the plate and dampening distributor FR or ink distrib-
14 ZW utor C.
17
Dampening form roller 16 and the first inking form
FEAW
16 roller 14 must be engaged with the plate. Neither roller
should be above the gap.
FR
Fig. 15 Installing the intermediate roller
1. Insert intermediate roller 17 into the supports
SG.901.1627-005GRAUND_00
(Fig. 16/1) on D.S. and on O.S.
The spring rods of the supports must be hooked in the
3 2 clamping device (Fig. 16/2). The sleeve (Fig. 16/3)
must be loose.
Fig. 16 Support for intermediate roller
2. Fasten intermediate roller 17 on both sides using
SG.901.8909-001GRAUND_00
the adjusting screws (Fig. 17/2).
Fig. 17 Adjusting screws
B.9.16 SC.999.0020/01
Dampening system
Adjusting the intermediate roller to the dampening
SG.901.1632-003GRAUND_00
form roller
Before adjusting the intermediate roller:
1. Throw on intermediate roller 17 at the control sta-
17 tion.
The inking unit is in contact with the dampening
16 system. On Vario presses, Vario mode must be
FEAW
switched off. Diagonal register = 0.
2. Throw on dampening form roller 16 and inking
form rollers 1 ... 4.
3. Insert strips of paper between intermediate roller
Fig. 18 Adjustment intermediate roller - dampening 17 and dampening form roller 16 (narrow strip
form roller pointing toward the intermediate roller).
Note
SG.901.8909-001GRAUND_00
Before adjusting the adjusting screws on
D.S. and O.S., slacken the lock nuts
(Fig. 19/1). Use the T-handle Allen key to
adjust the adjusting screws.
1 4. Use the adjusting screws (Fig. 19/2) on D.S. and
O.S. to move intermediate roller 17 so that it is in
2 light contact with dampening form roller 16. The
strips of paper must offer the same slight resis-
tance when they are pulled out.
5. Remove the strips of paper.
6. Turn the adjusting screws on D.S. and on O.S.
(Fig. 19/2) half a turn in clockwise direction.
7. Tighten the lock nuts on D.S. and on O.S.
(Fig. 19/1).
Fig. 19 Adjusting screws
Adjusting the intermediate roller to the inking form
SG.901.1628-005GRAUND_00
roller
1 2 3 Prior to the adjustment, throw on the dampening form
roller and inking form rollers 1 ... 4 on the control sta-
tion.
1. Release the lock screws (Fig. 20/1) on D.S. and
on O.S.
2. Release the sleeve (Fig. 20/2) on D.S. and on
O.S., until it is at some distance to the bearing
block (Fig. 20/3).
3. Turn the sleeve on D.S. and on O.S. back until it
is again in contact with the bearing block and you
can feel the resistance of the spring.
4. Using a 1/10-mm feeler gauge, check the printing
pressure of intermediate roller 17 to inking form
Fig. 20 Intermediate roller and inking form roller
roller 14 and of intermediate roller 17 to damp-
ening form roller 16. The gap must be equal be-
tween D.S. and O.S.
5. Tighten the lock screws (Fig. 20/1) on D.S. and
on O.S.
SC.999.0020/01 B.9.17
Dampening system
Note
When switching off inking form rollers
1 ... 4, the intermediate roller is raised by
the 1st inking form roller. The intermedi-
ate roller must be raised equally on D.S.
and on O.S. when the intermediate roller
shows a parallel contact area to the
1st inking form roller. This is shown by
the gap that appears between sleeve
(Fig. 20/2) and bearing block (Fig. 20/3).
Note
The setting of the stripe to the dampen-
ing form roller and the first inking form
roller must always be made together,
since the adjustment of one stripe influ-
ences the other. First adjust the stripe to
the dampening form roller and then the
stripe to the inking form roller.
Installing the water pan roller
SG.901.8912-001GRAUND_00
1 1. Grip water pan roller 18 by the recesses on the
2 side. Carefully lift or roll the water pan roller over
the support (Fig. 21/5) of the level sensor. Place
the water pan roller on the edge of the dampening
3
solution pan. Align the water pan roller centrally
between the adjusting screws (Fig. 21/2) on D.S.
4
and O.S.
2. Roll water pan roller 18 carefully into the bearing
shells over the edge of the dampening solution
pan.
3. Slide water pan roller 18 toward D.S.
5 4. Screw down the journals on D.S. and O.S. on the
bearing shells.
Fig. 21 Water pan roller Note
The Allen screws on D.S. and O.S. differ.
The Allen screw on D.S. has a high
head.
5. If you just removed water pan roller 18 in order to
clean the dampening solution pan, and metering
roller 19 is installed:
Turn back the adjusting screws into their initial
position. Use the indicator ring (Fig. 21/3) to re-
trieve the most recent position.
Close the locking mechanism of the adjusting
screws by tightening the hexagon-head screw
(Fig. 21/1) on D.S. and O.S.
B.9.18 SC.999.0020/01
Dampening system
Fitting the metering roller
SG.901.1605-000GRAUND_00
1
Note
The metering roller and water pan roller
have exactly the same length. When fit-
ting, ensure that the metering roller and
water pan roller are flush to each other
on the outside.
1. Insert metering roller 19 with roller journal into the
borehole on D.S. (Fig. 22/1) and engage the gear
2 (Fig. 22/2). Lay down the roller journal on the
bearing shell on O.S. with the flat side facing up-
ward.
2. Lightly tighten the screw (Fig. 23/1) such that it is
still possible to move the metering roller
Fig. 22 Fitting the metering roller D.S. (Fig. 23/2) in the axial direction.
SG.901.1604-007GRAUND_00 3. Align the metering roller (Fig. 23/2) in the axial
direction in such a way that the outside is flush
with the water pan roller.
4. Screw the roller journal on O.S. to the bearing
shell.
Fig. 23 Fitting the metering roller O.S.
Adjusting the metering roller to the water pan
SG.901.8905-002GRAUND_00
roller
1. Allow dampening solution to flow in.
2. Disengage dampening form roller 16 from the
plate at the control station.
DW
FEAW 19 3. Release the hexagon-head screws on the bear-
16 T
ing plates (Fig. 25/1) on D.S. and on O.S.
18 4. Allow water pan roller 18 and metering roller 19 to
turn.
Press the Wash dampening rollers button.
5. Disengage metering roller 19 from water pan
Fig. 24 Adjusting the metering roller to the water pan roller 18.
roller
Turn the adjusting screws (Fig. 25/2) on D.S. and
on O.S. in counterclockwise direction, until there
is a closed dampening solution film on the entire
water pan roller surface.
6. Engage metering roller 19 with water pan roller
18.
Turn the adjusting screws on D.S. and on O.S. in
clockwise direction until the center of the roller
becomes dull.
SC.999.0020/01 B.9.19
Dampening system
7. Engage metering roller 19 with water pan roller
SG.901.1629-004GRAUND_00
18 until a 10 cm wide strip of water forms on the
left and right of water pan roller 18.
8. Turn the adjusting screw another half turn in
clockwise direction.
9. Tighten the hexagon-head screws (Fig. 25/1).
10. Use the pin wrench to position the hole in the
symbol disc (Fig. 25/3) downwards.
Note
The hole in the symbol disc makes it
1 easier for you to find the basic adjust-
ment again if you wish to disengage wa-
2
ter pan roller 18 from metering roller 19,
3 for example in a poorly lit environment.
Fig. 25 Adjusting the metering roller to the water pan
roller
Adjusting the metering roller relative to the plate
SG.901.8906-002GRAUND_00
dampening roller
Proper adjustment is only possible when the plate
cylinder gap points towards the delivery.
1. Dry metering roller 19 with a cloth.
DW 2. Disengage metering roller 19 from dampening
16 19
FEAW form roller 16.
Turn the adjusting screws (Fig. 27/1) on D.S. and
on O.S. in counterclockwise direction.
3. Insert strips of paper between metering roller 19
and dampening form roller 16 (narrow strip point-
Fig. 26 Metering roller and dampening form roller ing toward the metering roller).
4. Engage the dampening rollers.
SG.901.8910-001GRAUND_00
5. Using the adjusting screws (Fig. 27/1) on D.S.
and on O.S., adjust metering roller 19 to damp-
ening form roller 16.
When they are pulled out, the strips of paper must
offer the same slight resistance on D.S. and on
1 O.S.
6. Disengage the dampening rollers.
7. Turn the adjusting screws (Fig. 27/1) on D.S. and
on O.S. another 1.5 turns in clockwise direction.
Fig. 27 Metering roller and dampening form roller
B.9.20 SC.999.0020/01
Dampening system
Checking the roller adjustment with contact strips
SG.901.1631-006GRAUND_00
During adjustment, inch the press until the plate cylin-
der gap points towards the delivery.
3 +1 mm
1. Switch off the dampening solution feed and allow
2,5 +1 mm
14 the dampening solution pan to run empty.
ZW 5 +1 mm
17 2. Switch off water pan roller 18 at the control sta-
4 -1 mm tion.
19 3. Fill the inking unit with a light ink and distribute it.
5 +1 mm 16
FEAW DW
Note
T
Dampening distributor FR must be cov-
18
6 +1 mm ered with dampening solution before you
FR engage intermediate roller 17 with inking
form roller 14 and dampening form roller
16.
Fig. 28 Ink stripe width (guide values) 4. At the control station, adjust intermediate roller
17 so that it is in contact with inking form roller 14
and dampening form roller 16. This inks up the
dampening system roller too.
5. When the ink is evenly distributed, stop the press
and wait for a few seconds.
Ink stripes are produced at the points of contact
on the inked rollers.
Note
The ink stripe must have the same width
on D.S. and on O.S. The roller con-
cerned must be readjusted when the ink
stripes deviate from the specifications in
Figure 28.
6. Adjust the ink stripe width between dampening
form roller 16 and dampening distributor FR.
Ink stripe width: 6 +1 mm
7. Adjust the ink stripe width between dampening
form roller 16 and the plate.
Engage the inking and inking form rollers with the
plate and then disengage them. Intermediate
roller 17 must be in contact with dampening form
roller 16 and inking form roller 14.
The contact pressure has an influence on the ink
stripe width between dampening form roller 16
and inking form roller 14.
Ink stripe width: 5 ±1 mm.
8. Adjust the ink stripe width between metering
roller 19 and dampening form roller 16.
Ink stripe width: 5 +1 mm.
9. Adjust the ink stripe width between intermediate
roller 17 and dampening form roller 16.
Ink stripe width: 2.5 +1 mm.
10. Adjust the ink stripe width between intermediate
roller 17 and ink form roller 14.
SC.999.0020/01 B.9.21
Dampening system
Ink stripe width: 3 +1 mm.
11. Clean the rollers of the dampening system after
the adjustment.
Checking that dampening solution is supplied
evenly over the entire image width
1. Allow the press to run with evenly inked up rollers
whilst the dampening form rollers and inking form
rollers are engaged.
2. The printing plate shall run uniformly on D.S. and
on O.S.
Adjust the water pan roller speed on the control
station correspondingly.
The plate must run clean evenly when the water pan
roller speed is increased. The ink must come off the
non-printing plate surface.
3. If the plate does not run clean evenly on D.S. and
O.S., correct the setting between metering roller
19 and water pan roller 18.
4. Disengage the dampening rollers.
5. Loosen the hexagon-head screws (Fig. 29/1) on
SG.901.1629-004GRAUND_00
D.S. and on O.S.
6. Use the adjusting screws (Fig. 29/2) on D.S. and
on O.S. to correct the adjustment.
● Turning the adjusting screw in clockwise di-
rection: The printing pressure between me-
tering roller 19 and water pan roller 18 is in-
creased. The transferred dampening solu-
tion amount is reduced.
● Turning the adjusting screw in counter-
clockwise direction: The printing pressure
1 between metering roller 19 and water pan
2 roller 18 is reduced. The transferred damp-
ening solution amount is increased.
3
7. Tighten the hexagon-head screws (Fig. 29/1) on
D.S. and on O.S.
Fig. 29 Adjusting screws
B.9.22 SC.999.0020/01
Dampening system
5 Blower bar
SC.B01.0002-000UTKENU_00
5.1 Setting the blower bar
Application
SG.901.0986-001GRAUND_00
In certain situations (such as low ink consumption of
the print motif), excess dampening solution can build
up in the inking unit. The blower bar contains a radial
fan which blows on an inking roller, thus causing parts
of the excess dampening solution to evaporate.
1 Disposing of excess dampening solution
The blower bar can be switched on and off at the con-
trol station. When the blower bar is switched on, the
blast air can be adjusted individually for separate
zones.
1. If you wish to dispose of excess dampening so-
lution, open the corresponding segment
(Fig. 30/1).
Fig. 30 Blower bar
SC.999.0020/01 B.9.23
Dampening system
6 Cleaning the dampening system
SG.901.0904-000UTKENU_07
6.1 Manually cleaning water pan roller and metering roller
Water pan roller 18 is not washed together with the
SG.901.3142-001GRAUND_00
press.
The motor-driven water pan roller 18 and metering
roller 19 stop when the dampening system guard is
swung up.
ZW
1. Allow the rollers to rotate. Press the Wash damp-
19 ening rollers button.
FEAW DW 2. Clean water pan roller 18 and metering roller 19
using a non-aggressive, fat free solvent and a
18 cloth soaked in alcohol.
T 3. Rinse with clear water.
FR
Caution - Risk of press damage!
Never use abrasive or acidic detergents
Fig. 31 Cleaning the water pan roller and the meter- for cleaning chromium-plated roller sur-
ing roller faces.
6.2 Notes on maintaining the dampening distributor
Clean the surface of the dampening distributor with
special care. This preserves the hydrophilic property
of the dampening distributor surface.
Prior to each contact with washing fluid or ink, the
chrome surface must always be moistened with water
and/or a water-alcohol mixture (such as a dampening
solution).
If you ink up the dry dampening distributor, this can
lead to a significantly poorer feed of dampening solu-
tion during the printing process.
In the event of long periods where no printing is
performed and during breaks
1. Press stops of more than 5 minutes:
Do not allow the press to continue running with
inked up inking and dampening rollers. If the
press is not going to print for more than 5 min,
stop the press.
2. Press stops of more than 1 hour:
Wash the inking rollers, the dampening rollers
and the printing plate.
3. Engage the dampening system with the plate and
allow it to turn for at least 1 minute.
Before the weekend
1. Start a wash program at the control station to
wash the inking rollers.
2. Clean the dampening system with a standard
commercial roller cleaning paste. Allow the paste
to react on the rollers for at least 5 minutes.
B.9.24 SC.999.0020/01
Dampening system
3. Wash the inking unit and the dampening system.
4. Engage the dampening system with the plate and
allow it to turn for at least 1 minute.
SC.999.0020/01 B.9.25
Dampening system
B.9.26 SC.999.0020/01
Delivery
Delivery
Delivery
1 Delivery - safety instructions ............................................................................................... B.10.7
1.1 To be observed when performing work .......................................................................... B.10.7
2 Operator protection through the protective device for the detection of whole body
access, DWBA ....................................................................................................................... B.10.10
2.1 What is the protective device for? .................................................................................. B.10.10
2.2 Arrangement of the light barriers ................................................................................... B.10.10
2.3 Control panels ................................................................................................................ B.10.11
2.4 Fault displays ................................................................................................................. B.10.13
2.5 Unlocking the DWBA when starting up the press .......................................................... B.10.14
2.6 Inserting strips and setting wedges with the DWBA ...................................................... B.10.14
2.7 Removing sample sheets with the DWBA ..................................................................... B.10.15
2.8 Pile change with the DWBA ........................................................................................... B.10.16
3 Guide pulleys ......................................................................................................................... B.10.19
3.1 Guide pulleys on the delivery ........................................................................................ B.10.19
3.2 Fields of application ....................................................................................................... B.10.20
3.3 Functioning principle of the locking device ................................................................... B.10.21
3.4 Fitting the guide pulley .................................................................................................. B.10.22
3.5 Positioning the guide pulleys ........................................................................................ B.10.24
3.6 Guide pulley with sheet supports .................................................................................. B.10.25
3.7 Removing a guide pulley ............................................................................................... B.10.26
4 Cover plates on the delivery ................................................................................................ B.10.27
4.1 Function/Task ................................................................................................................ B.10.27
4.2 Cover plates on the sheet ascent ramp ........................................................................ B.10.27
4.3 Cover plates in the horizontal area ............................................................................... B.10.30
4.4 Cover plates behind CleanStar ..................................................................................... B.10.31
4.5 Cover plate before rows of fans ..................................................................................... B.10.34
4.6 Cleaning the sheet guide plate under the CleanStar .................................................... B.10.35
5 Air in the sheet ascent ramp ................................................................................................ B.10.36
5.1 Suction and blast air on the delivery .............................................................................. B.10.36
5.2 Control panels for the air settings ................................................................................. B.10.36
5.3 Mask on the Prinect Press Center ................................................................................. B.10.37
5.4 Recommended setting - transfer zone .......................................................................... B.10.38
5.5 Recommended setting - sheet ascent ramp area ......................................................... B.10.39
5.6 Recommended setting - extension area ....................................................................... B.10.39
5.7 Sheet decurler ............................................................................................................... B.10.40
SC.999.0020/01 B.10.1
Delivery
6 Air in the pile area ................................................................................................................. B.10.41
6.1 General notes ................................................................................................................ B.10.41
6.2 Switching fans ON/OFF ................................................................................................ B.10.41
6.3 Adjusting the fans ......................................................................................................... B.10.42
6.4 Positioning the fans ....................................................................................................... B.10.43
6.5 Longitudinal blast tubes ................................................................................................ B.10.43
7 Powder spray device ............................................................................................................ B.10.44
7.1 Maintenance work .......................................................................................................... B.10.44
7.2 Powdering from below (optional) .................................................................................. B.10.44
8 Print-related notes on powdering ........................................................................................ B.10.45
8.1 Powder application - why is powdering necessary? ..................................................... B.10.45
8.2 Choosing the powder grain size and required powder .................................................. B.10.45
8.3 Disadvantages of powdering ......................................................................................... B.10.45
8.4 Required powder quality ............................................................................................... B.10.45
8.5 Factors that determine the powder volume ................................................................... B.10.46
8.6 To be observed during production ................................................................................ B.10.46
8.7 Powdering from below (optional) .................................................................................. B.10.46
8.8 Adjusting the stabilizing nozzles (optional) ................................................................... B.10.47
8.9 Checking the powder application .................................................................................. B.10.47
9 Format bridging device ......................................................................................................... B.10.49
9.1 Method of functioning and equipment ........................................................................... B.10.49
9.2 Setting the blast air ....................................................................................................... B.10.49
9.3 Cleaning ........................................................................................................................ B.10.49
10 Sheet brake system - Overview and variants ..................................................................... B.10.51
10.1 Types ............................................................................................................................. B.10.51
10.2 Chapter overview ........................................................................................................... B.10.51
11 Modular sheet brake system - overview ............................................................................. B.10.52
11.1 Design and components ................................................................................................ B.10.52
11.2 Component overview ..................................................................................................... B.10.53
11.3 Overview of adjustments ................................................................................................ B.10.56
11.4 Recommended settings for air and speed ..................................................................... B.10.58
12 Modular sheet brake system - handling the sheet brake modules .................................. B.10.59
12.1 Module support .............................................................................................................. B.10.59
12.2 Entering the component setup on the control system .................................................... B.10.59
12.3 Setting the valve on the module support ........................................................................ B.10.61
12.4 Setting the sheet brakes at an angle ............................................................................. B.10.62
B.10.2 SC.999.0020/01
Delivery
12.5 Inclining the brake modules ........................................................................................... B.10.63
12.6 Adjusting the friction wheel at the sheet brake module (tandem component setup) ...... B.10.64
12.7 Manually adjusting the position of the sheet brake module supports ............................ B.10.65
12.8 Removing/fitting a sheet brake module .......................................................................... B.10.66
12.9 Removing/fitting a starwheel module ............................................................................ B.10.68
12.10 Replacing starwheels ..................................................................................................... B.10.69
12.11 Replacing a sheet brake tape ........................................................................................ B.10.71
12.12 Maintenance / Cleaning ................................................................................................. B.10.71
12.13 Removing and fitting the sheet stop ............................................................................... B.10.72
12.14 Removing/fitting magnetic starwheel holders ................................................................ B.10.73
13 Modular sheet brake system - configuration variants for straight printing .................... B.10.75
13.1 General .......................................................................................................................... B.10.75
13.2 Standard component setup ............................................................................................ B.10.75
13.3 Maximum component setup for straight printing ............................................................ B.10.76
14 Modular sheet brake system - Component versions for straight printing and perfecting B.10.78
14.1 Component setup of the sheet brakes ........................................................................... B.10.78
14.2 Standard component setup ............................................................................................ B.10.79
14.3 Outer module supports in park position ......................................................................... B.10.80
14.4 Alternative component setup with 2 starwheel modules ................................................ B.10.81
14.5 Alternative population for small image-free area or small sheet size ............................. B.10.82
15 Modular sheet brake system - Remedies in the event of problems ................................. B.10.84
15.1 Remedies in the event of problems ............................................................................... B.10.84
16 Suction tapes ......................................................................................................................... B.10.85
16.1 Properties ....................................................................................................................... B.10.85
16.2 Suction tapes for sheet brake modules - tape width 10 mm .......................................... B.10.86
16.3 Suction tapes for sheet brake modules - tape width 20 mm .......................................... B.10.86
17 Gripper opening cam ............................................................................................................. B.10.87
17.1 Function ......................................................................................................................... B.10.87
17.2 Setting the gripper opening cam ................................................................................... B.10.87
17.3 Interplay between gripper opening, sheet brake and delivery air .................................. B.10.88
18 Overrun sheet control ............................................................................................................ B.10.90
18.1 Method of functioning .................................................................................................... B.10.90
18.2 Ultrasonic sensor .......................................................................................................... B.10.90
18.3 Comb ............................................................................................................................ B.10.91
SC.999.0020/01 B.10.3
Delivery
19 Sheet joggers ........................................................................................................................ B.10.92
19.1 Function ........................................................................................................................ B.10.92
19.2 Setting the lateral sheet joggers automatically ............................................................. B.10.92
19.3 Setting the lateral sheet joggers manually .................................................................... B.10.92
19.4 Setting the lateral sheet joggers to the sheet length ..................................................... B.10.94
19.5 Activating/deactivating the alignment movement of the lateral sheet joggers and at the
front edge ...................................................................................................................... B.10.95
20 Rear edge stop ...................................................................................................................... B.10.96
20.1 Function ........................................................................................................................ B.10.96
20.2 Setting the rear edge stop automatically ....................................................................... B.10.96
20.3 Setting the rear edge stop manually ............................................................................. B.10.97
20.4 Rear edge suction ......................................................................................................... B.10.98
21 CleanStar (option) ................................................................................................................. B.10.99
21.1 Function ........................................................................................................................ B.10.99
21.2 Operation ....................................................................................................................... B.10.99
21.3 Cleaning ......................................................................................................................... B.10.101
22 Removal of sample sheet ...................................................................................................... B.10.103
22.1 Function ........................................................................................................................ B.10.103
22.2 Removing sample sheets ............................................................................................... B.10.103
22.3 Removal of sample sheet with CleanStar ..................................................................... B.10.104
23 Tape inserter ........................................................................................................................... B.10.105
23.1 General information on tape inserter ............................................................................ B.10.105
23.2 Position of tape inserter ................................................................................................ B.10.105
24 Tape inserter on face side .................................................................................................... B.10.106
24.1 Design and function ...................................................................................................... B.10.106
24.2 Notes on operating the tape inserter ............................................................................. B.10.106
24.3 Inserting/changing a tape roll ........................................................................................ B.10.107
24.4 Cleaning tape inserter ................................................................................................... B.10.108
25 Lateral tape inserter D.S. / O.S. ............................................................................................ B.10.109
25.1 Function and design ...................................................................................................... B.10.109
25.2 Information on operating the tape inserter .................................................................... B.10.109
25.3 Inserting/changing the tape roll ..................................................................................... B.10.110
25.4 Resetting the tape inserter ............................................................................................ B.10.112
25.5 Lifting/lowering the tape inserter ................................................................................... B.10.112
25.6 Removing the tape module and tape feeder ................................................................. B.10.113
25.7 Cleaning the tape inserter ............................................................................................. B.10.114
25.8 Malfunctions .................................................................................................................. B.10.114
B.10.4 SC.999.0020/01
Delivery
26 Pile change ............................................................................................................................. B.10.117
26.1 Determining the actual size of the sheet ........................................................................ B.10.117
26.2 Function ........................................................................................................................ B.10.117
26.3 Pile control panel .......................................................................................................... B.10.118
26.4 Pile change ................................................................................................................... B.10.118
27 Non-stop operation ................................................................................................................ B.10.120
27.1 Function ........................................................................................................................ B.10.120
27.2 Equipment ...................................................................................................................... B.10.121
27.3 Sheet catcher in non-stop operation ............................................................................. B.10.122
27.4 Settings on the control station ........................................................................................ B.10.122
27.5 Recommended adjustments ......................................................................................... B.10.123
27.6 Checking the non-stop rake ........................................................................................... B.10.124
27.7 Manual non-stop operation ........................................................................................... B.10.124
27.8 Performing non-stop operation with non-stop rake ....................................................... B.10.126
27.9 Non-stop operation with rack board .............................................................................. B.10.127
27.10 Performing non-stop operation with rack board ............................................................. B.10.128
27.11 Non-stop pile changing with CleanStar .......................................................................... B.10.129
27.12 Elimination of malfunctions during non-stop pile changes ............................................ B.10.129
28 Automatic non-stop system ................................................................................................. B.10.132
28.1 Equipment ...................................................................................................................... B.10.132
28.2 Specifications ................................................................................................................. B.10.132
28.3 Determining the actual sheet size ................................................................................. B.10.133
28.4 Delivery control console ................................................................................................. B.10.133
28.5 Recommended settings ................................................................................................ B.10.134
28.6 Overview of the functional sequence for an automatic pile change ............................... B.10.134
28.7 Overview of the functional sequence for a rack change ................................................ B.10.136
28.8 Troubleshooting for an automatic non-stop pile change ............................................... B.10.138
29 Print-related information on the auto-non-stop system (optional) ................................... B.10.140
29.1 Function ......................................................................................................................... B.10.140
29.2 Required checks before an automatic pile change ....................................................... B.10.140
30 Troubleshooting on the delivery ......................................................................................... B.10.142
30.1 Overview ........................................................................................................................ B.10.142
30.2 Sheet drop at front edge ................................................................................................ B.10.142
30.3 Sheet drop at rear edge ................................................................................................. B.10.142
30.4 Excessive shingling ........................................................................................................ B.10.143
30.5 Marks ............................................................................................................................. B.10.143
SC.999.0020/01 B.10.5
Delivery
30.6 Pile formation ................................................................................................................. B.10.144
30.7 Sheet guide .................................................................................................................... B.10.145
B.10.6 SC.999.0020/01
Delivery
1 Delivery - safety instructions
SF.901.9000-000UTKENU_00
1.1 To be observed when performing work
Warning - Risk of injury from mov-
ing chain gripper systems!
Prior to any extensive work in the de-
livery that takes more than 5 minutes
to complete:
- Switch the main switch to 0/OFF and
lock it with a padlock.
- Leave a sign with the name of the
person authorized to switch on the
press.
Prior to any work in the delivery:
- Press the Emergency-stop palm but-
ton on the delivery control panel.
- Open the front guard on the delivery,
if existent.
When performing work while the press
is running (for example pile change,
removal of sample sheets, work with
spacer wedges), pay particular atten-
tion to the movement of the chain grip-
per systems.
Warning - Risk of injury by moving
pile support plate!
Prior to raising or lowering the pile sup-
port plate: Ensure, by means of a vi-
sual inspection that no-one is standing
in the hazardous area of moving parts
and that nothing can be jammed un-
derneath the pile support plate.
When the press is switched on: Never
stand underneath the pile support
plate. Do not sit on the pile support
plate. Do not ride on the pile support
plate.
SC.999.0020/01 B.10.7
Delivery
Warning - Explosion hazard and fire
hazard due to dust deposits!
Dust, such as powder or paper dust,
can result in fire hazard or explosion
hazard.
Therefore, clean the areas affected by
dust regularly, at least once a week,
using a vacuum cleaner.
Only use suitable and approved indus-
trial vacuum cleaners and avoid work-
ing with compressed air, as this could
swirl up the dust.
Warning - Risk of injury from falling!
There is a risk of falling and thus suf-
fering serious bodily injuries when
climbing on or off in the area of the
white sheet metal.
Only step on the designated foot-
boards (gray bulb plate) from the drive
side.
Caution - Damage to the delivery
caused by incorrect alignment of pal-
let and pile!
Please pay attention to the following
when raising a pallet or pile manually or
in non-stop mode: The pallet or paper
pile must be aligned correctly to avoid
damaging the front and lateral sheet jog-
gers. The non-stop rake must be posi-
tioned exactly in the grooves of the pal-
let. Piles or pallets may not be raised too
high as otherwise the gripper bars or the
nonstop rake may be damaged. There
must be no objects (e.g. wedges) on the
pallet or pile.
B.10.8 SC.999.0020/01
Delivery
Caution - Damage to the delivery
caused by malfunction of the pile
height sensor!
If the error message Pile height sensor
does not detect any printing material
is displayed on the control station, the
pile drive runs in emergency mode with-
out monitoring. The delivery pile is low-
ered by a calculated value. Depending
on the printing material and area cover-
age, the delivery pile can become bulky
and be hit by the gripper bars.
When in emergency mode, monitor the
pile height of the delivery pile with par-
ticular care. If necessary, move the de-
livery pile further downward manually.
Eliminate the cause of the emergency
mode (the sensor may be dirty). Contact
Heidelberg Service immediately if you
are not able to find the cause of the
emergency mode.
SC.999.0020/01 B.10.9
Delivery
2 Operator protection through the protective device for the detection of whole
SG.901.9117-000UTKENU_11
body access, DWBA
2.1 What is the protective device for?
This protective device protects you against hazards
from movable parts in the delivery. It prevents a restart
of the press while persons are inside the delivery.
The device for the detection of whole body access,
hereinafter referred to as DWBA, consists of several
light barriers that monitor the access openings at the
front and sides of the delivery. Using light beams, the
light barriers detect a whole body access in the open
places of the delivery.
When a light beam is interrupted (by the operator, for
example), the corresponding light barrier issues a sig-
nal that stops:
● the main drive,
● the pile drives,
● if applicable, the servo-drives for the sheet jog-
gers and the sheet brake.
2.2 Arrangement of the light barriers
The front, drive side and operator side of the delivery
are safeguarded by three light barriers each at varying
heights.
The light barriers consist of one transmitter rail and
one receiver rail with 3 light beams or light beam pairs
each.
The following pages inform you of function and han-
dling of these protective devices, and give you hints
that shall help you to avoid spurious tripping.
Selecting the removal direction of the delivery pile
There are the following options for the removal direc-
tion:
● Pile removal from the front side and D.S.
or
● Pile removal from the front side and O.S.
Please contact Heidelberg Service if you want to
change the lateral removal direction.
B.10.10 SC.999.0020/01
Delivery
Monitoring range delivery front side
SF.901.9100-000GRAUND_00
Here the pile support plate projects into the range of
the light beams. In order to avoid triggering the pro-
tective mechanism unnecessarily, each light barrier
has 2 light beams which need to be broken at the same
time to trigger the mechanism.
These light beams are spaced slightly apart so that the
pile support plate can only break one light beam.
1 ● Front light beams, top (Fig. 1/1)
4
● Front light beams, middle (Fig. 1/2)
2 5 ● Front light beams, bottom (Fig. 1/3)
● S = transmitter strip
3 6 ● E = receiver strip
Monitoring range delivery O.S.
Fig. 1 Delivery ● O.S light beam, top (Fig. 1/4)
● O.S. light beam, middle (Fig. 1/5)
● O.S. light beam, bottom (Fig. 1/6)
● S = transmitter strip
● E = receiver strip
Monitoring range delivery D.S.
The monitoring range is the same as on O.S.
2.3 Control panels
Design of the control panel
SG.901.8902-002GRAUND_00
There is a control panel on both the D.S. and O.S.
sides of the pile area and one in front of the pile. The
1 functions are the same on all control panels. Each
control panel influences and shows the status of the
DWBA at its side.
● DWBA - deactivate evaluation top button
2 (Fig. 2/2)
When the press is stopped: Pressing the button does
not have an effect.
When the press is running: Pressing the DWBA - de-
3 activate evaluation top button deactivates the surveil-
lance of the upper light barrier on this side for 20 sec-
onds. You can use this time for setting wedges, for
example.
4
The DWBA - evaluation inactive signal lamp is ON
during this time. (Fig. 2/4)
You may extend the deactivation time if these 20 sec-
onds are insufficient. The deactivation time is extend-
5 ed by another 20 seconds when you press the DWBA
- deactivate evaluation top button again.
● DWBA - pile exit button (Fig. 2/5)
Fig. 2 Design of control panel Pressing the DWBA - pile exit button deactivates the
surveillance at the exit side. This enables you to re-
move the pile. More detailed information about the pile
SC.999.0020/01 B.10.11
Delivery
changing sequence can be found in the section "Pile
change with the DWBA".
● Signal light Automatic procedure in progress
(Fig. 2/1), optional
Note
Please note that the control panels of
presses without an AutoPlate Pro plate
changer are not equipped with the ad-
ditional signal light Automatic procedure
in progress (Fig. 2/1).
The signal light Automatic procedure in progress flash-
es orange during an automatic plate change. The DW-
BA is active.
Do not carry out any work on the press while the Au-
tomatic procedure active signal light is flashing.
Do not carry out any work on or in the delivery while the
Automatic procedure active signal light is flashing.
● DWBA - monitoring signal lamp (Fig. 2/3)
The signal lamp is OFF: The monitoring at this side is
currently deactivated.
The signal lamp lights up green: The monitoring func-
tion on this side is activated.
The signal lamp lights up red: The monitoring device at
this side has responded. Depending on press config-
uration and operating status, the following drives are
stopped:
● Main drive
● Pile drives
● Servo-drives for sheet joggers and sheet brake.
Unlocking the drives: Press the Reset button (Fig. 3).
● DWBA - deactivation signal lamp (Fig. 2/4)
Signal lamp turns yellow: the monitoring function of at
least one light barrier has been deactivated. You may
now work inside the deactivated zone.
Signal lamp flashes in yellow (during last five seconds
of hide time): monitoring is still deactivated, but will
soon be activated again. Terminate your work in the
monitored area, or extend the deactivation time.
Reset button (Fig. 3)
FS.901.2061-001GRAUND_00
Press this button to unlock the press after the protec-
1 tive device has responded.
The Reset button is on the front side of the delivery.
1. Press the Reset button (Fig. 3) described in
Chapter A "Safety".
For elevated presses a foot switch is located in the pile
disposal area on the drive side or the operator's side
Fig. 3 Reset key that acts as a Reset button. The foot switch resets the
side on which it is located. The button at the front re-
sets the other areas. After switching on the press you
need to press the foot switch and the button at the front
for resetting purposes.
B.10.12 SC.999.0020/01
Delivery
Status of the DWBA
The status of the DWBA is indicated by the signal
lamps (Fig. 2/3 and Fig. 2/4). The colors of the signal
lamps have the following meaning:
● DWBA green = the DWBA is activated on this
side.
● DWBA red = the DWBA has responded and
blocks.
● DWBA yellow = the DWBA is deactivated at this
side. The deactivation time is running.
● DWBA yellow = the DWBA is deactivated at this
side. The last 5 seconds of the deactivation time
are running.
2.4 Fault displays
Fault displays when the DWBA responds
If the protective device is triggered, a fault is displayed:
● Fault display in the delivery
● Fault location = 12 or 70 (depends on the press)
Error messages on the control station
If a malfunction occurs at the DWBA, one of the fol-
lowing error messages is displayed at the control sys-
tem:
DWBA - movement lock main drive
1. Perform a visual check to ensure that there is no-
body in the hazardous zone of the delivery.
2. Unlock the main drive using the Reset button as
descried in chapter A "Safety".
DWBA - movement lock delivery drives
1. Perform a visual check to ensure that there is no-
body in the hazardous zone of the delivery.
2. Unlock the delivery drives using the Reset button
as described in chapter A "Safety".
DWBA soiled
1. Clean the windows of the light barrier at trans-
mitter and receiver side.
DWBA - error
1. Please notify Heidelberg Service.
Plausibility test error
DWBA - movement lock main drive
1. Please notify Heidelberg Service.
DWBA - warning current monitoring LED
1. Please notify Heidelberg Service.
SC.999.0020/01 B.10.13
Delivery
2.5 Unlocking the DWBA when starting up the press
When you switch on the press (main switch ON), the
DWBA is in the "triggered" state (DWBA red) and locks
the main drive and the drives in the delivery. Prior to
putting the press into operation you must unlock the
DWBA.
1. Perform a visual check to ensure that there is no-
body in the hazardous zone of the delivery, in
particular not in the range of the chain gripper
systems and the pile support plates.
2. Unlock the detection of whole body access using
the Reset button as described in the chapter A
"Safety".
Result
The DWBA is active (DWBA green). The
DWBA releases the drives. You may
now start up the press.
2.6 Inserting strips and setting wedges with the DWBA
The press is stopped
The DWBA is always active when the press is stopped
(DWBA green). The DWBA responds when you work
in the surveillance area of the DWBA (DWBA red).
Prior to starting up the press or one of the drives in the
delivery, you must unlock the DWBA by pressing the
Reset button (or the corresponding foot switch) as de-
scribed in the chapter A "Safety".
1. Perform a visual check to ensure that there is no-
body in the hazardous zone of the delivery, in
particular not in the range of the chain gripper
systems and the pile support plates.
2. Unlock the detection of whole body access using
the Reset button as described in the chapter A
"Safety".
Result
The DWBA is active (DWBA green). The
DWBA releases the drives. You may
now start up the press.
The press is running (the main drive turns)
The DWBA - deactivate evaluation top enables you to
deactivate the top light beam at one of the 3 sides. The
signal lamp DWBA - evaluation inactive shines at this
side (DWBA yellow).
Result
You have now 20 seconds to complete
your work at this side (such as inserting
wedges or aligning print sheets).
When the DWBA - evaluation inactive signal lamp
starts blinking, you must either terminate your work or
extend the deactivation time. Pressing the DWBA -
B.10.14 SC.999.0020/01
Delivery
deactivate evaluation top button extends the deacti-
vation time by another 20 seconds.
You can extend the deactivation time repeatedly by
pressing the DWBA - deactivate evaluation top button
repeatedly.
Changing the access side
You can deactivate the DWBA only at one side at any
one time. However, you may change the access side
at any time and without waiting.
1. Press the DWBA - deactivate evaluation top but-
ton at the required control panel.
Result
The signal lamp DWBA - evaluation in-
active lights up at this side (DWBA yel-
low). When the DWBA was deactivated
at another side, it will be reactivated im-
mediately there (the DWBA there
changes from yellow to green).
You have now 20 seconds to complete your work at
this side (such as inserting wedges or aligning print
sheets).
You can extend the deactivation time repeatedly by
pressing the DWBA - deactivate evaluation top button
repeatedly.
2.7 Removing sample sheets with the DWBA
Response of the DWBA
The top light beam at the front side might be interrupt-
ed when you remove a sample sheet. This light beam
is deactivated when you press the Removal of sample
sheet button.
The following conditions must be fulfilled to deactivate
the top light beam.
● No active locks (DWBA green).
● Deactivation for pile removal is not active.
● The delivery must transport paper.
Removing a sample sheet
1. Press the Sample sheet removal button.
Result
The top light beam at the front side is
deactivated (DWBA yellow, maximum
20 seconds). The sheet catchers move
into working position. The guard in front
of the sheet catchers opens.
2. Pull the sample sheet.
3. Press the Sample sheet removal button again.
SC.999.0020/01 B.10.15
Delivery
Result
The guard in front of the sheet catchers
closes. The sheet catchers move into
home position. The DWBA becomes ac-
tive immediately (DWBA green).
Removing several sample sheets or waste sheets
If you want to remove several sample sheets, you may
extend the maximum deactivation time of 20 seconds.
1. Press the Sample sheet removal button.
Result
The top light beam at the front side is
deactivated (DWBA yellow, maximum
20 seconds). The sheet catchers move
into working position. The guard in front
of the sheet catchers opens.
2. You can now collect the sheets. The DWBA
starts blinking yellow after 15 seconds: Press the
DWBA - deactivate evaluation top button.
Result
The deactivation time is extended by an-
other 20 seconds (DWBA yellow).
You can extend the deactivation time any times by
20 seconds.
Tip
Press the DWBA - deactivate evaluation
top button before pulling out the sheet.
This gives you enough time to remove
the sheets.
Once you have removed the sheets:
3. Press the Sample sheet removal button again.
Result
The guard in front of the sheet catchers
closes. The sheet catchers move into
home position. The DWBA becomes ac-
tive immediately (DWBA green).
2.8 Pile change with the DWBA
The light beams are inevitably interrupted when the
delivery pile is removed. Pressing the button DWBA -
pile exit deactivates the surveillance and enables you
to remove the pile.
Follow the procedure described below in order to avoid
spurious triggering of the DWBA.
Pile removal without non-stop operation
1. Move the pile support plate down to the floor.
2. Press the DWBA - pile exit button at the side at
which you want to remove the pile.
B.10.16 SC.999.0020/01
Delivery
Result
The bottom light barrier at the removal
side is deactivated for a maximum of
20 seconds (the DWBA yellow).
3. Move in the trolley. Raise the pile and move out
the pile.
There is a sensor in the delivery that extends the de-
activation time if you start pile removal within 20 sec-
onds.
The feeler deactivates all light beams at the exit side
when it detects the pile removal.
Result
You have now 20 seconds for removing
the pile (DWBA yellow).
The middle and top light beams become active after
these 20 seconds have elapsed. The bottom light
beam is deactivated for another 20 seconds (DWBA
yellow).
4. Move an empty pallet into the delivery during this
time.
What can I do if there is not enough time for in-
serting a pallet?
You may extend the deactivation time of the bottom
light beam once by another 20 seconds by pressing
the DWBA - pile exit button. Subsequently, the surveil-
lance is reactivated (DWBA green). Use the following
procedure if you could not insert the empty pallet dur-
ing this time.
Tip
Raise the pile support plate to a level that
is higher than the middle light barrier.
Press the DWBA - deactivate evaluation
top button. The upper light barrier is now
deactivated for 20 seconds (DWBA yel-
low). You may now raise the pallet man-
ually and push it onto the pile support
plate without triggering the DWBA.
Pile removal in non-stop operation
1. Insert the auxiliary pile support (non-stop rake or
pile board) in order to pile up on the auxiliary pile.
2. Move the pile support plate down to the floor.
3. Press the DWBA - pile exit button at the side at
which you want to remove the pile.
Result
The bottom light barrier at the removal
side is deactivated for a maximum of
20 seconds (the DWBA yellow).
4. Move in the trolley. Raise the pile and move out
the pile.
SC.999.0020/01 B.10.17
Delivery
There is a sensor in the delivery that extends the de-
activation time if you start pile removal within 20 sec-
onds.
The feeler deactivates all light beams at the exit side
when it detects the pile removal.
Result
You have now 20 seconds for removing
the pile (DWBA yellow) and for inserting
an empty pallet.
All light beams are reactivated after these 20 seconds
(DWBA green).
What happens if the DWBA responds now?
In non-stop operation, the main drive is not stopped as
long as the sheets are laid onto the auxiliary pile.
However, the drives for main pile, auxiliary pile and
sheet size adjustment at the delivery are disabled
(DWBA red).
Note
The press continues running, but the
auxiliary pile is not lowered as long as
the DWBA is red. If you do not reset the
pile drives, the press will stop as soon as
the upper pile edge has reached the
maximum permissible position.
You may now insert the pallet. Then you must press
the Reset button as described in chapter A "Safety" to
unlock the pile drives again (DWBA green).
The DWBA also monitors the main drive as soon as
the pile support plate is no longer on the floor.
Deactivation during pile removal by Autopile Plus
Autopile Plus automatically deactivates the surveil-
lance. Intervention is not usually required here.
Condition: You must switch Autopile Plus to automatic
mode at the press control station (button Automatic
mode ON); only then will the transport be executed
automatically.
B.10.18 SC.999.0020/01
Delivery
3 Guide pulleys
FS.901.9121-000UTKENU_04
3.1 Guide pulleys on the delivery
You can operate your press with or without guide pul-
FS.901.1097-000GRAUND_00
leys as required.
The guide pulleys are located on the sprocket wheel
1 shaft at the sheet ascent ramp of the delivery (Fig. 4/1).
Your press is supplied with a guide pulley with sheet
supports (Fig. 5/3) as standard.
On presses with cardboard kit (special equipment), an
additional two guide pulleys with continuous guide ring
(Fig. 5/1) are supplied.
You can fit and remove the guide pulleys or move them
along the sprocket wheel shaft in only a few steps.
Fig. 4 Sprocket wheel shaft in the delivery
Guide pulleys
FS.901.1086-000GRAUND_00
1 Depending on the configuration, your press contains
2 the following:
● Guide pulley with continuous guide ring (Fig. 5/1):
○ For continuously image-free areas.
○ Position on the sprocket wheel shaft prefer-
ably at the edge of the sheet or in the center
of image-free areas.
● Guide pulley with sheet supports (Fig. 5/3):
○ The sheet supports can be engaged/disen-
gaged individually.
○ Particularly well-suited for use in perfecting.
○ Position preferably in the center of the
sprocket wheel shaft.
or
3 ● Mixed equipment:
4 ○ Guide pulleys with continuous guide ring
and guide pulleys with sheet supports.
Chain sprocket shaft
The guide for the guide pulley on the sprocket wheel
shaft varies depending on the configuration of your
presses:
● Guide with key (Fig. 5/2) for presses without per-
fector.
or
● Guide with V-groove (Fig. 5/4) for presses with
suction segment disks, i.e. presses with perfec-
tor.
A special guide plate facilitates alignment of the
Fig. 5 Guide pulleys - illustration may deviate from
guide pulley in the V-groove of the sprocket
original
wheel shaft.
SC.999.0020/01 B.10.19
Delivery
Table of variants
Possible variants are listed in the following table.
Guide Guide Sprocket Sprock-
pulley pulley wheel et wheel
with con- with shaft shaft
tinuous sheet with key with V-
guide supports groove
ring
Straight ● ● ●
printing
Perfect- ● ●
ing
Tab. 1
Caution - Risk of collision with grip-
per bars!
Avoid using guide pulleys without guide
plate on sprocket wheel shafts with V-
groove. An exact alignment of the guide
pulley on the sprocket wheel shaft is not
possible without a guide plate.
Only use guide pulleys with a corre-
sponding a guide plate on a sprocket
wheel shaft with V-groove.
Caution - Risk of collision with suc-
tion discs!
When moving the suction discs to the
position for the smallest sheet size,
these can collide with fitted guide pul-
leys.
Before changing the sheet width, ensure
that the guide pulley has been removed.
3.2 Fields of application
When processing stiff short grain papers you must
support the print sheet in the central area of the
sprocket wheel shaft. Processing short grain papers
without guide pulleys may lead to print problems and
damage to the press.
Always use guide pulleys for:
● Short grain paper with grammages of more
than 600 g/m2
● Printing materials with flexural strength of more
than 130 mNm (as per DIN 53121)
● Printing materials longer than 650 mm
● Stock thicknesses of more than 0.8 mm
B.10.20 SC.999.0020/01
Delivery
3.3 Functioning principle of the locking device
FS.901.5600-000GRAUND_00
2 ... 3 mm
1 2 3
Fig. 6 Releasing the locking device of the guide pulley
To open the locking device, proceed as follows:
1. Slacken the screw (Fig. 6/1) using an Allen key.
This lifts up the screw head and the washer
(Fig. 6/2).
An internal spring pushes up the washer.
Please note: The screw is not captive.
2. Unscrew the screw only until a gap of 2 ... 3 mm
is visible under the washer (Fig. 6/2).
You can now lift up the sleeve and release the locking
device.
3. Pull the sleeve (Fig. 6/3) upward.
4. Swivel the sleeve to the side.
Reverse this procedure to close the locking device.
SC.999.0020/01 B.10.21
Delivery
3.4 Fitting the guide pulley
Caution - Damage to the press
FS.901.1091-000GRAUND_00
through damaged guide plate!
To preserve the sprocket wheel shaft
(Fig. 7/2), the guide plate (Fig. 7/1) is
made from a special material that can
become deformed when handled im-
1 properly.
If a guide plate is deformed, the align-
ment to the gripper bars is no longer
guaranteed. Deformations of the guide
plate prevent secure clamping on the
sprocket wheel shaft.
Before inserting the guide pulley, ensure
2 that the guide plate is undamaged.
When fitting the guide pulley, ensure that
the guide plate is inserted exactly into
the V-groove of the sprocket wheel
Fig. 7 Guide plate shaft. Avoid any damage to the guide
plate.
In the event of damaged guide plates, please contact
your Heidelberg Service agency.
B.10.22 SC.999.0020/01
Delivery
Depending on the printing material and print job, it can
FS.901.1090-000GRAUND_00
be advantageous to fit guide pulleys in your press.
The fitting procedure is roughly identical for all guide
pulley variants.
Fitting
1. Open the guard above the sprocket wheel shaft.
2. Inch the press until the key or V-groove of the
sprocket wheel shaft is at the top.
Note
Depending on the press configuration,
the sprocket wheel shaft has four V-
1
grooves on its circumference. Turn the
V-groove to the top at which the gripper
bar is also located above the V-groove.
Caution - Machine damage!
The guide pulley can tilt to the side and
slide off the sprocket wheel shaft.
2 Hold on to the guide pulley on the
sprocket wheel shaft. Pay attention to
gripper bars and neighboring compo-
nents.
3. Place the guide pulley in the correct position (see
3 Fig. 10) on the sprocket wheel shaft.
Note
The guide pulley is positioned correctly
on the sprocket wheel shaft when the
key/V-groove, the recess of the guide
pulley and the gripper bar are all aligned
(see Fig. 9).
Fig. 8 Closing the clamping mechanism
4. Swivel the bracket (Fig. 8/1) upwards.
FS.901.1026-000GRAUND_00
5. Pull the sleeve (Fig. 8/2) upward and allow it to
slide into the top recess.
6. Align the guide pulley axially on the sprocket
wheel shaft.
7. Tighten the Allen screw (Fig. 8/3).
When the Allen screw is tightened, the guide pul-
ley is fixed on the sprocket wheel shaft.
8. Close the open guard.
Fig. 9 Guide pulley, gripper bars
SC.999.0020/01 B.10.23
Delivery
3.5 Positioning the guide pulleys
Position one guide pulley with continuous guide ring
FS.901.1087-000GRAUND_00
1 (Fig. 10/1) on each side, preferably in the image-free
2 area at the sheet edge. Each clamping mechanism is
1 facing toward the center of the press.
Position the guide pulley with adjustable sheet sup-
ports (Fig. 10/2) approximately in the center of the
sprocket wheel shaft.
Fig. 10 Guide pulleys on sprocket wheel shaft
Moving the guide pulley
FS.901.1088-000GRAUND_00
1. Open the guard above the sprocket wheel shaft.
2. Inch the press until the key or V-groove of the
sprocket wheel shaft is at the top.
3. Slacken the Allen screw (Fig. 11/1) by approx.
two rotations.
The clamping mechanism is released. You can move
the guide pulley on the sprocket wheel shaft in the axial
direction.
4. If possible, move the guide pulley on the sprocket
wheel shaft to image-free areas.
5. Tighten the Allen screw (Fig. 11/1) again.
6. Close the open guard.
Fig. 11 Moving the guide pulley
B.10.24 SC.999.0020/01
Delivery
3.6 Guide pulley with sheet supports
You can engage or disengage the sheet supports in-
FS.901.1095-000GRAUND_00
1 dividually in accordance with the print image.
Engaging the sheet supports
Position the sheet supports in image-free areas, if
possible.
1. To release, gently press the sheet support
(Fig. 12/1) to the side.
The sheet support slides upward supported by a
spring and engages.
2. Ensure that the sheet support has engaged cor-
rectly.
Fig. 12 Engaging a sheet support
Disengaging the sheet supports
FS.901.1096-000GRAUND_00
1 You can disengage sheet supports that are located in
the print image.
1. Gently push the sheet support (Fig. 13/1) to the
side and down against the spring pressure to-
ward the sprocket wheel shaft.
The sheet support engages.
2 2. You may have to push the sheet support
(Fig. 13/2) to the side again in order to ensure it is
engaged.
3. Ensure that the sheet support has engaged cor-
rectly.
Fig. 13 Disengaging a sheet support
SC.999.0020/01 B.10.25
Delivery
3.7 Removing a guide pulley
You can also operate your press without guide pulleys
FS.901.1089-000GRAUND_00
depending on the printing material.
The removal procedure is roughly identical for all guide
pulley variants.
Removing
1. Open the guard above the sprocket wheel shaft.
2. Inch the press until the key or V-groove of the
1 sprocket wheel shaft is at the top.
Caution - Machine damage!
2 The clamping mechanism of the guide
pulley is released. The guide pulley can
tilt to the side and slide off the sprocket
wheel shaft.
Hold on to the guide pulley on the
sprocket wheel shaft. Pay attention to
gripper bars and neighboring compo-
nents.
3 3. Loosen the screw (Fig. 14/1)
4. Lift up the sleeve (Fig. 14/2) and swivel it down-
ward (Fig. 14/3).
5. Open the bracket (Fig. 14/4).
6. Remove the guide pulley from the sprocket wheel
shaft.
Caution - Machine damage!
In the event of improper handling, the
4
circumference of guide pulleys with
sheet supports can get damaged.
You must not rest guide pulleys with
sheet supports on their edge. Lay the
Fig. 14 Opening the clamping mechanism
guide pulley down on a flat surface.
7. Lay the guide pulley down flat in a clean, protect-
ed location.
8. Close the open guard.
B.10.26 SC.999.0020/01
Delivery
4 Cover plates on the delivery
FS.901.9171-000UTKENU_01
4.1 Function/Task
A sheet guide plate is fitted to the delivery on your
press to assist sheet travel. Powder dust may start to
accumulate on the sheet guide plates during opera-
tion. Clean the sheet guide plates at regular intervals.
You can find notes on this in the separate "Mainte-
nance and cleaning" manual.
Cover plates are mounted on the sheet guide plates to
optimize sheet travel and reduce the quantities of pow-
der dust released into the pressroom. To clean the
sheet guide plates, you have to open the cover plates.
4.2 Cover plates on the sheet ascent ramp
In the sheet ascent ramp on the delivery (Fig. 15),
FS.901.9104-000GRAUND_00
3 2 1 cover plates are fitted to the individual sections of the
sheet guide. The individual cover plates become ac-
cessible when the large hinged guard on the sheet as-
cent ramp is opened.
● Lower cover plate (Fig. 15/1)
● Central cover plate (Fig. 15/2)
● Upper cover plate (Fig. 15/3)
Note
Depending on press equipment and dry-
er variant, the cover plates can become
very hot during operation. Avoid any di-
rect contact with the cover plates.
Caution - Machine damage!
Avoid any pressure on the cover plates.
Fig. 15 Cover plates on the sheet ascent ramp Do not lean on the cover plates. De-
formed cover plates can lead to colli-
sions with the gripper bars.
Always grasp both handles of the cover
plates to prevent the cover plates from
becoming twisted during opening or
closing, as this would cause them to be-
come sluggish.
SC.999.0020/01 B.10.27
Delivery
Opening the cover plates
FS.901.9125-000GRAUND_00
1 1. Inch the press and move the gripper bar
(Fig. 16/1) above the cross bar or outside the
working area.
Fig. 16 Gripper bar above the cross bar
2. Grasp both handles on the lower cover plate
FS.901.9106-000GRAUND_00
(Fig. 17/1) and fold it down.
The cover plate folds in on itself.
Fig. 17 Open the lower cover plate
3. Grasp both handles on the central cover plate
FS.901.9107-000GRAUND_00
(Fig. 18/1) and pull it up.
The cover plate folds in on itself.
Fig. 18 Opening the central cover plate
B.10.28 SC.999.0020/01
Delivery
4. Allow the folded cover plate to engage in the lock
FS.901.9108-000GRAUND_00
(Fig. 19/1) on D.S. and O.S.
The cover plate tips downwards slightly. The cov-
er plate is retained in position as a result.
Fig. 19 Allow the cover plate to engage
5. Grasp the top cover plate (Fig. 20/1) and fold it
FS.901.9109-000GRAUND_00
1 down.
The cover plate folds in on itself.
You can now clean the sheet guide plates in the sheet
ascent ramp using a dry, lint-free cloth. You can find
notes on this in the "Maintenance and cleaning" man-
ual.
Fig. 20 Opening the upper cover plate
Closing the cover plates
FS.901.9110-000GRAUND_00
1 2 1. Close the three cover plates one after the other.
Start with the upper cover plate.
2. Then close the central cover plate (Fig. 21/1) and
the lower cover plate (Fig. 21/2).
3. Grasp both handles on the cover plates and fold
them shut.
4. Close the large hinged guard on the sheet ascent
ramp.
Fig. 21 Closing the cover plates
SC.999.0020/01 B.10.29
Delivery
4.3 Cover plates in the horizontal area
● Cover plate in front of the powder spray unit
FS.901.9122-000GRAUND_00
3 2 1 (Fig. 22/1)
● Cover plates after the CleanStar slide-in unit
(Fig. 22/2)
● Cover plate in front of the rows of fans (Fig. 22/3)
Fig. 22 Cover plates in the horizontal area
1. Open the guard (Fig. 23/1) in front of the powder
FS.901.9126-000GRAUND_00
spray unit.
Fig. 23 Cover plate before the powder unit
B.10.30 SC.999.0020/01
Delivery
2. Grasp the handle (Fig. 24/1) and pull the cover
FS.901.9127-000GRAUND_00
plate upwards.
The cover plate folds in on itself.
3. Allow the cover plate to tip forwards slightly.
The cover plate is locked in position.
Closing the cover plate
4. Lift the cover plate by the handle slightly to close.
Fold down the cover plate until flat.
1
Fig. 24 Pulling back the cover plate
4.4 Cover plates behind CleanStar
There are more cover plates located downstream of
FS.901.9128-000GRAUND_00
the CleanStar in the direction of sheet travel. You must
fold open the cover plates to clean the sheet guide
plates positioned underneath.
Fig. 25 Cover plate behind CleanStar
SC.999.0020/01 B.10.31
Delivery
1. Grasp the recessed grip (Fig. 26/1) on the cover
FS.901.9111-000GRAUND_00
plate with your fingers.
Fig. 26 Recessed grip on the cover plate
2. Lift and pull back the three-piece cover plate
FS.901.9112-000GRAUND_00
(Fig. 27/1).
The cover plate folds in on itself.
Fig. 27 Lifting up the cover plate
B.10.32 SC.999.0020/01
Delivery
Note
FS.901.9123-000GRAUND_00
The folded cover plate tilts forwards
slightly and locks in position.
Fig. 28 Tilting the folding plate slightly
3. Grasp the third part of the cover plate (Fig. 29/1)
FS.901.9113-000GRAUND_00
and fold up.
Fig. 29 Folding up the cover plate
SC.999.0020/01 B.10.33
Delivery
A magnet on the handle (Fig. 30/2) holds the cover
FS.901.9114-000GRAUND_00
plate (Fig. 30/1) in position.
4. Use a dry, lint-free cloth to clean the sheet guide
plate.
Closing the cover plate
5. Proceed in reverse order to close the cover
1 plates.
Note
Open cover plates can cause smudging
and delivery problems during produc-
2 tion.
Fig. 30 Cover plate folded up
4.5 Cover plate before rows of fans
1. Grasp the cover plate (Fig. 31/2) and fold onto the
FS.901.9116-000GRAUND_00
magnetic strip (Fig. 31/1).
The magnetic strip retains the cover plate se-
curely in position.
1 2. Use a dry, lint-free cloth to clean the sheet guide
plate.
Closing the cover plate
3. Fold down the cover plate.
Fig. 31 Cover plate and magnetic strip
B.10.34 SC.999.0020/01
Delivery
4.6 Cleaning the sheet guide plate under the CleanStar
You can unlock and pull out the CleanStar on O.S to
SF.901.9037-000GRAUND_00
give you good access from above to clean the sheet
1 guide plate.
1. Open the guard on the extension module on O.S.
(Fig. 32/1).
2. Push the stop lever (Fig. 32/2) on the CleanStar
(Fig. 32/3) upwards.
3. Pull out the CleanStar up to the stop.
3 2
Fig. 32 CleanStar on O.S.
The extracted CleanStar (Fig. 33/1) ensures access to
FS.901.9124-000GRAUND_00
the sheet guide plate.
4. Clean the sheet guide plate (Fig. 33/2) using a
dry, lint-free cloth.
You can find notes on this in the "Maintenance
and cleaning" manual.
1
Fig. 33 Cleaning the sheet guide plate
To enable optimal suction you have to completely in-
SF.901.9037-000GRAUND_00
sert and lock the CleanStar again.
1
5. Slide the CleanStar (Fig. 34/3) into the extension
module up to the stop.
6. Push the stop lever (Fig. 34/2) on the CleanStar
all the way down.
The lock is not electronically monitored.
7. Close the guard on the extension module on O.S.
(Fig. 34/1).
3 2
Fig. 34 Locking the CleanStar
SC.999.0020/01 B.10.35
Delivery
5 Air in the sheet ascent ramp
SC.901.9030-000UTKENU_05
5.1 Suction and blast air on the delivery
The suction air and blast air devices on the delivery
SC.901.9904-003GRAUND_00
● guide the sheet over sheet guide plates (sheet
7 5
guide) to the sheet brake,
● slow down the sheet for depositing onto the pile
(sheet brake),
1 ● deposit the printed sheet stabilized by air onto the
pile (delivery air system).
Air guidance areas on the Preset Plus delivery:
1 Blast tubes - sprocket wheel shaft
2 Sheet guide plate transfer
3 Sheet decurler
4 Sheet guide plate ascent
6 4 3 2 5 Sheet guide plate sheet brake
6 Sheet brake
Fig. 35 Preset Plus delivery 7 Delivery air system
Air guidance areas on the extended Preset Plus de-
SC.901.9905-002GRAUND_00
livery:
3 2 1
1 Sheet guide plate extension 1
2 Sheet guide plate extension 2
3 Sheet guide plate extension 3
Depending on the press configuration, up to 3 exten-
sions are possible.
Fig. 36 Extended Preset Plus delivery
5.2 Control panels for the air settings
Preset values for all air control elements are stored in
the control station. The preset values depend on the
printing material properties. Once the print job has
been started, the preset values are accepted by the
press or transferred from the loaded print job.
You can manually adjust the air in the sheet ascent
ramp on the control station.
B.10.36 SC.999.0020/01
Delivery
5.3 Mask on the Prinect Press Center
SC.901.9031-001GRAENU_00
Paper run
Sheet brake
6 7
2 3 4
5
Fig. 37 Paper run menu
Prinect Press Center
SC.901.9032-000GRAUND_00
1. At the Prinect Press Center, select the tab Press
1 overview and then the menu Paper run.
2. Select the extension module or modules in the
2 diagram.
The display changes to the detail view (Fig. 37).
Extension module / modules. The display high-
lighted in orange shows which machine section
you are in (Fig. 37/2).
In the detail view you can select all blue arrows
Fig. 38 Paper run menu
(Fig. 37/1) individually or all at once (Fig. 37/6).
Individual selection / sum selection
● Individual selection: Only one arrow can be se-
lected.
● Sum selection: All arrows that can be selected for
the carrier air setting are selected.
If the blue arrow is shown as a double arrow, you can
additionally select and set at least 2 or more zones.
Selecting a double arrow
When you select a double arrow, for example
(Fig. 37/3), the affected zones (Fig. 37/5) are dis-
played.
An adjustment device (Fig. 38/2) appears. You can
change the setting by pressing up or down on the ad-
justment device or by swiping.
SC.999.0020/01 B.10.37
Delivery
Zone diagram
SG.901.9033-002GRAUND_00
E2 E1
E E
E
Fig. 39 Schematic diagram of the blast air zones
Zone arrangement in the area of the sheet ascent
ramp.
Zone A1 ... A4
Area A: sheet guide plate transfer zone
Zone B1 ... B5
Area B: sheet guide plate ascent ramp
Zone C1 ... C2
Area C: sheet guide plate extension 1
Zone D1 ... D2
Area D: sheet guide plate extension 2
Zone E1 ... E2
Area E: sheet guide plate extension 3
After configuring your press, up to 3 extensions
(C ... E) can be designated.
5.4 Recommended setting - transfer zone
In the area of transfer zone "A" there are five ad-
justable blast air zones.
● Zone 1: Sprocket wheel shaft blast tubes. The
blast tubes support the transfer of the printing
material to the sheet decurler. They counteract a
possible sheet sinking at low printing speed.
● Zone A1: guide plate teeth help separate the
sheet from the impression cylinder.
● Zones A2 ... A4: laterally blowing lines of nozzles
below the sprocket wheel shaft.
Setting recommendation:
B.10.38 SC.999.0020/01
Delivery
Zone A1: If the print sheet forms a wave over the guide
plate in the infeed area, reduce the adjustment value.
Zone A2 ... A4: If a print sheet forms a wave, increase
the setting value of the corresponding zone of the
sheet guide plate.
If the sides or rear edge of a print sheet flutter, reduce
the setting value of the corresponding zone of the
sheet guide plate.
5.5 Recommended setting - sheet ascent ramp area
In the area of the sheet ascent "B" there are five ad-
justable blast air zones.
● Zones B1 ... B5: laterally blowing lines of nozzles
in the sheet ascent ramp and the transfer zone.
Zones B2 and B3 are located underneath the
slide-in dryer.
Setting recommendation:
If the dryer is switched on, the print sheet can form a
wave. If this is the case, increase the setting value of
the corresponding zone of the sheet guide plate.
If the sides or rear edge of a print sheet flutter, reduce
the setting value of the corresponding zone of the
sheet guide plate.
You can observe the sheet run through the inspection
window in the area of the dryer slide-in units.
5.6 Recommended setting - extension area
A press with an extended Preset Plus delivery can
consist of up to 3 extensions (C ... E). Each extension
has two guide plate zones (C1, C2, D1, D2, E1, E2).
Setting recommendation:
If a print sheet forms a wave, increase the setting value
of the corresponding zone of the sheet guide plate.
If the sides or rear edge of a print sheet flutter, reduce
the setting value of the corresponding zone of the
sheet guide plate.
You can observe the sheet run through the inspection
window in the area of the dryer slide-in units.
SC.999.0020/01 B.10.39
Delivery
5.7 Sheet decurler
The sheet decurler (Fig. 40/1) consists of a profile
SC.901.9702-004GRAUND_00
piece with air extraction apertures. It is located in the
sheet guide of delivery below the sprocket wheel shaft.
The print sheets are smoothed out as they pass across
the sheet decurler.
Fig. 40 Position of the sheet decurler
The preset value for the air at the sheet decurler is
initially 0%.
If necessary, you can manually adjust the air at the
sheet decurler.
● On the control station
● On the delivery control panel
1. Press the button Powder / Dryer (Fig. 41/1) on the
SC.901.9030-003GRAUND_00
delivery control panel. The corresponding menu
1
appears in the display. (Fig. 41).
2. If you wish to decurl the print sheet even further,
press the + button (Fig. 41/2).
or
If you wish to decurl the print sheet less, press the
button - (Fig. 41/3).
2
The display shows the suction output of the sheet de-
curler.
3
Tip
If the rear edge of the print sheet curves
upwards, the suction air on the sheet de-
curler has been set too high. If the rear
Fig. 41 KID - Accessories
edge of the print sheet curves down-
wards, the suction air on the sheet de-
curler has been set too low.
B.10.40 SC.999.0020/01
Delivery
6 Air in the pile area
FS.901.9102-000UTKENU_06
6.1 General notes
In the pile area of the delivery you can alter the air
FS.901.9102-000GRAUND_01
2 3 2 4 settings at the following elements:
● Fans (Fig. 42/1)
● 3 longitudinal blast tubes (Fig. 42/2)
● Suction belts (Fig. 42/3, known as "sheet slow-
down device" together)
● Rear edge suction fan (Fig. 42/4), for perfecting
only
Note
Preset values for the delivery air system
are used as basic settings and may re-
quire adjustment depending on the print-
1 ing material, speed and print subject.
Fig. 42 Delivery air system
Print-related notes
● A minimum of air should be used for pressing the
arriving sheet onto the pile.
● Thin printing material tends towards curling at the
front edge. Increase the blast air volume of the
second fan group from the outside. This gives the
sheet a wave form. It prevents the curling of the
sheet. The outer blast tubes may provide useful
assistance here.
● Use the longitudinal blast tubes as little as pos-
sible. Too much blast air, in particular on the cen-
ter of the sheet
○ lifts up the sheet margins,
○ deteriorates the sheet travel at the sheet
brake,
○ can cause scratches via the sheet brake.
Note
Scraps of paper on the delivery air sys-
tem may block or restrict the effective-
ness of individual fans. The production
of a tidy pile is then no longer possible.
6.2 Switching fans ON/OFF
Fans that are located outside the format blow air un-
derneath the sheet. This makes it more difficult to pro-
duce a stable pile.
SC.999.0020/01 B.10.41
Delivery
Automatically
If you set the sheet size on the control system, all
groups of fans that are not needed are switched off
automatically.
Manual mode
You can switch groups of fans on and off individually:
● on the control system
or
● on the delivery console.
Note
If the guard on the delivery is opened,
the fans are switched off when the press
comes to a standstill.
6.3 Adjusting the fans
The fans are divided into groups (Fig. 43), which can
SF.901.9912-000GRAUND_01
be controlled separately. You can move the outer fans
in the first and second row laterally.
Straight printing:
● 30 fans, 11 groups
Perfecting:
● 24 fans, 10 groups
1
Every fan group can be adjusted on the delivery con-
trol panel.
You can learn more about adjusting the fan groups in
the operating manual for the control system.
Fig. 43 Fans and longitudinal blast tube
B.10.42 SC.999.0020/01
Delivery
6.4 Positioning the fans
● Row of fans above the front edge of the pile
FS.901.9103-000GRAUND_01
1 2 3 4 5 (Fig. 44/1)
● Row of fans (Fig. 44/2)
● Row of fans (Fig. 44/3)
● Row of fans (Fig. 44/4)
● Row of fans above the sheet brake, for straight
printing only (Fig. 44/5)
You can move the outer fans in the first two rows.
Fig. 44 Positioning the fans
Basic setting
When processing sheet sizes larger than 63 x 88 mm,
you can move the fans on the first and second rows
inwards. When processing large sheet sizes, slide the
fans outwards accordingly.
6.5 Longitudinal blast tubes
The longitudinal blast tubes are secured to the lead
SF.901.9911-000GRAUND_01
edge of the sheet in the running direction of the paper.
The longitudinal blast tube has boreholes (Fig. 45/1),
through which blast air is blown from above onto the
falling sheet. Heavily curled sheets are buckled down-
ward. This improves the delivery behavior of the
sheets.
1 Automatic setting of the longitudinal blast air
The volume of blast air of the longitudinal blast tube is
adjusted automatically when you set the job data on
the control. This enables you to make manual preset-
tings on the delivery control panel.
You can learn more about the choice of different set-
tings in the operating manual for the control system.
Fig. 45 Longitudinal blast tubes with boreholes
SC.999.0020/01 B.10.43
Delivery
7 Powder spray device
SG.901.9104-000UTKENU_03
7.1 ÕÕÕÕÕÕÕÕÕ
ÕÕÕÕÕÕÕÕÕ
Maintenance work
ÕÕÕÕÕÕÕÕÕ Check the proper functioning of powder spray device
SG.901.9163-001GRAUND_00
ÕÕÕÕÕÕÕÕÕ 1
and powder spray nozzles at regular intervals. For
more information please refer to the chapter "Press,
Print-related notes on powdering".
Clean the powder hose and the powder spray nozzle if
the powder is applied irregularly.
1. Control panel selection: Press the Select control
panel button twice (with no more than 0.5 sec-
onds between presses). The LED lights up.
2. Open the guard above the powder spray device.
3. Inch the press until the gripper bars are outside
the suction duct.
4. Pull the lever on D.S. upwards until the powder
spray device (Fig. 46/1) and the suction duct are
Fig. 46 Powder spray device in the upper stable position.
5. Perform the cleaning work that is described in the
maintenance manual (chapter "Checklists of pe-
ripheral equipment").
Note
Always clean the powder spray device
with dry material. Observe the notes in
the manufacturer's instructions.
6. Swing the powder spray device into its working
position. Ensure that the powder hoses are not
squeezed.
7. Close the guard above the powder spray device.
8. To deselect a control panel: Press the Control
panel selection button twice (with an interval of
no more than 0.5 seconds). The LED goes out.
7.2 Powdering from below (optional)
This function is only available when your printing press
is equipped with the PowderStar Exatronic Duo Plus
powder spray device.
The nozzle rail, which transfers the print sheet to the
metal foil, is equipped with blast chambers. These
blast chambers are used to spray powder onto the
print sheet from below. This reduces smearing and
blocking of the print sheets. You can set the powder
volume on the control station. Please refer to the op-
erating manual from the manufacturer here.
B.10.44 SC.999.0020/01
Delivery
8 Print-related notes on powdering
SG.901.1118-000UTKENU_05
8.1 Powder application - why is powdering necessary?
The application of powder produces a gap between
the delivered sheets.
The air gap prevents the sheets from setting off (trans-
ferring the fresh ink onto the rear of the sheet on top)
and blocking (sticking together) and ensures oxidative
drying through an air pocket.
8.2 Choosing the powder grain size and required powder
Anti set-off powder is available in various particle sizes
(approx. 15 to 75 µm). When choosing the right anti
set-off powder, the following applies:
● The rougher the printing material, the coarser the
powder grain should be.
● The thicker the ink film, the more powder is need-
ed.
Note
It is essential that you read and under-
stand the manufacturer's specifications
for the anti set-off powder.
8.3 Disadvantages of powdering
● The gloss and scuff resistance of the product is
reduced.
● The powder is deposited on machine parts and
blankets.
● Powdering can cause malfunctions in the finish-
ing process, especially with laminating, foil
stamping and when running through packaging
and labeling machines.
Note
Keep the powder application as low as
possible.
8.4 Required powder quality
Note
When selecting the powder you must al-
so observe the safety instructions in the
section "Safety, basic safety instruc-
tions". For example, you can find a se-
lection of tested products for Saphira.
● Ensure that the powder quality is high, with a low
percentage of fine particulates.
● Only use starch-based powder when you work
with several print passes. Mineral-base powder
SC.999.0020/01 B.10.45
Delivery
can scour the printing coating of the printing
plate.
● Store the powder in closed containers at a dry
place. Damp powder can have lumps.
8.5 Factors that determine the powder volume
The following conditions require more powder:
● Printing material of low absorbency
● Higher ink film thickness through areas, in which
several colors are printed on top of each other
● Heavy weight of the delivery pile due to printing
material with little volume and large pile height
The following conditions require less powder:
● Inline varnishing (for UV gloss polish and disper-
sion varnish you may be able to greatly reduce
the powder spraying or dispense with it altogeth-
er)
● Optimum sheet travel setting with minimum air
guide
● Absorbent and voluminous printing material
● Small pile height due to frequent pile changes
and rack delivery
● Little ink application (when making the printing
plates, keep the option of achromatic composi-
tion or under-color reduction in mind).
8.6 To be observed during production
● Set up the print job with a low powder quantity.
● Do not change the type of powder or the powder-
grain diameter during production.
● Check the pile for delivery. If possible, reduce the
powder application.
● Make up smaller piles or use the rack delivery.
● Note down or save favorable powder spray de-
vice and powder spray nozzle settings for repeat
orders.
8.7 Powdering from below (optional)
If your powder spray device has a function for pow-
dering from below, you can vary the set powder vol-
ume via the powder volume balance on the control
station. This reduces smearing and blocking of print
sheets. The normal setting values for this are:
● 95 to 98% powder from above
● 5 to 2% powder from below
The respective powder volume balance must however
be set individually by the press operator. Powder is
applied from below via a nozzle rail integrated in the
sheet guide plate.
B.10.46 SC.999.0020/01
Delivery
8.8 Adjusting the stabilizing nozzles (optional)
Stabilizing nozzles create powder-stabilizing air
around the powder jet and thus ensure high powdering
efficiency (a high level of application efficiency). The
powder-stabilizing air is dependent on the grammage
and is preset as a preset value. The current value of
the powder-stabilizing air can be adjusted using the +/-
buttons on the control station.
8.9 Checking the powder application
Check that the powder spray device and powder spray
SG.901.3716-002GRAUND_00
nozzles function correctly. These checks should be
1 2 carried out at regular intervals in line with the mainte-
nance schedule in the manufacturer's instruction man-
ual. To check the powder application, you can perform
the following test:
1. Move the pile support plate all the way down and,
if necessary, remove the pile from the delivery.
2. Position the gripper bars in inching mode in such
a way that they do not obstruct any powder dis-
charge.
3. Secure the printing press against being put into
3
operation. Press the Emergency stop button.
4. Open the front guard on the delivery.
Fig. 47 Delivery diagram
5. Place a darkly-printed sheet with maximum sheet
size or a clean blanket (Fig. 47/1) under the pow-
der spray nozzles (Fig. 47/2). Move the sheet
above the sheet brake (Fig. 47/3) in the direction
of the arrow until it is under the powder spray
nozzles (Fig. 47/2).
6. Switch the powder spray device to manual mode.
7. Set the powder metering volume to maximum
output and maximum sheet size.
8. Create a static spray pattern by switching on the
powder spray device for approx. 1 min.
9. Carefully pull out the sheet from under the pow-
der spray nozzles and lay it out flat for assess-
ment.
The sheet must show an even nozzle pattern corre-
sponding to the number of powder spray nozzles
(Fig. 48). The number of nozzles is specified in the
manufacturer's operating manual for the powder spray
device. The number of nozzles can vary depending on
the press model.
Note
Once you have checked the result, read-
just the powder volume at the powder
spray device to the current job (automat-
ic mode). Release the emergency stop
button and close the front guard on the
delivery.
SC.999.0020/01 B.10.47
Delivery
Check the following points when powder application is
uneven (Fig. 49):
Powder spray device
SG.901.1126-001GRAUND_00
● Is the powder distributor clogged up?
Powder spray nozzles
● Are all powder spray nozzles open?
● Is a powder spray nozzle clogged?
Hose connection
● Is a hose bent or clogged?
Fig. 48 Uniform powder application ● Is a hose damaged?
● Is the connection to the powder spray device and
SG.901.1127-001GRAUND_00
to the powder tube OK?
If the powder application is even, but it appears that the
volume applied is too little, please check the following
points:
Powder spray device
● Is the compressor pressure sufficient? To deter-
mine this, you should also refer to the error mes-
Fig. 49 Uneven powder application sages on the display of the powder spray device
and in the operating manual of the powder spray
device manufacturer.
● Are the powder container and metering unit free
from dirt, clumps and clogging up?
Note
Powder can be applied by one to four
rows of powdering nozzles depending
on the powder spray device.
B.10.48 SC.999.0020/01
Delivery
9 Format bridging device
SC.901.9105-000UTKENU_01
9.1 Method of functioning and equipment
Format bridging consists of:
● a nozzle rail for powdering from below (optional)
● a metal foil with guide and clamping device
● a guide plate with Venturi nozzles
When setting the printing press to a small sheet size,
the sheet slow-down device moves up to the delivery
pile. The gap that appears is closed by the format
bridging device. The guide plate, to which the metal foil
is attached, is moved together with the sheet slow-
down device. The metallic foil is moved with it auto-
matically. Air is blown through the Venturi nozzles of
the sheet guide plate. This blast air creates a defined
distance between print sheet and guide plate, and
transfers the print sheet to the sheet slow-down de-
vice.
9.2 Setting the blast air
The guide plate immediately in front of the sheet slow-
down device is crucial for producing a stable pile. The
guide plate ensures that the sheet slow-down device
takes on the sheet. The Blast air can be adjusted on
the delivery control panel.
Setting recommendation:
Note
The recommendations stated below are
only reference values intended to help
you to quickly establish a stable operat-
ing state.
● When processing lightweight substrates, set the
blast air at the sheet guide plate to 0 %.
● When processing substrates with higher weights,
use a setting for the blast air at the sheet guide
plate of up to 20 %.
● Reduce the volume of blast air if the sheet is flut-
tering on the sheet guide plate.
● Reduce the volume of blast air or the press speed
if the sheet is not taken over and slowed down by
the sheet slow-down device.
9.3 Cleaning
During face and back printing, ink particles can build
up on the metal foil. Clean the metal foil when ink
builds up on the metal foil.
1. Remove the pile from the delivery.
2. Set the press to the sheet size of the new print
job.
SC.999.0020/01 B.10.49
Delivery
Tip
Select a slightly smaller sheet size than
is necessary for the new print job. This
ensures that the entire area of the metal
foil is cleaned.
3. Secure the press against starting up again: Press
the Emergency-stop palm button on the next-
nearest control panel. Open the front guard on
the delivery.
Note
If there is powder on the guide plate and
it then gets wet, the nozzles get blocked.
To avoid this, the blower must be
switched on during the cleaning process.
4. Clean the guide plate using a dry cloth or com-
pressed air.
Note
The metal foil of the format bridging de-
vice is very sensitive. Only use light
pressure when cleaning the metal foil.
5. Clean the metal foil thoroughly using a damp
cloth and cleaner.
6. Release the Emergency-stop palm button. Close
the front guard on the delivery.
B.10.50 SC.999.0020/01
Delivery
10 Sheet brake system - Overview and variants
FS.901.9061-000UTKENU_05
10.1 Types
Modular sheet brake system
On modular sheet brake systems, a tape driving roller
and friction wheels transfer the force onto the sheet
brakes. The brake modules and sheet guiding ele-
ments are compatible with all presses equipped with a
modular sheet brake system. For example, you can
also use Speedmaster XL 106 sheet brake modules
for the Speedmaster XL 75 or XL 145.
2 variants of modular sheet brake system are avail-
able:
● Modular sheet brake system with timed (dynam-
ic) drive
The sheet brakes transfer the printing sheets ap-
proximately at press speed. During the braking
phase, the sheet brakes decrease in speed and
slow down the printing sheet.
The timed drive is ideal for use in presses with
perfector, because the print sheet is decelerated
in a very gentle manner.
● Modular sheet brake system with continuous
drive
The continuous drive operates at a constant
speed during the entire braking phase. The con-
tinuous drive is standard equipment for presses
without perfector.
10.2 Chapter overview
● Modular sheet brake system - Overview and vari-
ants
● Modular sheet brake system - Handling the brake
modules
● Modular sheet brake system - component ver-
sions for front printing
● Modular sheet brake system - component ver-
sions for front and back printing/perfecting
● Modular sheet brake system - Remedies in the
event of problems
SC.999.0020/01 B.10.51
Delivery
11 Modular sheet brake system - overview
FS.901.9066-000UTKENU_06
11.1 Design and components
FS.901.8000-001GRAUND_00
1
5
4
3
Fig. 50 Modular sheet brake system
1 Guide plate for sheet size bypass
2 Sheet brake
3 Sheet stop
4 Guide rail for sheet stops
5 Tape driving roller
The modular sheet brake system consists of an ad-
justable sheet brake carriage which carries the 5 mod-
ule supports and the tape driving roller. The sheet size
adjustment and the positioning of the brake system are
motor-driven.
B.10.52 SC.999.0020/01
Delivery
Design of the sheet brake
FS.901.9115-000GRAUND_00
2 3 4 5 6 7 8 In this manual, each module support that carries com-
ponents is described as a sheet brake.
Figure 51 shows the motor-controlled sheet brake with
servo-drive and its alternative, the manually adjustable
sheet brake with clamping lever.
1 Tape driving roller
1 2 Left-hand brake module
3 Drive roller with friction wheel
4 Module support (motor-controlled)
5 Guiding cross bar
6 Valve
9
7 Suction tape
10 11 12 13 8 Right-hand brake module
9 Driver pin for sheet stop
10 Sheet stop
11 Guide rail for sheet stops and sheet guiding ele-
ments (starwheel holder)
12 Knurled screw
13 Clamping lever for manual adjustment (optional)
Fig. 51 Design of the sheet brake
11.2 Component overview
Note
Some of the following components are
standard equipment. The standard
equipment of presses with and without
perfector varies.
All components shown here can be used
in all presses equipped with the modular
sheet brake system.
SC.999.0020/01 B.10.53
Delivery
Sheet brake modules for 10 mm suction tape width
FS.901.8045-000GRAUND_00
1 These brake modules are standard components in
presses with a perfector. The suction tape width of
10 mm requires smaller image-free areas. If 10 mm
suction tapes are used, each image-free area needs to
2 be 9 ... 12 mm.
Equipment supplied as standard on presses with a
perfector:
● 3 sheet brake modules for installation on the left
side (Fig. 52/1).
● 2 sheet brake modules for installation on the right
side (Fig. 52/2).
Fig. 52 Sheet brake modules for 10 mm suction tape
width
Sheet brake modules for 20 mm suction tape width
FS.901.8046-000GRAUND_00
1 These brake modules are standard components in
presses without a perfector. The larger suction tape
width requires larger image-free areas than with the
sheet brake modules with 10 mm suction tapes.
2 Equipment supplied as standard on presses without a
perfector:
● 3 sheet brake modules for installation on the left
side (Fig. 53/1).
● 2 sheet brake modules for installation on the right
side (Fig. 53/2).
Fig. 53 Sheet brake modules for 20 mm suction tape
width
Starwheel modules
FS.901.8047-000GRAUND_00
1 The starwheel modules support the sheet when the
image-free area for brake modules is not large
enough. Equipment supplied as standard on presses
with a perfector:
2 ● 1 starwheel module for attachment on left side
(Fig. 54/1).
● 1 starwheel module for attachment on right side
(Fig. 54/2).
Fig. 54 Starwheel modules
B.10.54 SC.999.0020/01
Delivery
Magnetic sheet stops
FS.901.8018-001GRAUND_00
The magnetic sheet stops prevent sheets from jump-
ing back and being pulled between the sheet brake
and the guide rail.
Equipment supplied as standard:
● 3 magnetic sheet stops for attachment on left
side (Fig. 55/1).
1 2
● 2 magnetic sheet stops for attachment on right
side (Fig. 55/2).
Fig. 55 Magnetic sheet stops, front and top view
Magnetic starwheel holders
FS.901.8020-000GRAUND_00
The magnetic starwheel holders support the sheets if
no components are fitted on the module support, for
example.
● Magnetic starwheel supports (Fig. 56).
Fig. 56 Magnetic starwheel holders
Knurled screws
FS.901.8022-000GRAUND_01
The knurled screw is fastened in the thread on the
empty side of the module support to protect it from dirt.
● Knurled screws (Fig. 57).
Fig. 57 Knurled screws
Friction wheels
FS.901.8016-000GRAUND_01
Each friction wheel is supplied with 4 Allen screws.
When the friction wheel is replaced, the Allen screws
should be replaced as well.
Equipment supplied as standard:
● 2 friction wheels
● 8 Allen screws M 3 x 8
Note
For information on replacing the friction
wheels, see the separate "Maintenance
and Cleaning for Customers" manual.
Fig. 58 Friction wheel and screws
SC.999.0020/01 B.10.55
Delivery
Allen wrench
FS.901.8023-000GRAUND_01
The Allen wrench is used to fasten and unfasten the
sheet brake modules on the module support.
● Allen wrench (Fig. 59).
Note
Use only the Allen wrench provided to
Fig. 59 Allen wrench install and remove the sheet brake mod-
ules.
11.3 Overview of adjustments
Parameters Adjustment element Information
Only with timed drive: Control station or de- Standard setting: Dynamic (timed) drive.
Switchover between livery control panel In Continuous drive mode, the sheet brake behaves the same way as
dynamic (timed) and the old sheet brake system.
continuous drive:
Fitting components to Control station or de- You have to enter the components provided in order for the press
the module supports livery control panel control system to position the module supports correctly.
Delivery speed Delivery control panel See table with setting recommendations.
Suction air for all sheet Delivery control panel See table with setting recommendations.
brakes
Suction air/blast air for Valve block for the Empty module support: Set the adjustment lever to zero position.
individual sheet brake sheet brakes
Sheet size/lateral po- Control station: Auto- Where possible, position the sheet brakes in image-free areas.
sition of sheet brake matic adjustment If the sheet brakes are not positioned sensibly in the automatic set-
when the sheet size is ting, check the component setup entry on the control station.
specified.
The minimum distance between two module supports is 100 mm. If
Delivery control pan- you cannot move the sheet brakes to maximum sheet size, check the
el: Individual adjust- components provided for the module support and the setting on the
ment of the lateral po- control station.
sition.
3 or 4 sheet brakes Control station When 3 or 4 sheet brakes are selected: The sheet brakes which are
can be selected not needed are automatically parked outside the sheet area.
Inclination of sheet At the sheet brake
brake module modules
Inclined position of At the sheet brake Set symmetrically at an angle.
brake module modules With a tandem component setup, do not align at an angle.
Air supply in delivery Delivery control panel See table with setting recommendations.
area
Tab. 2 Setting options
B.10.56 SC.999.0020/01
Delivery
Adjusting the brake modules
SF.901.6607-000GRAUND_00
You can adjust the air supply to each sheet brake
module using the adjustment levers at the valve block
(Fig. 60).
1 Blast air setting range (depends on the product
line)
2 Zero position
When the adjustment lever is in this position, the
1 suction air and blast air are off.
3 Suction air manometer
4 Suction air adjustment range
2 If a print sheet runs at an incline into the pile formation
area, you can perform various air settings at the indi-
vidual brake modules to compensate for the inclined
position. This causes the print sheet to be slowed
3 down on one side.
Possible reasons for a print sheet arriving at an incline:
● Sheet brakes set asymmetrically at an angle
4 ○ The middle sheet brake (of 3 or 5 brakes) is
Fig. 60 Valve block for air regulation - example (may set at an angle.
differ according to product line) ○ One of the outer sheet brakes is at an angle
while the other sheet brake is straight.
● Uneven color assignment of the print sheet.
● Irregular adhesion of the sheet on the suction
tape.
1. Open the door on the delivery on O.S.
2. Adjust the suction air for each sheet brake mod-
ule at the adjustment levers (Fig. 60) of the valve
block.
Checking the vacuum for the sheet brake
The pile formation process can be disturbed by an in-
sufficient or excessive vacuum at the sheet brakes.
You can check the vacuum at the manometer
(Fig. 60/3) of the "Sheet brake" valve block.
Vacuum control Adjustment lever Negative pres- Action
value on the de- for air regulation sure (manome-
livery console ter)
100 % All 5 adjustment At least 0.35 bar. If the negative pressure does not reach this value:
levers are at the Check whether the valves of the module supports are
bottom stop (suc- set to the right equipment.
tion air fully open).
50 % All 5 adjustment At least 0.3 bar If the negative pressure drops below 0.3 bar:
levers in zero posi- Clean the filter in the air supply line of the sheet brake
tion (Fig. 60/2). (see the "Maintenance and Cleaning for Customers"
manual).
100 % All 5 adjustment At least 0.5 bar If the vacuum drops below 0.5 bars: Have Heidelberg
levers in zero posi- Service check the vacuum pump.
tion (Fig. 60/2).
Tab. 3 Negative pressure at the "Sheet brake" valve block
SC.999.0020/01 B.10.57
Delivery
11.4 Recommended settings for air and speed
The sheet brake is optimally adjusted if the lead edge
LS.901.6556-000GRAUND_00
2 of the sheet hits the edge between the delivery pile and
the sheet jogger (as shown in Fig. 61/1).
1
Insufficient brake action or delayed gripper open-
ing
3 The sheet hits the sheet joggers (Fig. 61/2).
● Reduce the tape speed or
● Increase the suction air volume (vacuum at the
sheet brakes) or
● Set an earlier gripper opening time.
Excessive brake action or premature gripper
opening
The sheet brushes over the top sheet in the pile
(Fig. 61/3).
● Increase the tape speed or
Fig. 61 Lead edge of sheet on the delivery pile
● Set a later gripper opening time.
B.10.58 SC.999.0020/01
Delivery
12 Modular sheet brake system - handling the sheet brake modules
FS.901.9067-000UTKENU_08
12.1 Module support
The standard component setup is indicated by the pins
XG.901.6033-000GRAUND_00
(Fig. 62/1) on the module support.
1 Using the module supports with the standard compo-
nent setup will offer you the largest possible adjust-
ment range.
Depending on the configuration, lateral adjustment of
the position of the sheet brake modules is performed
by means of a servo-drive or manually. When auto-
matically adjusting the position via the servo-drive, you
need to enter the corresponding information into the
control system. When manually adjusting the position,
use the scale behind the sheet brake modules for ori-
entation.
Fig. 62 Pins for indicating the standard component
setup
12.2 Entering the component setup on the control system
The control system requires the information on the
component setup in order to move the module sup-
ports into the correct lateral position and to display the
position and component setup correctly.
Note
If the components fitted are entered in-
correctly, the sheet brakes do not move
into the correct position, but are offset by
35 mm or 70 mm.
Components fitted on both sides of the module
LS.901.6533-000GRAUND_00
supports (tandem component setup)
The reference point for the positioning is the center of
the module support.
Note
For the tandem component setup, you
can fit two sheet brake modules each
with a tape width of either 10 mm or
20 mm. If you fit the sheet brakes with 2
brake modules (tandem component set-
up), you have to set the sheet brake in a
Fig. 63 Components fitted on both sides of the mod- straight line. If you set them at an angle,
ule supports (tandem component setup) one brake module is not driven and its
drive roller is damaged.
SC.999.0020/01 B.10.59
Delivery
Note
When configuring the tandem compo-
nent setup, ensure that the friction
wheels have the same degree of wear.
New friction wheels usually have a larger
diameter than friction wheels that have
already been in use for long periods. Dif-
ferent diameters could cause the brake
modules to run unevenly.
Components fitted on the left side of the module
LS.901.6561-000GRAUND_00
support
The reference point for the positioning is the center of
the left-hand sheet brake tape module. The control
system positions the module support with a 35 mm
offset to the right.
Note
If you set the sheet brake at an angle, the
sheet brake tape moves outward by
about 6 mm at the front. If necessary,
you may have to correct the position of
Fig. 64 Components fitted on the left side of the the sheet brake accordingly.
module support
Components fitted on the right side of the module
LS.901.6520-000GRAUND_00
support
The reference point for the positioning is the center of
the right-hand sheet brake tape module. The control
system positions the module support with a 35 mm
offset to the left.
Note
If you set the sheet brake at an angle, the
sheet brake tape moves outward by
about 6 mm at the front. If necessary,
you may have to correct the position of
Fig. 65 Components fitted on the right side of the the sheet brake accordingly.
module support
No components fitted on the module support
LS.901.6504-000GRAUND_00
The reference point for the positioning is the center of
the module support.
Fig. 66 No components fitted on the module support
B.10.60 SC.999.0020/01
Delivery
12.3 Setting the valve on the module support
You need to set the valve (Fig. 67/1) on the module
XG.901.6034-000GRAUND_00
support in accordance with the component setup. If the
setting is incorrect, the brake modules are not supplied
with suction air or infiltrated air is drawn in.
Note
Use the short Allen wrench provided
(width across flats: 5 mm) or a fork
wrench (width across flats: 10 mm) to
make adjustments.
Fig. 67 Module support
Module supports fitted with sheet brake modules
XG.901.6037-000GRAUND_00
on both sides
1. Set the valve to the position with both marks
(Fig. 68/1).
Fig. 68 Valve position equipped on both sides
Left-hand module support fitted with sheet brake
XG.901.6035-000GRAUND_00
module
1. Set the valve to the position with the mark on the
left-hand side (Fig. 69/1).
Fig. 69 Valve position equipped on the left-hand
side
SC.999.0020/01 B.10.61
Delivery
Right-hand module support fitted with sheet brake
XG.901.6036-000GRAUND_00
module
1. Set the valve to the position with the mark on the
right-hand side (Fig. 70/1).
Fig. 70 Valve position equipped on the right-hand
side
Module support with no components fitted or with
XG.901.6038-000GRAUND_00
starwheel module
1. Set the valve to the position with no marks
(Fig. 71/1).
Fig. 71 Valve position not equipped
12.4 Setting the sheet brakes at an angle
To tauten the sheets, you can set the sheet brakes at
FS.901.8005-000GRAUND_00
an angle to the direction of sheet travel. The module
1 2 3 4 5 supports click into place in the following positions:
● Module support on D.S. (Fig. 72/1 and 2): Center
position or towards D.S.
● Module support on O.S. (Fig. 72/4 and 5): Center
position or towards O.S.
● Central module support. (Fig. 72/3): Center po-
sition, towards D.S.or towards O.S. Make sure
that this module support is in the correct position
when locking into place.
Note
You have to set the sheet brakes at an
Fig. 72 Angled setting options angle symmetrically.
B.10.62 SC.999.0020/01
Delivery
Caution - Risk of damage to the fric-
tion wheel!
If you fit the sheet brakes with 2 brake
modules (tandem component setup),
you have to set the sheet brakes in a
straight line. When two sheet brake
modules are set at an angle, one sheet
brake module is not driven. This can
cause damage to the friction wheel.
Procedure for setting at an angle
XG.901.6105-000GRAUND_01
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. To set the sheet brake at an angle: Grasp the
sheet brake (Fig. 73/1) and push it toward the
side frame. The sheet brake swivels into the an-
gled position and locks into place.
3. To set the sheet brake straight: Grasp the sheet
brake (Fig. 73/1) and push it toward the center of
1 the press. The sheet brake clicks into the straight
position.
Fig. 73 Setting the sheet brake at an angle
4. Release the Emergency stop button. Close the
front guard on the delivery.
12.5 Inclining the brake modules
Setting the inclination
XG.901.6106-000GRAUND_00
● The sheet brake modules can be angled in 2 po-
sitions:
○ Horizontal position (Fig. 74/1): Useful for
short sheet lengths and stiff printing mate-
rials to offer improved print sheet response.
○ Angled downward (Fig. 74/2): Standard, in
1 2 particular for perfecting and when process-
ing thin printing materials.
Note
Set all brake modules to the same incli-
nation.
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. Grasp the brake module and swing it into the de-
sired position. The brake module clicks into the
corresponding position.
3. Release the Emergency stop button. Close the
Fig. 74 Inclined positions
front guard on the delivery.
SC.999.0020/01 B.10.63
Delivery
12.6 Adjusting the friction wheel at the sheet brake module (tandem component setup)
If the sheet brake modules are operated in a tandem
SG.901.9805-000GRAUND_00
2 component setup, even a slight difference in the height
of the friction wheels may lead to the two modules be-
ing out of sync. In this case, one friction wheel
(Fig. 75/2) is not or just barely in contact with the drive
shaft (Fig. 75/3). If you find that the two sheet brake
module are out of sync, eliminate the problem by cor-
recting the difference in height (Fig. 75/1) of the friction
wheels. One of the two sheet brake modules is
equipped with an eccentric shaft. Adjust this shaft to
set the two friction wheels to the same height.
1
3
Fig. 75 Diagram: Tandem component setup
Distinguishing characteristic of sheet brake mod-
SG.901.9804-000GRAUND_00
ules with an adjustable friction wheel
Sheet brake modules with an adjustable friction wheel
1 have a groove (Fig. 76/1) in the shaft of the friction
wheel.
● Basic setting: The groove (Fig. 76/1) is vertical.
● Turn clockwise (Fig. 76/3) to move the friction
wheel toward the drive shaft.
2 ● Turn counterclockwise (Fig. 76/2) to move the
3
friction wheel away from the drive shaft.
Fig. 76 Brake module
Checking the suction tapes
SG.901.9801-002GRAUND_00
1. Press the cleaning button (Fig. 77/1). Observe
the suction tapes. All suction tapes must turn at
the same speed. If a suction tape does not turn in
sync with the others, you must remove both sheet
brake modules of the module support.
Checking the friction wheels for wear
2. Press the emergency stop button on the delivery
1 control panel.
3. Remove both sheet brake modules of the tandem
component setup.
4. Check if one friction wheel shows more wear than
the other. If this is the case, replace both friction
Fig. 77 Cleaning button wheels. See Replacing the friction wheel of the
drive roller.
Adjusting the friction wheel
5. If the friction wheels are equally worn, adjust the
sheet brake module at the groove (Fig. 78/1) us-
ing a screwdriver.
B.10.64 SC.999.0020/01
Delivery
Note
If the suction tape at the adjustable sheet
brake module is out of sync, adjust the
setting by turning the groove
max. + 0.2 mm / +90° counterclockwise
(Fig. 78/2).
If the suction tape at the non-adjustable
sheet brake module is out of sync, adjust
the setting by turning the groove max. -
0.2 mm / -90° clockwise (Fig. 78/3).
Checking the adjustment
SG.901.9804-000GRAUND_00
6. Mount both sheet brake modules.
7. Release the emergency stop button on the deliv-
1 ery control panel.
8. Check again if the two suction tapes move in sync
with the other suction tapes.
9. If not, correct the adjustment as needed.
3 2
Fig. 78 Adjusting the sheet brake module, neutral
position
12.7 Manually adjusting the position of the sheet brake module supports
In accordance with your press configuration, you can
LS.901.6581-010GRAUND_00
2 manually adjust the position of the sheet brake module
1
supports.
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. To adjust the position of the sheet brake module
support, you need to release the clamping lever
(Fig. 79/1). To do this, swivel the clamping lever
by 90° in the counterclockwise direction.
3. Use the scale (Fig. 79/2) on the cross bar behind
the sheet brake module as a means of orienta-
tion.
4. Fasten the sheet brake module support. To do
Fig. 79 Sheet brake module supports this, swivel the clamping lever by 90° in the clock-
wise direction.
Tip
Remove unused sheet brake modules.
You thereby preserve the suction tape in
question.
5. Release the Emergency stop button. Close the
front guard on the delivery.
SC.999.0020/01 B.10.65
Delivery
12.8 Removing/fitting a sheet brake module
Note
XG.901.6107-000GRAUND_01
The procedure is the same for sheet
brake modules with 10 mm and 20 mm
wide sheet brake tapes.
Removing the brake module
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. Slacken the screw (Fig. 80/2) using the Allen
1 2 wrench (Fig. 80/1). Turn out the screw until the
brake module is disconnected from the module
support. The screw can then be moved back and
forth.
Fig. 80 Screw on the brake module 3. Pull the brake module away from the module
support in a lateral direction. The brake module is
released and can be taken out.
Note
XG.901.6121-000GRAUND_00
If the module support has no compo-
nents fitted on one or both sides, you
must screw in the knurled screw
(Fig. 81/1) on the side(s) with no com-
ponent fitted. The knurled screw protects
the thread in the module support from
becoming soiled with powder.
1
2 4. Adjust the setting of the valve (Fig. 81/2) on the
module support to suit the altered component
setup.
5. Release the Emergency stop button. Close the
front guard on the delivery.
Fig. 81 Knurled screws 6. Enter the altered component setup on the control
system.
Installing the brake module
XG.901.6181-000GRAUND_01
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. Adjust the setting of the valve (Fig. 82/1) on the
module support to suit the new component setup.
3. Remove the knurled screw (Fig. 82/2) from the
side on which you wish to fit the brake module.
4. Insert the brake module next to the module sup-
1 2 port. Push the drive roller into the hollow which is
formed by the tape driving roller and the cross
Fig. 82 Inserting the brake module bar.
5. Lift up the sheet brake module slightly at the front
(arrow, Fig. 82). The underside of the sheet brake
module is now in contact with the tape driving
roller.
B.10.66 SC.999.0020/01
Delivery
6. Hold the sheet brake module (Fig. 83/1) tilted up-
XG.901.6182-000GRAUND_00
ward slightly. Position it parallel and flush with the
2 module support (Fig. 83/2).
Note
Ensure that the sheet brake module is
flush with the module support.
Fig. 83 Positioning the brake module against the
module support
7. Slide the brake module backward onto the mod-
XG.901.6183-001GRAUND_00 ule support.
The brake module tilts into the horizontal position
and clicks into place. The module support is lifted
up slightly when this happens.
Fig. 84 Sliding the brake module onto the module
support
8. Fasten the brake module with the screw
XG.901.6107-000GRAUND_01
(Fig. 85/2).
Caution - Risk of damage due to loose
screw!
Tighten the screw with the supplied Allen
wrench (Fig. 85/1).
9. Set the brake module to the desired inclination.
10. Release the Emergency stop button. Close the
front guard on the delivery.
1 2 11. Enter the altered component setup on the control
system.
Fig. 85 Screw on the brake module
SC.999.0020/01 B.10.67
Delivery
12.9 Removing/fitting a starwheel module
Caution - Risk of damage to the star-
FS.901.8048-000GRAUND_00
1 wheels!
The starwheels (Fig. 86/1) can easily get
bent. Store and handle the starwheel
modules (Fig. 86/4) carefully so that the
starwheels do not bend.
Removing a starwheel module
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
2 trol panel.
2. Slacken the screw (Fig. 86/3) on the starwheel
module. Pull the starwheel module off the module
support and remove the part.
3. Adjust the setting of the valve (Fig. 86/5) to suit
the new component setup.
4. Release the Emergency stop button.
5. If necessary, enter the modified component set-
5 up on the control station or on the delivery touch
screen.
Fitting a starwheel module
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel.
2. Position the starwheel module (Fig. 86/4) parallel
3 4 to and up against the module support.
3. Slide the starwheel module onto the module sup-
Fig. 86 Removing/fitting a starwheel module port in the direction of the arrow (Fig. 86).
Align the screw (Fig. 86/3) on the starwheel mod-
ule with the threaded hole in the module support
(Fig. 86/2).
Using the screw, fasten the starwheel on the
module support.
4. Adjust the valve (Fig. 86/5) on the module sup-
port to suit the modified component setup, i.e. set
the valve to the position with no mark. The suc-
tion air on the module support is switched off.
5. Release the Emergency stop button.
6. Enter the modified component setup on the con-
trol station or on the delivery touch screen.
B.10.68 SC.999.0020/01
Delivery
12.10 Replacing starwheels
When the starwheels are worn out or damaged, you
FS.901.8032-000GRAUND_00
can replace them.
1 1 2
1. Unscrew the two screws (Fig. 87/1).
2. Pull the bearing plate (Fig. 87/2) off the starwheel
module. The bearing plate can be removed easily
if you move it to and fro slightly while doing so.
Fig. 87 Starwheel module
3. Remove the two starwheels (Fig. 88/1).
FS.901.8033-000GRAUND_00
Fig. 88 Starwheel module demounted
SC.999.0020/01 B.10.69
Delivery
4. Plug new starwheels (Fig. 89/1) into the bushes
FS.901.8034-000GRAUND_00
of the bearing plate (Fig. 89/2).
2
1
Fig. 89 Starwheels on the bearing plate
5. Screw the starwheel module together.
FS.901.8035-000GRAUND_00
1 1 2 Screw in the two screws (Fig. 90/1). To start with,
only tighten the screws loosely.
6. Align the bearing plate (Fig. 90/2) and the middle
piece parallel in such a way that the top edges are
flush with one another.
7. Check the parallel alignment by turning the star-
wheels.
The two starwheels must turn easily and smooth-
ly without grinding or jamming. If the starwheels
do not turn easily and smoothly, correct the align-
ment of the bearing plates.
8. If both starwheels turn easily and smoothly, firmly
Fig. 90 Starwheel module assembled tighten the screws (Fig. 90/1). Check whether the
starwheels turn easily and smoothly again.
Caution - Risk of damage to the star-
wheels!
Ensure that the starwheels turn easily
and smoothly before inserting the star-
wheel module. Sluggish starwheels
cause marks on the printing material and
wear very quickly.
B.10.70 SC.999.0020/01
Delivery
12.11 Replacing a sheet brake tape
Note
XG.901.6108-000GRAUND_00
Always replace all worn sheet brake
tapes on all brake modules. In this way
you avoid unequal deceleration of the
1
sheets caused by tapes with differing
grip.
Replacing a sheet brake tape
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2
Removing a sheet brake tape
2. Pull the sheet brake tape (Fig. 91/1) over the front
Fig. 91 Removing a sheet brake tape roller (Fig. 91/2) to remove it from the sheet brake
module.
3. Remove the sheet brake tape from the sheet
brake module.
Mounting a sheet brake tape
4. First place the sheet brake tape (Fig. 91/1) over
the drive roller (pin feed drum) of the sheet brake
module.
5. Then pull the sheet brake tape over the front
roller (Fig. 91/2).
6. Release the Emergency stop button. Close the
front guard on the delivery.
7. Check that the sheet brake tapes run properly by
pressing the Turn tape driving roller button.
12.12 Maintenance / Cleaning
You will find information on
● Changing the friction wheel of the driving roller
● Changing the bearings in the driving roller
● Cleaning the brake modules
in the "Maintenance and Cleaning" manual.
SC.999.0020/01 B.10.71
Delivery
12.13 Removing and fitting the sheet stop
The sheet stops (Fig. 92/1 and 93/1) prevent sheets
XG.901.6111-000GRAUND_00
from jumping back and being pulled between the sheet
brake and the guide rail (Fig. 92/3). The sheet stops
are angled to the left or to the right.
Aligning the sheet stop
● If components are fitted on one side of the sheet
brake module: The raised side should point to-
ward the sheet brake module (Fig. 92).
2 3 ● For tandem component setup or if no compo-
nents are fitted on the module support, the align-
ment is not important.
1 Each module support has a driver pin (Fig. 92/2) which
also sets the sheet stop when the sheet size is adjust-
Fig. 92 Left-hand sheet stop ed. The sheet stop is magnetically held in place on the
guide rail (Fig. 92/3).
Note
The sheet stop has a recess for the driv-
er pin of the module support. If you insert
the sheet stop into the starwheel, it is al-
so set during sheet size adjustment. The
driver pin also secures the sheet stop
mechanically.
Removing the sheet stop
XG.901.6112-000GRAUND_00
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. The sheet stop is magnetically held in place on
the guide rail. You can lift and pull out the sheet
stop (Fig. 92/1).
3 3. If necessary, clean the sheet stop.
2
1
Fig. 93 Right-hand sheet stop
B.10.72 SC.999.0020/01
Delivery
Fitting the sheet stop
FS.901.8050-001GRAUND_00
1. Position the sheet stop in such a way that the
driver pin (Fig. 94/1) extends into the recess on
the sheet stop.
1 2. Plug the sheet stop (Fig. 94/2) onto the guide rail
(Fig. 92/3). Push the sheet stop onto the guide
2 rail until it is held in place magnetically.
3 Note
Make sure that the sheet stop is not
clamped behind the edge (Fig. 94/5).
4 Check that the positioning is correct
(Fig. 94/4).
3. Release the Emergency stop button. Close the
front guard on the delivery.
Fig. 94 Fitting the sheet stops correctly
12.14 Removing/fitting magnetic starwheel holders
Caution - Risk of damage to the star-
LS.901.6506-001GRAUND_00
wheel!
Before you move the outer module sup-
ports to their park position, ensure that
no magnetic starwheel holders are fitted
1 to the outer module supports. When
moving to their park position, the star-
wheels can get damaged by the chain
guides.
2 The starwheel (Fig. 95/1) supports the sheet, espe-
cially when no components are fitted to the module
supports. The magnetic starwheel holders can be po-
sitioned anywhere on the guide rail (Fig. 95/2).
Note
Fig. 95 Magnetic starwheel holder The magnetic starwheel holders have a
recess for the driver pin of the module
support. If you are using a magnetic star-
wheel holder on the driver pin, it is also
set during sheet size adjustment. You
can correct any minor deviations manu-
ally.
SC.999.0020/01 B.10.73
Delivery
Removing magnetic starwheel holders
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
2. Lift the starwheel support (Fig. 95/1) and pull it
out.
3. If necessary, clean the starwheel holder.
Fitting magnetic starwheel holders
1. Position the starwheel support in such a way that
the driver pin protrudes into the recess on the
starwheel holder.
2. Plug the starwheel support (Fig. 95/1) onto the
guide rail (Fig. 95/2). Push the starwheel support
onto the guide rail until it is held in place mag-
netically.
3. Release the Emergency stop button. Close the
front guard on the delivery.
B.10.74 SC.999.0020/01
Delivery
13 Modular sheet brake system - configuration variants for straight printing
FS.901.9068-000UTKENU_02
13.1 General
The following tables contains component configura-
tions ideal for sheets printed on one side or with a fully
dried rear side.
13.2 Standard component setup
Standard component setup
This configuration variant provides effective braking.
Use this configuration when working in automatic non-stop mode. Pay particular attention to the configuration of the
magnetic sheet stops at the outer edges of the format.
1 2 3 4 5
6 7
Module support D.S. outer (1) D.S. inner (2) Center (3) O.S. inner (4) O.S. outer (5)
Component setup Sheet brake mod- Sheet brake mod- Sheet brake mod- Sheet brake mod- Sheet brake mod-
ule L ule L ule L ule R ule R
Magnetic sheet
stop
(front view)
Edge of format Edge of format
D.S. (6) O.S. (7)
SC.999.0020/01 B.10.75
Delivery
Standard component setup
Entry on the con-
trol system
(top view)
Valve setting on
the sheet brake
module
Slide controller Suction air Suction air Suction air Suction air Suction air
for air settings
Tab. 4 Standard component setup
13.3 Maximum component setup for straight printing
Maximum component setup for straight printing
The maximum component setup makes sense when working in straight printing mode and processing very heavy or
limp printing material.
● For this configuration, you will require brake modules for suction tapes 20 mm wide.
● Equip the brake modules with flat suction tapes.
● You can fit the 5 module supports with 2 brake modules each (tandem component setup).
● Mount one adjustable and one non-adjustable sheet brake module onto each sheet brake.
● Label the sheet brake modules according to their position (e.g. as in the figure: 1a / 1b).
● Make sure that both friction wheels show the same degree of wear.
● Straighten the sheet brakes. If you set them at an angle, one brake module is not driven and the friction wheel may
be damaged.
1 2 3 4 5
1a 1b 2a 2b 3a 3b 4a 4b 5a 5b
Module support D.S. outer (1) D.S. inner (2) Center (3) O.S. inner (4) O.S. outer (5)
Component setup Brake module Brake module Brake module Brake module Brake module
20 mm L and R 20 mm L and R 20 mm L and R 20 mm L and R 20 mm L and R
B.10.76 SC.999.0020/01
Delivery
Maximum component setup for straight printing
Entry on the con-
trol system
Valve setting on
the sheet brake
module
Slide controller Suction air Suction air Suction air Suction air Suction air
for air settings
Angled setting: Caution - Risk of damage to the friction wheel!
No! If you fit the sheet brakes with 2 brake modules (tandem component setup),
you have to set the sheet brakes in a straight line. When set at an angle, one
sheet brake module is not driven, which can damage the friction wheel.
Tab. 5 Maximum component setup
SC.999.0020/01 B.10.77
Delivery
14 Modular sheet brake system - Component versions for straight printing and
FS.901.9069-000UTKENU_02
perfecting
14.1 Component setup of the sheet brakes
In the following tables you can see the component
configurations most commonly used in practice and
the necessary settings for each of these. You can also
find details on how to set everything up and make the
respective settings in the following sections.
Presses with perfector
For presses fitted with a perfector, the standard range
of items supplied includes brake modules for a tape
width of 10 mm and starwheel modules.
Presses without perfector
For presses without a perfector, the standard range of
items supplied includes brake modules for a tape width
of 20 mm. Ridged tapes that require a smaller image-
free area than flat suction tapes are available for these
brake modules. Starwheel modules are available as
accessories.
Note
When using the 10 mm wide suction
tapes, a pressure-free are of 9 to 12 mm
each is required. Depending on the
grammage and sheet size, it may not be
possible to print with the maximum ma-
chine speed when using less than 5
sheet brake modules.
B.10.78 SC.999.0020/01
Delivery
14.2 Standard component setup
Standard component setup
This component setup offers sound braking and is ideal if the printing form has the image-free areas needed. Use this
configuration when working in automatic non-stop mode. Pay particular attention to the configuration of the magnetic
sheet stops at the outer edges of the format.
1 2 3 4 5
6 7
Module support D.S. outer (1) D.S. inner (2) Center (3) O.S. inner (4) O.S. outer (5)
Component setup Sheet brake mod- Sheet brake mod- Sheet brake mod- Sheet brake mod- Sheet brake mod-
ule L ule L ule L ule R ule R
Magnetic sheet
stop
(front view)
Edge of format Edge of format
D.S. (6) O.S. (7)
SC.999.0020/01 B.10.79
Delivery
Standard component setup
Entry on the con-
trol system
Valve setting on
the sheet brake
module
Slide controller Suction air Suction air Suction air Suction air Suction air
for air settings
Angled setting to D.S. to D.S. No to O.S. to O.S.
Tab. 6 Standard component setup
14.3 Outer module supports in park position
Outer module supports in park position
If the printing form does not have many image-free areas, you can move the two outer module supports to their park
position. These module supports then move outside the outer edges of the print image. Prerequisite for optimum
sheet travel: The printing material is not too heavy.
This table shows the park position. Alternatively, the outer sheet brake modules can also be left empty without any
components. You then have to adjust the setting on the control system and the valves.
Caution - Damage to the starwheels!
Before you move the outer module supports to their park position, ensure that no magnetic
starwheel holders are fitted. In their park position, the starwheels can get damaged by the chain
guides.
1 2 3 4 5
Module support D.S. outer (1) D.S. inner (2) Center (3) O.S. inner (4) O.S. outer (5)
Component setup Park position Sheet brake mod- Sheet brake mod- Sheet brake mod- Park position
ule L ule L ule R
B.10.80 SC.999.0020/01
Delivery
Outer module supports in park position
Sheet brake mod- Sheet brake mod-
ule R or without ule L or without
components components
Entry on the con- Depends on com- Depends on com-
trol system ponent setup ponent setup
Valve setting on Depends on com- Depends on com-
the sheet brake ponent setup ponent setup
module
Slide controller 0 Suction air Suction air Suction air 0
for air settings
Angled setting Any to D.S. No to O.S. Any
Tab. 7 Standard component setup
14.4 Alternative component setup with 2 starwheel modules
Alternative component setup with 2 starwheel modules
This component setup is particularly suitable when printing areas with extremely high color placement on the un-
derside of the sheet. The two starwheel modules on the inner module supports support the print sheet and prevent
smearing of the sheet at the edge of the guide plate.
1 2 3 4 5
Module support D.S. outer (1) D.S. inner (2) Center (3) O.S. inner (4) O.S. outer (5)
Component setup Sheet brake mod- Starwheel mod- Sheet brake mod- Starwheel mod- Sheet brake mod-
ule L ule L ule L ule R ule R
SC.999.0020/01 B.10.81
Delivery
Alternative component setup with 2 starwheel modules
Entry on the con-
trol system
Valve setting on
the sheet brake
module
Slide controller Suction air 0 Suction air 0 Suction air
for air settings
Angled setting to D.S. No No No to O.S.
Tab. 8 Alternative component setup with 2 starwheel modules
14.5 Alternative population for small image-free area or small sheet size
Alternative population for small image-free area or small sheet size
This component setup is particularly suitable when there is no print-free area in the center of the sheet due to a heavy
solid area across the entire width. The two outer module supports are in their park position. The two inner module
supports are fitted with sheet brake modules. The center module support supports the print sheet, either with a
starwheel module or a sheet brake module, which is controlled by blast air. Since only 2 sheet brake modules are
being used, it might not be possible to print at maximum speed.
Caution - Damage to the starwheels!
Before you move the outer module supports to their park position, ensure that no magnetic
starwheel holders are fitted. In their park position, the starwheels can get damaged by the chain
guides.
1 3 4 5
2
Module support D.S. outer (1) D.S. inner (2) Center (3) O.S. inner (4) O.S. outer (5)
Component setup Park position Sheet brake mod- Starwheel mod- Sheet brake mod- Park position
Sheet brake mod- ule L ule L (or R) ule R Sheet brake mod-
ule R or without ule L or without
components components
B.10.82 SC.999.0020/01
Delivery
Alternative population for small image-free area or small sheet size
No starwheels! No starwheels!
Entry on the con- Depends on com- Depends on com-
trol system ponent setup ponent setup
(or right)
Valve setting on Dependent on Dependent on
the sheet brake population (when population (when
module not populated, not populated,
close) close)
Slide controller 0 Suction air 0/Blast air Suction air 0
for air settings
Angled setting Any to D.S. No to O.S. Any
Tab. 9 Alternative population for small image-free area or small sheet size
SC.999.0020/01 B.10.83
Delivery
15 Modular sheet brake system - Remedies in the event of problems
FS.901.9070-000UTKENU_01
15.1 Remedies in the event of problems
The following table helps you to eliminate problems.
Problem Cause Corrective measure
Tandem component setup: One Sheet brake is set at an angle. The Set the sheet brake straight.
brake module does not turn. friction wheel is not in contact with the Adjust the friction wheels.
tape driving roller.
The sheet is pulled at an angle. Un- Valves on the module supports are Check the valves and correct the set-
even braking effect of the sheet not set to the correct component set- ting.
brakes. up.
Braking tapes do not have the same Replace the braking tapes as a set.
grip.
Sheet brakes are not set at an angle Set the D.S. and O.S. sheet brakes
symmetrically. outward. The central sheet brake
must not be set at an angle.
Sheet does not jump evenly at the Set all the sheet brakes to the same
sheet brake. One or more sheet inclination. For paper over 80 g/m2:
brakes are inclined. Set the sheet brakes horizontally.
Tape driving roller of the sheet slow- Clean the tape driving roller. Check
down system soiled. Friction wheel of the friction wheels of the brake mod-
a brake module is damaged. ule.
Air for sheet brake on valve block in- On the valve block set the slide con-
correctly set. troller for the populated brake module
to suction air.
The sheet is damaged at the front The sheet collides with the front sheet Reduce the delivery speed.
edge. jogger. Delivery speed is too high.
The incoming sheet is marked by the The incoming sheet brushes over the Increase the delivery speed.
top sheet on the pile. pile surface. Delivery speed is too
low.
The sheet brake positions at a 35 mm Component setup is entered incor- Enter the correct component setup.
or 70 mm offset to the presetting. rectly on the control system.
The sheet brake cannot be set to Module supports do not have the Set up the module supports with the
maximum sheet size. standard component setup or the standard component setup. Enter the
component setup has not been en- correct component setup.
tered correctly on the control system.
Tab. 10 Remedy
B.10.84 SC.999.0020/01
Delivery
16 Suction tapes
FS.901.9072-000UTKENU_04
16.1 Properties
Function of the suction tapes
The suction tapes establish contact between sheet
brake and sheet and transmit the braking force onto
the accelerated sheet. Different suction tapes that vary
in hardness, rubber composition and shape are avail-
able for different printing materials and applications.
Hard or soft rubber composition?
● Suction tapes with a hard rubber composition
have a longer service life and are suitable for a
wide range of printing materials.
● Suction tapes with a softer rubber compound are
suitable for smooth and shiny printing materials
that are prone to marking.
Note
Always equip all sheet brake modules
with the same type of suction tape. In the
event of wear, always replace the com-
plete set of suction tapes to avoid sheet
travel malfunctions caused by the vary-
ing adhesive forces of suction tapes.
Storing suction tapes
If you remove and place the brake modules into stor-
age or do not intend to use the printing press for more
than 1 week, remove the suction tapes. Store the suc-
tion tapes in a dry location and protected from light.
This will prevent deformation and cracks in the rubber
layer and extend the service life of the suction tapes.
Note
Depending on the printing material,
grammage, printing speed and other pa-
rameters, you need to determine the op-
timum suction tapes for the specific print
job. If problems occur, you can also try
the other suction tape types.
The suction tapes are part of the standard scope of
delivery for your printing press. The following tables
show other suction tapes that are compatible with the
brake modules. The application recommendations are
only suggestions.
SC.999.0020/01 B.10.85
Delivery
16.2 Suction tapes for sheet brake modules - tape width 10 mm
Description / part num- Field of application
ber (use only for friction wheel sheet brake)
Suction tape with 8 mm Suction tape for narrow sheet brake modules.
rib, grooved, yellow All-purpose tape with high holding power for a wide range of stock
F4.614.885 / (high durability).
Suction tape with 7 mm Suction tape for narrow sheet brake modules.
rib, grooved, red Suitable for scratch-sensitive stock (medium durability).
F4.614.891 /
Tab. 11 Suction tapes with a width of 10 mm
16.3 Suction tapes for sheet brake modules - tape width 20 mm
Description / part num- Field of application
ber
Suction tape 20 mm, Suction tape for wide sheet brake modules.
green All-purpose tape for a wide range of stock (high durability).
M2.015.880 /
Suction tape 20 mm, Suction tape for wide sheet brake modules.
gray Suitable for very scratch-sensitive stock (low durability).
F4.614.831 /
Suction tape with 9 mm Suction tape for wide sheet brake modules.
rib, gray Suitable for very scratch-sensitive stock and work-and-turn jobs
F4.614.821 / with a small image-free area (low durability).
Tab. 12 Suction tapes with a width of 20 mm
B.10.86 SC.999.0020/01
Delivery
17 Gripper opening cam
SC.901.9065-000UTKENU_03
17.1 Function
The sheet is gripped by the grippers at the front edge
LS.901.6556-010GRAUND_00
4
(Fig. 96/1) and is transported to the top of the delivery
pile (Fig. 96/2). As long as the grippers are closed, the
2 1 2 sheet is transported at press speed. If applicable, the
rear edge of the sheet is held by 2, 3 or 5 sheet brake
3
modules (Fig. 96/3) via suction. The sheet brake mod-
ules are equipped with rotating perforated suction
tapes. These suction tapes suck the sheet against the
rear edge (Fig. 96/4). The sheet brake modules rotate
9 at the so-called delivery speed. At this point there is
some slip between the sheet and the suction tape. If
5 the gripper opening cam has opened the grippers
6 (Fig. 96/5), the lead edge of sheet is free (Fig. 96/7).
The rear edge is held in place by the suction effect of
7 the suction tape and the sheet is slowed to delivery
8 speed. By rotating the suction tape, the sheet is trans-
8
ported until it is released by the sheet brake module.
The delivery air system (Fig. 96/6) presses the sheet
Fig. 96 Gripper opening and sheet brake function down onto the pile. The sheet is positioned between
the stops (Fig. 96/8). The gripper opening time, the
speed of the sheet brake and the air volume from the
delivery air system can be adjusted within set limits.
17.2 Setting the gripper opening cam
By using preset values, the gripper opening, sheet
brake and delivery air system are already set to rea-
sonable values.
The sheets running in should be guided by the grippers
as long as possible. However, if they are guided for too
long, they collide too hard and the front edge is dam-
aged.
The "flight path" of the sheet depends on several fac-
tors, including:
● sheet size,
● grain direction,
● color assignment,
● grammage,
● machine speed,
● settings of the sheet slow-down device,
● air settings in the pile area.
The press control system sets the gripper opening to a
virtually optimal value on the basis of the preset val-
ues. Furthermore, the press control system compen-
sates the gripper opening in the event of speed
changes. For difficult printing materials and motifs you
need to adapt the gripper opening. The gripper open-
ing time can be set on the delivery control panel.
SC.999.0020/01 B.10.87
Delivery
Tip
The heavier the sheet, the earlier the
grippers have to open.
Tip
The faster the printing speed, the earlier
you need to open the grippers.
17.3 Interplay between gripper opening, sheet brake and delivery air
The gripper opening, sheet brake and delivery air all
LS.901.6556-001GRAUND_00
have an effect on the sheet delivery. When setting the
gripper opening you need to take into account the in-
fluence of the sheet brake on the rear edge of sheet
1 2 and the delivery air.
The sheet stop (Fig. 97/1) is vertical to the top sheet
(Fig. 97/5) on the delivery pile.
Ideal flight path of the sheet
Ideally, the gripper opening and sheet brake are co-
ordinated so that the lead edge of sheet (Fig. 97/3)
arrives precisely at the point at which the sheet stop
5 4 3
and the top sheet meet and does not jump back. The
sheet is then laid on the top sheet without any mis-
alignment.
Sheet strikes against the stops
If the sheet strikes the stops too hard (Fig. 97/2), the
Fig. 97 Flight path of the sheet
following occurs:
● Damage to the front edge of the sheet
● Striking noises when the front edge hits the stops
● The sheet jumps back from the stops
● The sheet arches upward at the stops (Fig. 97/2)
In unfavorable circumstances a subsequent
sheet can run over the stop as an overrunning
sheet.
Measures:
● Open the grippers earlier
● Reduce the delivery speed at the sheet brake
● Increase the delivery air
Sheet lays down before the stops
If the gripper opening is set too early (Fig. 97/4):
● The front edge slides over the top sheet and
scratches the surface
● The rear edge arches upward at the stops
Measures:
● Open the grippers later
● Increase the delivery speed at the sheet brake
● Reduce the delivery air
B.10.88 SC.999.0020/01
Delivery
Tip
Depending on your observations, initially
optimize the sheet delivery by adjusting
the gripper opening.
Tip
If adjusting the gripper opening is not
sufficient, change the delivery speed at
the sheet brake and the air volume on
the delivery air system.
SC.999.0020/01 B.10.89
Delivery
18 Overrun sheet control
SC.901.9080-000UTKENU_05
18.1 Method of functioning
The overrun sheet control ensures that no print sheets
SC.901.9080-002GRAUND_00
2 are conveyed beyond the delivery pile. The printing
press stops when a print sheet:
● overruns the delivery pile,
● gets stuck to the gripper,
● is pulled along by the gripper.
The overrun sheet control consists of:
● ultrasonic sensor (Fig. 98/1)
1 ● comb (Fig. 98/2)
Fig. 98 Overrun sheet control
18.2 Ultrasonic sensor
The ultrasonic sensor (Fig. 100/1) detects print sheets
SF.901.9063-000GRAUND_00
which have overrun the delivery pile. The press is
1 stopped when the sensor detects a sheet.
Troubleshooting
1. Open the glass guard (Fig. 99/1).
2. Remove all overrun print sheets. The overrun
print sheets are located
● in the area of the ultrasonic sensor.
● above the pile.
Fig. 99 Delivery
B.10.90 SC.999.0020/01
Delivery
3. If more than one sheet has overrun you should
SG.901.9081-002GRAUND_00
also check the area above the dryers.
● Open the guard above the delivery.
● Remove all overshot print sheets from this
area.
4. Close the glass guard and the guard above the
1 delivery.
Note
Before the press can be put back into
operation, you must open the glass
guard and close it again.
Fig. 100 Ultrasonic sensor
18.3 Comb
Sheets transported by the gripper bars are stopped by
the comb in the return flow after the gripper opening.
SC.999.0020/01 B.10.91
Delivery
19 Sheet joggers
FS.901.9111-000UTKENU_05
19.1 Function
Lateral sheet joggers
FS.901.9856-001GRAUND_00
There is one sheet jogger each on D.S. and O.S. of the
1
delivery. The two sheet joggers align the lateral pile
edge.
The sheet joggers are flexibly supported so that they
can adapt to the upper pile edge.
The sheet joggers are safeguarded against colliding
with the pile/pile support plate.
The back and forward movement of the cheek of the
lateral sheet joggers (Fig. 101/1) supports the align-
ment of the lateral pile edge. The two sheet joggers run
asynchronously because the sheet jogger on D.S. op-
erates more slowly than the one on O.S. to ensure
smooth pile alignment.
Fig. 101 Sheet jogger D.S. Note
To obtain a pile with straight edges, do
not apply the sheet joggers too strongly
on the pile. The sheet joggers must
briefly lift off the pile during the alignment
movement.
Vibrating front edge alignment
The alignment movement of the front edge supports
the alignment of the pile edge in the direction of sheet
travel.
19.2 Setting the lateral sheet joggers automatically
Requirement
The lateral sheet joggers can only be set
to a smaller sheet size, e.g. in the case of
a job change, if the pile support plate is in
the lower end position. A larger format
can be set at any time.
The lateral sheet joggers are set automatically to the
sheet size following the entry of the format on the con-
trol station. During the positioning process of the sheet
joggers, they are moved slightly beyond the actual
sheet size width. The sheet joggers then move inward
to the specified sheet size.
19.3 Setting the lateral sheet joggers manually
You can correct the position of the lateral sheet jog-
gers on the delivery control panel manually (for exam-
ple, following a pull distance correction).
If the non-stop rake is being used in the delivery, you
cannot move the lateral sheet joggers.
The sheet jogger adjustment range is dependent on
the sheet size.
B.10.92 SC.999.0020/01
Delivery
Note
If you change a value at the control sta-
tion or at the delivery control panel, the
display is updated automatically. Values
that you change on the delivery control
panel are automatically updated on the
control station.
Correction on the delivery control panel
FS.901.9164-002GRAUND_00
The increment for all entries in this menu is 1 mm. The
1 relative deviation (xx) from the Preset value is dis-
played at the symbol (sheet jogger / rear edge stop).
2 3 If the arrow at the symbol points towards the pile, the
xx
sheet jogger / rear edge stop is positioned within the
sheet format; if the arrow points away from the pile, it is
outside the sheet format.
xx xx
Individual correction
4 5 ● Sheet jogger D.S. (Fig. 102/2)
Depending on the direction of the arrow on the
button, pressing the button (Fig. 102/2) will move
the sheet jogger towards or away from the pile.
Fig. 102 Delivery/pile stops menu ● Sheet jogger O.S. (Fig. 102/3)
Depending on the direction of the arrow on the
button, pressing the button (Fig. 102/2) will move
the sheet jogger towards or away from the pile.
● Rear edge stop (Fig. 102/1)
Depending on the direction of the arrow on the
button, pressing the button (Fig. 102/2) will move
the rear edge stop towards or away from the pile.
Note
The arrow shows the direction of motion
of the selected sheet jogger.
Correction on both sides
● Pressing the buttons (Fig. 102/4 or 5) will move
both sheet joggers (D.S. and O.S.) in the direc-
tion indicated by the arrow.
Caution - Risk of damaging sheet jog-
ger and pile!
Avoid collisions between the sheet jog-
gers and the pile.
If you move the sheet jogger manually,
the selected sheet jogger will continu-
ously move toward or away from the pile
for as long as the button is kept de-
pressed.
The movement towards the pile is not
safeguarded - a collision with the pile is
possible!
SC.999.0020/01 B.10.93
Delivery
19.4 Setting the lateral sheet joggers to the sheet length
Sheet length 550 ... 750 mm
When processing printing materials with a sheet
length of 550 mm ... 750 mm, the lateral sheet joggers
must be at the stop (Fig. 104/2).
Note
As long as the lateral sheet joggers are
in this position, the rear edge stop can
only be set to a sheet length of
550 to 750 mm. The rear edge stop
would otherwise collide with the lateral
sheet joggers.
Sheet length less than 550 mm
Before you can process sheets with a sheet length
smaller than 550 mm, you need to position the sheet
joggers at the front stop.
Note
Position the sheet joggers against the
front stop. If the sheet joggers are posi-
tioned centrally between the stops, this
can have an impact on the non-stop op-
eration.
Relocating the sheet joggers
FS.901.9120-001GRAUND_00
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel.
2. Release the clamping lever at the sheet jogger
(Fig. 103/1).
To do so, push down the clamping lever until it is
vertical and hold the lever in this position.
Note
1 The clamp may be difficult to release due
to adhering powder dust.
Fig. 103 Releasing the sheet joggers on O.S.
3. Grip the sheet jogger by the mounting plate
FS.901.9121-001GRAUND_00
(Fig. 104/1) and push the unit against the stop
(Fig. 104/2).
4. Lock the sheet jogger in position by releasing the
clamping lever. The clamping lever swings up in-
to the vertical position.
2 Result
The sheet jogger D.S. is locked in posi-
tion.
1
5. Move the sheet jogger on D.S. using the same
method.
Fig. 104 Sheet jogger O.S. at the end stop
B.10.94 SC.999.0020/01
Delivery
Note
After you have moved the sheet joggers
on D.S. and on O.S. up to the stop, you
can set the rear edge stop to a sheet
length of less than 550 mm.
6. Release the Emergency stop button.
19.5 Activating/deactivating the alignment movement of the lateral sheet joggers and at the front
edge
Prinect Press Center
FS.901.9167-000GRAENU_00
Paper run
1 1. At the Prinect Press Center, select the tab Press
overview and then the menu Paper run.
2. Select the delivery in the diagram.
2 4 The display changes to the detail view (Fig. 105)
Delivery.
3 You can activate and deactivate the alignment move-
ment individually at the sheet joggers on D.S.
(Fig. 105/2) and O.S. (Fig. 105/4) and at the front edge
(Fig. 105/3).
The alignment movement can be activated and deac-
tivated at the control station and/or at the delivery con-
trol panel.
Fig. 105 Prinect Press Center, paper run
Note
The front edge can only be aligned when
the press is running.
SC.999.0020/01 B.10.95
Delivery
20 Rear edge stop
SG.901.0910-000UTKENU_02
20.1 Function
The rear edge stop (Fig. 106/1) supports the alignment
SG.901.9858-003GRAUND_00
of the rear edge of the pile.
The rear edge is safeguarded against colliding with the
pile/pile support plate. If the pile/pile plate presses the
stops on the rear edge stop upwards, the control sys-
tem switches off the pile lifting mechanism approxi-
mately 6 mm before reaching the final stop.
Fig. 106 Rear edge stop
20.2 Setting the rear edge stop automatically
Following the entry of the format on the control station,
the rear edge stop is set automatically to the sheet
size.
Note
The rear edge travel range depends on
the position of the sheet joggers and on
the format.
Sheet length less than 550 mm
It is only possible to set the rear edge to the minimum
sheet size once the pile support plate has been low-
ered to the floor. Larger sheet sizes of up to 750 mm
can be set at any time.
Requirement
Before you can process sheets having a
sheet length of less than 550 mm, you
need to move the sheet joggers manu-
ally into the "Sheet length less than
550 mm" position. Refer to the "Sheet
jogger" chapter for further details.
1. Move the pile support plate downwards until it
rests on the floor.
2. Secure the printing press against being started
up: Press the Emergency stop button on the de-
livery control panel. Open the front guard on the
delivery.
3. Move the sheet jogger into the "Sheet length less
than 550 mm" position (see chapter "Press, de-
livery, sheet joggers").
4. Release the Emergency stop button. Close the
front guard on the delivery.
B.10.96 SC.999.0020/01
Delivery
5. On the control station open the Job/Printing
material menu.
6. Enter the format and press the OK button.
The rear edge stop adjusts to the sheet size.
Note
If you set a format on the control station
that is smaller than 550 mm while the
sheet joggers are in the "Sheet length
larger than 550 mm" position, the rear
edge stop stops in the 550 mm position.
7. Set the sheet joggers to the "Sheet length less
than 550 mm" position.
8. Press the OK button again in the Job/Printing
material menu on the control system.
The rear edge stop is repositioned.
Sheet length 550 - 750 mm
After entering a sheet length of 550 to 750 mm at the
control station, the rear edge automatically adjusts to
the sheet size.
20.3 Setting the rear edge stop manually
You can manually correct the rear edge stop position
on the delivery control panel. If you alter a value at the
delivery control panel, the display on the control sta-
tion is updated automatically.
Caution - Risk of damaging the rear
edge stop and/or pile!
If you change the position, the rear edge
stop will continuously move toward or
away from the pile for as long as the but-
ton is kept depressed. The manual
movement to the pile is not safeguarded.
Avoid any collision of the rear edge stop
with the pile/pallet.
SC.999.0020/01 B.10.97
Delivery
20.4 Rear edge suction
Depending on the configuration of the printing press,
SG.901.9802-001GRAUND_00
there are fans (Fig. 107/1) at the rear edge of sheet in
the delivery. The fans extract the air between the
falling print sheet and the pile. The print sheet is de-
posited on the pile more quickly and avoids contact
1 with the subsequent sheet.
A preset value for the rear edge suction is stored in the
control station. The value depends on the printing ma-
terial properties. The printing press applies the preset
value after starting the print job.
You can manually engage or disengage the rear edge
suction:
● on the control station
or
● on the delivery control panel.
Fig. 107 Rear edge suction
B.10.98 SC.999.0020/01
Delivery
21 CleanStar (option)
SG.901.9118-000UTKENU_08
21.1 Function
During the printing process, solvent vapors (of varnish
SG.901.0995-005GRAUND_00
1
and inks, for example) and dust (powder, paper) build
7 2 3
4 up in the air. CleanStar reduces the pollution with dust
and solvent vapors in the pressroom.
CleanStar consists of the following components:
1 Swing-out suction device
2 Chain clip brush
3 Gripper bar brushes
6 5 4 Suction on D.S. and O.S. (depending on the de-
livery version)
5 Sealing brushes (depending on the delivery ver-
sion)
6 Deflector plate
7 Suction device at the front edge
● Exhaust air cleaning cabinet or blower
The brushes clean the gripper bar system. They brush
paper dust and powder off the gripper bars.
Fig. 108 Delivery pile diagram The sealing brushes (Fig. 108/5) serve the partition so
that the powder stays below the delivery air system.
The sealing brushes do not touch the gripper bars.
The suction device significantly reduces the discharge
of dust and solvent vapors from the press. The suction
removal sucks the dust and solvent vapors from the
delivery. Depending on the equipment fitted, the suc-
tion device channels this air into the exhaust air clean-
ing cabinet or out of the pressroom via a blower.
CleanStar can only operate efficiently, when the de-
flector plate is closed.
21.2 Operation
The following states are preset upon press Start-up:
SG.901.9917-000GRAUND_00
● Suction device switched on
● Deflector plate open
Fig. 109 Open/close the deflector plate button
SC.999.0020/01 B.10.99
Delivery
Close the deflector plate after you have completed all
FS.901.9101-001GRAUND_00
makeready work on the pile. When the deflector plate
is closed, the suction removal at the front edge works
efficiently.
1 1. Press the Open/close deflector plate button
(Fig. 109; 111/2).
A closed deflector plate (Fig. 110/1) is opened.
or
An open deflector plate (Fig. 111/1) is closed.
Note
After removing another sample sheet,
the deflector plate closes automatically
after 10 seconds.
Fig. 110 Deflector plate closed
FS.901.9100-002GRAUND_00
Fig. 111 Deflector plate open
Removal of sample sheet
The deflector plate opens automatically when you
press the Removal of sample sheet button (see chap-
ter "Press, delivery, removal of sample sheet").
Non-stop pile change
The deflector plate opens automatically when the aux-
iliary pile support raises the front edge shaft (see chap-
ter "Press, delivery, non-stop pile change").
B.10.100 SC.999.0020/01
Delivery
You can switch off the suction on the control station.
SG.901.9195-000GRAUND_00
1
The suction removal is reactivated after you start up
the press again.
Note
3 In order to keep dust and solvent vapor
in the pressroom to a minimum, do not
switch off the suction device if at all pos-
2 sible.
If, for example, sheet delivery problems are caused by
the suction removal with thin printing materials, reduce
the exhaust air flow in the exhaust air cleaning cabinet.
Depending on the feeder version, CleanStar has a
maximum of two reducing dampers (Fig. 112/1) con-
nected in the exhaust air cleaning cabinet.
Note
1
In the factory, the handle (Fig. 112/3) for
controlling the exhaust air flow is set to
maximum according to the scale
(Fig. 112/2).
1. Only reduce the exhaust air with the handle of the
Fig. 112 Exhaust air cleaning cabinet with throttle throttle valve in exceptional cases.
valve 2. Once you have finished your print job, set the
maximum exhaust air flow again.
Note
When the exhaust air flow volume is too
low, the control station will show an error
message: Suction power of CleanStar
too low. To clear the error message,
open the reducing dampers on the ex-
haust air cleaning cabinet.
21.3 Cleaning
When conducting maintenance work on CleanStar
please note the instructions in the "Customer mainte-
nance" manual.
Please observe the notes in the manufacturer's oper-
ating manual when you carry out maintenance work on
the exhaust air cleaning cabinet.
SC.999.0020/01 B.10.101
Delivery
Cleaning the sheet guide plate or powder spray
SG.901.9163-001GRAUND_01
nozzles
1
You may swing up the suction device when you wish to
clean the sheet guide plate underneath the suction
device, or the powder spray nozzles. Depending on
the delivery version the flap plate on the delivery air
system can also be swung up.
1. Secure the press against starting up again: Press
the Emergency-stop palm button on the next-
nearest control panel.
2. Open the guard above the powder spray device.
3. Swing the suction housing (Fig. 113/1) upward
and out (Fig. 114/1).
4. Open the flap plate on the delivery air system.
Fig. 113 Pile module with hinged suction housing
Note
SG.901.9196-000GRAUND_00
1 Inching the press manually is not possi-
ble.
5. Carry out the necessary cleaning work.
6. Swing the suction housing into its working posi-
tion.
7. Close the flap plate on the delivery air system.
8. Close the guard above the powder spray device.
9. Release the Emergency stop button.
Fig. 114 Pile module with hinged suction housing
Cleaning the delivery air system
SG.901.0995-006GRAUND_00
1 1. Secure the press against starting up again: Press
the Emergency-stop palm button on the next-
nearest control panel.
2. Open the guard on the delivery.
3. Clean the delivery air system (Fig. 115/1) using a
vacuum cleaner or broom.
4. Close the guard on the delivery.
5. Release the Emergency stop button.
Fig. 115
B.10.102 SC.999.0020/01
Delivery
22 Removal of sample sheet
SG.901.9112-000UTKENU_06
22.1 Function
The removal of sample sheets function allows you to
remove one or more sheets from the pile. For the du-
ration of sample sheet removal, all sheets running in
are deposited on the sheet catchers. After the sample
sheets have been removed, the held sheets are de-
posited on the pile.
22.2 Removing sample sheets
1. Adjust the interleaving behavior of the sheet
catchers at the control station.
You can
● switch all the sheet catchers on/off,
or
● switch the outer sheet catchers on/off to
match the sheet size.
Removal of sample sheet with pile lowering
SG.901.9859-001GRAUND_00
1 Note
You can switch on and off the automatic
pile lowering function for sample sheet
removal at the control station.
1. Place one finger onto the upper pile edge, and
gather the desired number of sheets.
2. Press the Sample sheet removal button
(Fig. 116/1) again on D.S. or on O.S.
● The main pile moves down.
Note
For a removal of a sample sheet, the
main pile moves down by approximately
Fig. 116 The sample sheet removal button on D.S. 2 cm. If you wish to remove the sheet
and O.S. earlier, press the Sample sheet removal
button during the pile movement.
3. Press the Sample sheet removal button
(Fig. 116/1) again.
● The main pile stops.
● The sheet catchers move into the pile and
hold the incoming sheets away from the
pile.
● The front edge stop swings downward.
4. Remove the sample sheets.
5. Press the Sample sheet removal button
(Fig. 116/1).
● The front edge stop swings upward.
● The sheet catchers move out of the area of
the sheet delivery and release the retained
sheets.
SC.999.0020/01 B.10.103
Delivery
Removal of sample sheet without pile lowering
1. Place one finger onto the upper pile edge, and
gather the desired number of sheets.
2. Press the Sample sheet removal button
(Fig. 116/1) on D.S. or on O.S twice in short suc-
cession.
● The sheet catchers move into the pile and
hold the incoming sheets away from the
pile.
● The front edge stop swings downward.
3. Remove the sample sheets.
4. Press the Sample sheet removal button
(Fig. 116/1).
● The front edge stop swings upward.
● The sheet catchers move out of the area of
the sheet delivery and release the retained
sheets.
22.3 Removal of sample sheet with CleanStar
CleanStar reduces the pollution with dust and solvent
SG.901.9917-000GRAUND_00
vapors in the pressroom. Please refer to the chapter
"Press, delivery, CleanStar" for details about design
and function of CleanStar.
The deflector plate is supported flexibly. You may lift
up the deflector plate with your hand to view, for ex-
ample, the upper pile edge, or to put wedges into the
Fig. 117 Open/close the deflector plate button pile.
1. Open the deflector plate. Press the Open/close
deflector plate button (Fig. 117).
Note
The closed deflector plate opens auto-
matically when you press the Removal of
sample sheet button.
2. Carry out the removal of sample sheet.
The front edge shaft is open during the removal of the
sample sheet. You cannot close the deflector plate
during this time. An error message appears on the
control station.
3. Close the deflector plate after the removal of the
sample sheet. Press the Open/close deflector
plate button (Fig. 117).
B.10.104 SC.999.0020/01
Delivery
23 Tape inserter
CX.901.0270-000UTKENU_03
23.1 General information on tape inserter
The tape inserter is used to separate sheets in the de-
livery pile. For this purpose, a strip of paper is inserted
between the upper pile edge and a falling sheet. The
tape is inserted by the press control system.
Further information on the tape insertion process is
available in the control station operating manual. The
insertion process can be triggered automatically via a
counting function or manually.
23.2 Position of tape inserter
Depending on the configuration of your press, the tape
SC.901.0255-001GRAUND_00
1 inserter can be located on D.S. or on O.S or on the face
side of the delivery pile. The respective position is
fixed. Changing to another position can only be carried
out by Heidelberg Service.
Tape inserter on D.S.
The tape inserter is located below the guard on the
drive side (Fig. 118/1).
2 Tape inserter on O.S.
The tape inserter is located below the guard on the
3 operator's side (Fig. 118/3).
Tape inserter on face side
The tape inserter is located behind the glass guard
(Fig. 118/2) on the face side of the pile.
Fig. 118 Tape inserter position overview
SC.999.0020/01 B.10.105
Delivery
24 Tape inserter on face side
CX.901.0260-000UTKENU_01
24.1 Design and function
The tape inserter is used for marking separations in
CX.901.0260-000GRAUND_00
the delivery pile. The tape inserter is controlled via the
control station and inserts tapes precisely between
1 2 3 4
falling sheets on the face side of the delivery pile. The
tape inserter is fastened on the front edge system and
is located behind the glass guard.
Design
7 Control elements (Fig. 119)
1 Roll mounting
6 2 Pneumatic connection
5 3 Power supply/signal connection
Fig. 119 Tape inserter 4 Cutting head
5 FEED pushbutton for tape supply
The Feed pushbutton is only active immediately
after the tape inserter is switched on. When the
tape inserter has received the first signal to insert
tape, the Feed pushbutton is disabled. To reac-
tivate the Feed pushbutton, you have to switch
the tape inserter off and on again.
6 On/Off switch ON/OFF
7 Tape feeder
24.2 Notes on operating the tape inserter
Additional instructions for the tape inserter
Note
The tape inserter comes with an addi-
tional manual with instructions on safety,
maintenance and troubleshooting.
Please also observe this additional man-
ual.
Note
The tape rolls are 15 mm wide and con-
sist of paper with a grammage of
80 g/m2.
The roll mounting module is equipped
with a roll in the delivery scope. A pack-
age of 4 is also included.
You can order supply rolls as a pack of
20 from your Heidelberg agency.
Factory setting of the tape inserter
The tape inserter is set as follows ex factory:
● Tape length: 100 mm
● Holding time: 0.5 seconds
● Tape transport speed: 345 mm/s
B.10.106 SC.999.0020/01
Delivery
These factory default settings can be changed by Hei-
delberg Service if necessary. You can find more infor-
mation on this in the additional manual.
24.3 Inserting/changing a tape roll
1. Switch the On/Off switch (Fig. 120/5) off.
CX.901.0261-000GRAUND_00
1 2 3 4
2. Loosen the star knob (Fig. 120/1). Take off the
support disk (Fig. 120/2).
3. If necessary, press the tape roll (Fig. 120/3) flat.
Insert the tape roll (Fig. 120/3) into the roll man-
5 6 drel (Fig. 120/4). Observe the direction. It must
be possible to unwind the tape roll counterclock-
wise (as shown in Fig. 121).
4. Attach the support disk (Fig. 120/2). Screw on the
star knob (Fig. 120/1).
5. Pull a few centimeters of tape from the roll.
Fig. 120 Tape roll
Note
CX.901.0262-000GRAUND_00
Insert the roll as shown in Fig. 121. The
loop of paper (close to Fig. 121/5) is
1
needed for unwinding the tape. If you in-
sert the roll the wrong way around, not
2 enough tape will be unrolled. This results
in a malfunction and the inserted tapes
are of different lengths.
6. Insert the tape into the tape guide below the
5 guide roll (Fig. 121/3).
7. Push the tape up to the transport roller
4 3 (Fig. 121/5).
8. Guide in the end of the tape under the transport
roller. Turn the transport roller by hand while do-
ing so.
9. Switch the On/Off switch (Fig. 120/5) on.
10. Hold down the Feed pushbutton for the tape feed
(Fig. 120/6) until the tape emerges from the front
Fig. 121 Tape guidance, diagram
of the cutting head.
11. Release the Feed pushbutton for the tape feed
(Fig. 120/6). The tape is cut off and the tape in-
serter is ready to be used.
If necessary, repeat steps 10 and 11.
SC.999.0020/01 B.10.107
Delivery
24.4 Cleaning tape inserter
1. If necessary, use a fine brush to remove paper
CX.901.0263-000GRAUND_00
dust and dirt from the following parts.
● Transport roller (Fig. 122/1)
● Tape guide (Fig. 122/2)
1 ● Cutting head (Fig. 122/3)
2
3
Fig. 122 Cleaning points on the tape inserter
B.10.108 SC.999.0020/01
Delivery
25 Lateral tape inserter D.S. / O.S.
CX.901.0250-000UTKENU_05
25.1 Function and design
The tape inserter is used for marking separations in
CX.901.0250-000GRAUND_00
the delivery pile. The tape inserter is controlled via the
3 2 1 control station and inserts tapes precisely between
falling sheets. It is attached to the sheet jogger and
automatically adjusts itself to the respective sheet
width. You can position the tape inserter along the
sheet length within predefined boundaries and lift it out
of the operating position by 20 mm.
Design
The tape inserter (Fig. 123) consists of a tape module
positioned directly on the upper pile edge, a tape feed-
er, a roll support module and a control module.
Fig. 123 Tape inserter Depending on the configuration of your press, the tape
inserter can be fitted on D.S. or on O.S.
1 Tape module
2 Tape feeder
3 Roll support module
The roll support module has an Insert/change
tape roll button and LEDs that indicate if the de-
vice is ready to run or if there is a malfunction.
25.2 Information on operating the tape inserter
Additional instructions for the tape inserter
Note
A separate manual with safety instruc-
tions, maintenance instructions and
troubleshooting notes is provided within
the scope of delivery of the tape inserter.
Please also observe this additional man-
ual.
The minimum sheet length is reduced when using
the tape inserter.
Note
If the press is equipped with a tape in-
serter, you can no longer set the small-
est sheet length. You can only process
the smallest sheet length by removing
the tape module and tape feeder. The
press control system monitors whether
the tape module and tape feeder are in-
stalled. Depending on the installation
status, the control system defines sheet
size limits. You can view the specifica-
tions in the Printing material menu.
SC.999.0020/01 B.10.109
Delivery
Tape rolls
Note
The tape rolls are 10 mm wide and con-
sist of paper with a grammage of
100 g/m2.
On delivery, the roll support module car-
ries one tape roll. A package of 4 rolls is
supplied additionally.
You can order tape rolls as a pack of 20
from your Heidelberg agency.
25.3 Inserting/changing the tape roll
1. Depending on the installation position, the roll
SC.901.0254-001GRAUND_00
1 support module is located either on D.S. or on
1
O.S. at the delivery (Fig. 124/1), laterally below
the guard.
The roll support module, tape feeder and tape
module are displayed in their installation position
on O.S. in the following diagrams.
2. Press the button (Fig. 126/3). Wait until the green
LED lights up. A tape roll can only be changed
when the green LED is lit.
If a tape roll is already inserted, the tape is pulled
into the roll support module.
Note
The green LED indicates that the tape
has been fully pulled back into the roll
support module. If you open the roll sup-
port module before the green LED lights
up, the tape is torn.
Fig. 124 Position of the roll support module
3. Put your hand in the recessed grip and open the
CX.901.0253-001GRAUND_00
roll support module (Fig. 125/1).
Fig. 125 Opening the roll support module
B.10.110 SC.999.0020/01
Delivery
4. Swing up the pivoted lever (Fig. 126/2).
CX.901.0251-000GRAUND_00
5. Remove the winding core and any remaining
2 tape from the roll support module.
1
6. Detach the beginning of the tape from the new
tape roll. If necessary, press the tape roll flat.
7. If necessary, cut the beginning of the tape such
that it is straight.
Note
To guarantee a trouble-free infeed pro-
cess, the beginning of the tape must be
cut at right angles.
3
8. Mount the tape roll over the pivoted lever
4
(Fig. 126/2) and onto the roll mandrel
(Fig. 126/1). Please observe the direction of
Fig. 126 Inserting a tape roll
winding!
Note
Observe the pictograph (Fig. 126/4) on
the inside of the roll support module.
9. Swing the pivoted lever (Fig. 126/2) down again.
Ensure that all layers of the tape roll are inside the
guide roll (Fig. 127/6) of the pivoted lever.
Note
If the tape is not inside the guide roll of
the pivoted lever, a malfunction occurs
and the inserted tapes have different
lengths.
10. Unwind the tape by several centimeters.
11. Press the button (Fig. 127/5). Insert the begin-
CX.901.0252-000GRAUND_00
1 2 3 ning of the tape into the tape infeed slot
4 (Fig. 127/4).
When you press the button (Fig. 127/5), the step-
per motor (Fig. 127/2) for the tape infeed starts.
As soon as the beginning of the tape (Fig. 127/3)
has reached a defined position, the stepper mo-
tor stops.
12. Close the roll support module. The tape is auto-
matically pulled through the tape feeder.
Note
5 If the sheet jogger is set to almost max.
6 sheet width, the tape is automatically
pulled in by the tape module (Fig. 123/1).
Fig. 127 Diagram of the tape feeder If the sheet jogger is set for narrower
sheets, the tape stops several centime-
ters after leaving the tape feeder. You
then have to manually feed the begin-
ning of the tape into the tape module
(Fig. 123/1).
You have 60 seconds to feed in the tape.
SC.999.0020/01 B.10.111
Delivery
13. If necessary, feed the beginning of the tape into
the tape module. The tape will then be pulled in
automatically by the tape inserter.
14. If you have not inserted the beginning of the tape
into the tape module within 60 seconds, press the
button (Fig. 127/5) again. You now have another
30 seconds to insert the beginning of the tape into
the tape module.
15. If both attempts to insert the tape into the tape
module have failed, the roll support module re-
tracts the tape. The green LED lights up.
16. Open the roll support module. Proceed from step
10.
Note
Alternatively you can manually move the
sheet jogger to the max. sheet width
when changing the tape. This ensures
that the tape is fed directly to the tape
inserter. The tape infeed procedure then
works automatically.
25.4 Resetting the tape inserter
When the roll support module is opened, the control
system of the tape inserter is reset to the insert tape
roll state. The unwound tape is not automatically
pulled back. You need to remove the remaining tape
from the respective modules.
25.5 Lifting/lowering the tape inserter
If the upper pile edge is higher in the area of the tape
inserter, you can raise the tape inserter by a defined
value of approx. 20 mm. This function can be switched
on and off at the delivery control panel.
Note
If the pile is uneven in the area of the
tape inserter, raise the tape inserter.
Correct the upper pile edge, e.g. using
pile wedges. Lower the tape inserter to
the operating position again.
B.10.112 SC.999.0020/01
Delivery
25.6 Removing the tape module and tape feeder
In order to process the min. sheet length, you must
CX.901.0255-000GRAUND_00
remove the tape module and the tape feeder. Ensure
that you follow the steps in the correct order when re-
moving and fitting the units. Start by removing the tape
1 module. Reverse this procedure to mount the parts.
2
1. Position the sheet jogger to sheet width 700 -
800 mm or manually lower the non-stop rake.
2. Disconnect the cable from the plug (Fig. 128/2).
3. Disconnect the pneumatic connection to the
rapid-action coupling (Fig. 128/1).
Fig. 128 Disconnecting cables
4. Press the spring locking device (Fig. 129/1) up in
CX.901.0256-000GRAUND_00
1 2 the direction of the arrow. Pull the tape module
(Fig. 129/2) against the direction of sheet travel
and out of the support.
Fig. 129 Releasing the tape module
5. Pull the end of the tape feeder out of the roll sup-
CX.901.0257-000GRAUND_00
port module.
1
6. Press the spring locking device (Fig. 130/1). Re-
move the tape feeder from the support.
Note
The control system monitors the pres-
ence of the tape feeder and the tape
module. After removal, a General mal-
function, tape inserter error message
appears on the control station. When the
error message is acknowledged, the
sheet size limit is removed.
7. Acknowledge the error message on the control
station.
Fig. 130 Releasing the tape feeder
8. If you wish to use the tape insertion function
again, follow the above steps in the reverse order
to fit the tape feeder and tape module.
The sheet length limit is automatically activated
after the units are fitted.
SC.999.0020/01 B.10.113
Delivery
25.7 Cleaning the tape inserter
1. Use a paint brush to remove paper dust and dirt
CX.901.0254-001GRAUND_00
1 from the cutter head (Fig. 131/1).
2. Blow out the tape feeding device and the tape
module as indicated by the arrows.
Remove the tape feeder and the tape module to
do this.
Fig. 131 Cleaning points at the tape module, tape
feeder
3. In order, for example, to remove paper scraps,
CX.901.0254-002GRAUND_00
remove the cover (Fig. 132/1) from the tape mod-
ule. To do this, unscrew the three screws
(Fig. 132/2).
1
For additional information on the subject of main-
tenance and cleaning, see the separate operat-
ing manual of the tape inserter.
Note
When unscrewing the screws, make
sure that they are not captive.
Fig. 132 Screwing off tape module
25.8 Malfunctions
Type of error message Possible cause Remedy
General malfunction, tape inserter The tape module and tape feeder are This malfunction only occurs after de-
removed. liberate action has been taken. You
have removed the units in order to set
the press to the minimum sheet
length.
Select the malfunction on the control
station. Open the saved information.
Acknowledge the malfunction.
You can only acknowledge the mal-
function if the tape module and tape
feeder are removed.
General malfunction, tape inserter End of tape feeder not fully engaged Push the tape feeder into the opening
with roll support module. of the roll support module.
Ensure that the end of the tape feeder
engages correctly.
B.10.114 SC.999.0020/01
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Type of error message Possible cause Remedy
General malfunction, tape inserter Roll support module open. Close the roll support module.
General malfunction, tape inserter No tape roll inserted. Insert a new tape roll.
Proceed in accordance with the infor-
mation given in Inserting/changing a
tape roll.
General malfunction, tape inserter No tape detected in roll support mod- Start the Inserting/changing a tape
ule. roll procedure from the beginning.
General malfunction, tape inserter Tape torn between roll support mod- Perform a reset by opening the roll
ule and tape module. support module.
Remove all tape remaining in the tape
module, in the tape feeder and in the
roll support module.
Insert the tape properly and proceed
according to the instructions in Insert-
ing/changing a tape roll.
General malfunction, tape inserter No tape detected in tape module. Press the button on the roll support
The tape was not fed into the tape module.
module within 60 seconds. Feed the beginning of the tape into
The beginning of the tape is still lo- the tape module.
cated outside the tape feeder. You have 30 seconds to do this.
General malfunction, tape inserter No tape detected in tape module. Perform a reset by opening the roll
The tape was not fed into the tape support module.
module within the additional 30 sec- Proceed from point 10 according to
onds. the instructions in Inserting/chang-
The beginning of the tape was auto- ing a tape roll.
matically pulled back into the roll sup-
port module.
The green LED on the roll support
module lights up.
General malfunction, tape inserter Tape roll completely used up. Perform a reset by opening the roll
support module.
Insert a new tape roll properly; pro-
ceed according to the instructions in
Inserting/changing a tape roll.
General malfunction, tape inserter Tape cannot be pulled out automati- Perform a reset by opening the roll
cally. support module.
Remove all tape remaining in the tape
module, in the tape feeder and in the
roll support module.
Insert the tape properly and proceed
according to the instructions in Insert-
ing/changing a tape roll.
Tape roll is used up The tape roll is almost used up. You Insert a new tape roll.
have around 50 tapes remaining from Proceed in accordance with the infor-
the point at which the error message mation given in Inserting/changing a
appears. tape roll.
If you cannot remedy the error with the suggested troubleshooting measure, please notify Heidelberg Service.
SC.999.0020/01 B.10.115
Delivery
Type of error message Possible cause Remedy
If there are no other malfunctions, continue printing.
Tab. 13 Error messages of the tape inserter
B.10.116 SC.999.0020/01
Delivery
26 Pile change
SG.901.9114-000UTKENU_04
26.1 Determining the actual size of the sheet
Note
Make sure that the actual sheet size
matches the input on the delivery control
console by directly measuring the sheet
size.
26.2 Function
1 Pile height sensor
SG.901.9893-000GRAUND_00
2 Upper limitation of pile support plate
3 Lateral sheet jogger
4 Upper slow travel range
1 5 Fast travel range
2 3
4
6 Lower slow travel range
You can place pallets or special pile boards for non-
stop operation onto the pile support plate. The maxi-
mum pallet size is 1200 mm x 800 mm.
You can move the pile upwards or downwards using
5
the buttons on the delivery control panel (Fig. 134).
Between the upper and lower speed limitation
(Fig. 133/5) the pile moves at a high speed, inside the
upper (Fig. 133/4) or lower (Fig. 133/6) speed limita-
tion range it moves at a low speed.
6
Fig. 133 Pile control
Upwards
The pile moves at a high speed up to the upper speed
limitation while you hold the button down (Fig. 134/3).
When the pile reaches the upper speed limitation
(Fig. 133/4), the travel speed of the pile is automati-
cally reduced. From this position on, you can move the
pile/the pile support plate in inching mode upwards to
the upper limitation of the pile support plate
(Fig. 133/2).
Further limitations for the upwards movement of the
pile/the pile support plate are:
● the pile height sensor
● Raising the
○ Lateral sheet joggers
○ Rear edge stops
○ Front edge shaft
SC.999.0020/01 B.10.117
Delivery
Downwards
Downwards, the pile can be lowered up to the lower
speed limit
● in inching mode, by pressing the button
(Fig. 134/4) repeatedly;
or
● continuously, by holding down the self-locking
button (Fig. 134/4) for more than 1.5 seconds.
The pile stops automatically 12 cm above the floor.
From the lower speed limitation on (Fig. 133/6), you
can lower the pile down to the floor in inching mode.
During production the pile moves step-by-step down-
wards with the delivered sheets. In this process the
pile height sensor (Fig. 133/1) maintains the upper pile
edge at a constant level.
26.3 Pile control panel
1 Auxiliary pile up (only with non-stop delivery)
SG.901.9876-001GRAUND_00
1 3 2 Auxiliary pile down (only with non-stop delivery)
3 Main pile up
4 Main pile down
2 4
5 Pile stop
Fig. 134 Control panel on the delivery control panel
26.4 Pile change
You can move the pile out of the delivery in the direc-
tion of sheet travel or sideways towards O.S.
1. Press the Main pile down button (Fig. 134/4).
● Inching mode = press the button repeatedly.
● Continuously = press the button for more
than 1.5 seconds. You can release the but-
ton as soon as the pile starts to move down-
wards.
The pile support plate travels downward. For
safety reasons, the pile support plate stops the
down motion 12 cm above ground.
2. Press the Main pile down button (Fig. 134/4)
again.
Move the pile in inching mode down to the floor.
3. Move the full pallet out of the delivery.
B.10.118 SC.999.0020/01
Delivery
4. Place an empty pallet onto the pile support plate.
SG.901.9890-000GRAUND_00
Align the pallet on the pile support plate
● centrally between D.S. an O.S. on the pile
support plate
2 3 4 ● to the five boreholes (Fig. 135/1) in the pile
support plate in the direction of sheet travel.
(Center borehole = front edge of the pile)
1
5. Move the main pile upwards.
When the pile reaches the upper speed limitation,
the speed is automatically reduced to a slower
speed.
6. Finally, move the pile to its upper end position in
inching mode.
Fig. 135 Aligning the pallet
Repositioning the pile stop on the pile support
plate
If, for example, due to reasons of space for example,
you wish to move the pile out of the delivery towards
D.S., you need to change the position of the stop
(Fig. 135/3) on the pile support plate.
1. Release the Allen screw (Fig. 135/2) on the pile
stop using an Allen wrench.
2. Position the pile stop (Fig. 135/3) the right way
round over the boreholes (Fig. 135/4) on O.S.
3. Tighten the Allen screw on the pile stop using an
Allen wrench.
SC.999.0020/01 B.10.119
Delivery
27 Non-stop operation
FS.901.9113-000UTKENU_09
27.1 Function
Non-stop operation allows you
● to change the pile while the press is in production
or
● to form a new rack pile.
While you are performing the pile change or position-
ing the distance pieces, the printed sheets are de-
posited on the auxiliary pile support (rake or rack
board).
Depending on the specifications of the press, the
equipment supplied includes the following auxiliary
pile supports:
● Non-stop rake
● Non-stop carriage for rack board
● Non-stop rake and non-stop carriage for rack
board
Depending on the configuration, you can use the non-
stop rake, the non-stop carriage for rack boards or
both auxiliary pile supports alternately on the delivery.
Specifications
Maximum downward movement of the auxiliary
pile: 300 mm
Maximum weight of the auxiliary pile: 300 kg
Maximum number of sheets on the auxiliary pile (de-
pends on the grammage of the sheets):
Sheet thickness up to 0.06 mm: 4000 sheets.
Sheet thickness between 0.06 mm and 0.1 mm:
2400 sheets.
Sheet thickness above 0.1 mm: 1500 sheets.
Note
The press stops once the maximum
number of sheets or the maximum
height of the auxiliary pile has been
reached.
B.10.120 SC.999.0020/01
Delivery
27.2 Equipment
Non-stop operation with non-stop rake
FS.901.9872-001GRAUND_00
● Non-stop rake (Fig. 136/1)
● Pile table, grooved (Fig. 136/2)
2
Fig. 136 Non-stop rake
Non-stop operation with rack board
FS.901.9861-001GRAUND_00
● Rack board (Fig. 137/1)
● Non-stop carriage for rack board (Fig. 137/2)
● Distance piece (Fig. 137/3)
● Pile board, smooth
● Insertion angles
Fig. 137 Non-stop carriage for rack board
Non-stop operation with rack board and non-stop
rake
● Non-stop rake (Fig. 136/1)
● Pile table, grooved (Fig. 136/2)
● Rack board (Fig. 137/1)
● Non-stop carriage for rack board (Fig. 137/2)
● Distance piece (Fig. 137/3)
● Insertion angles
SC.999.0020/01 B.10.121
Delivery
27.3 Sheet catcher in non-stop operation
Sheet catchers at the front edge
FS.901.9860-000GRAUND_00
● Inner sheet catchers with gripper function
(Fig. 138/1)
● Middle sheet catchers without gripper function
(Fig. 138/2)
● Outer sheet catchers without gripper function
(Fig. 138/3)
1 Sheet catchers at the rear edge
● Sheet catchers without gripper function
(Fig. 139/1)
The delivery is equipped with six sheet catchers at the
3 2 3 front edge and two sheet catchers at the rear edge.
The 6 sheet catchers at the front edge are fixed in a
hinged frame. After the auxiliary pile support has been
Fig. 138 Sheet catchers and grippers - front edge set to the front edge shaft, the main pile is lowered by
the set "sheet catcher" descending distance. At the
FS.901.9949-000GRAUND_00
same time, the sheet catcher unit swings downwards.
Next, the sheet catcher move in according to format
and angle.
The sheets running in are deposited on the sheet
catchers. When the gripper function is active, the two
inner sheet catchers (Fig. 138/1) close later by 360°.
The sheet catchers at the rear edge (Fig. 139/1) move
into the pile after the selected "insertion time", shortly
after the sheet catchers at the front edge.
While the sheet catchers are holding the sheets, the
main pile is lowered by the selected "auxiliary pile sup-
port" descending distance. Do not insert the auxiliary
1 pile support until some air from the upper pile area has
escaped. The auxiliary pile support can now be insert-
Fig. 139 Sheet catchers - rear edge
ed without trouble. The grippers at the inner sheet
catchers open once the auxiliary pile support has been
inserted all the way. The sheet catchers move back.
The sheets are deposited on the auxiliary pile support.
27.4 Settings on the control station
Note
The grippers at the inner sheet catchers
are only active in connection with the
non-stop function.
1. Adjust the sheet catchers at the control station.
Information on this is available in the operating
manual for the control system.
Depending on the sheet size, you can select the
following settings:
● Insert / do not insert all sheet catchers.
● Insert / do not insert outer sheet catchers.
● Switch the grippers of the inner sheet catch-
ers on/off.
B.10.122 SC.999.0020/01
Delivery
● Switch the sheet catchers at the rear edge
on/off.
● Time of insertion of the rear sheet catchers.
Determines the number of revolutions that
are performed between inserting the front
sheet catcher and inserting the rear sheet
catchers.
● Switch on/off the movable rear edge.
● "Sheet catcher" descending distance.
Determines the distance by which the main
pile is lowered before the sheet catchers are
inserted.
● "Auxiliary pile support" descending dis-
tance.
Determines the distance by which the main
pile must be lowered in order to enable the
auxiliary pile support (non-stop rake or rack
board) to be inserted.
● Descending distance for "distance piece"
In non-stop operation with rack board, this
value defines the distance by which the
main pile must be lowered in order to enable
the distance pieces to be inserted. The set
value corresponds to the height of the dis-
tance pieces.
27.5 Recommended adjustments
The following recommended adjustment values are
guide values. They shall help you in adjusting your
press to the print-related requirements of the individual
print jobs.
● Adjust the air in the pile area to the lowest level
possible. You avoid the tendency to build roofs.
● Adjust the gripper opening cam such that the
front edge of the print sheet lands shortly above
the pile level. The print sheet can thus be caught
by the sheet catchers.
● Adjust the "sheet catcher" descending distance
to 15 mm. This puts the pile height sensor to the
front edge an on maximum drop height. Chang-
ing the sensor level adjusts the "sheet catcher"
descending distance accordingly.
● Adjust the "auxiliary pile support" descending dis-
tance to 45 mm. Correct this value according to
the pile formation. The auxiliary pile support must
not touch the main pile during insertion.
● When the "auxiliary pile support" descending dis-
tance is set to 0 mm, the main pile will not stop
before a second sensor detects that the auxiliary
pile support is inserted.
SC.999.0020/01 B.10.123
Delivery
● Switch on the rear sheet catcher when you:
○ print on printing material of low grammage;
○ perform a non-stop pile change with rack
board.
● Adjust the insertion time such that the rear sheet
catcher enter the pile 5 sheets after the front
sheet catchers.
27.6 Checking the non-stop rake
Deformed rods may collide with the rotating chain grip-
per systems when they are inserted into the delivery.
Before inserting the non-stop rake, ensure that the
rods are straight, level and that they are not deformed.
Check the rods of the non-stop rake at regular inter-
vals. The rods should be located approximately 5 mm
above the rake support to ensure proper support of the
non-stop rake. If the rods are underneath the rake
support when they are inserted, you must bend them
back to their original position.
You must also bend the rods back to their original po-
sition if they are bent upward, as they may otherwise
collide with the front edge shaft or not come to rest on
the rake support.
27.7 Manual non-stop operation
Preparing non-stop operation
1. Set the pile change parameters at the control
station. Information on this is available in the op-
erating manual for the control system.
2. Prepare an empty pile table or a pallet and a
means of transport for the non-stop pile change.
3. Make sure that the rods of the non-stop rake are
not deformed.
4. Prepare rack boards and Heidelberg distance
pieces for the rack operation.
Depending upon the production speed, you will only
have a brief period available for a pile change/rack pile
formation.
B.10.124 SC.999.0020/01
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Initiating non-stop operation
SG.901.9870-002GRAUND_00
1. Attach the auxiliary pile support to the delivery.
Hold the auxiliary pile support symmetrically.
● Where to hold the non-stop rake (Fig. 140).
● Where to hold the non-stop carriage for rack
board (Fig. 141).
Align the auxiliary pile support centrally in the de-
livery. Lift the auxiliary pile support and insert it
into the brackets on D.S. and O.S. from above.
Caution - Risk of damaging the non-
stop rake!
Bent rods can impair the effectiveness of
non-stop operation. Do not hold the rods
when swinging up a non-stop rake.
Fig. 140 Non-stop rake
2. Switch on the corresponding auxiliary pile sup-
FS.901.9871-000GRAUND_00
port at the control station.
Note
When you use the non-stop carriage for
the rack board, you may insert the rack
board prior to folding up.
3. Swing up the auxiliary pile support by the cross
bar.
Tip
Wait until the main pile moves down-
wards. Then move the auxiliary pile sup-
port up to the front edge shaft.
Fig. 141 Non-stop carriage for rack board
4. Prior to changing the pile, ensure that:
FS.901.9902-001GRAUND_00
● the press rotates,
and
1
● the auxiliary pile frame is at the top position.
Note
If these conditions are not satisfied, the
automatic functional sequence will not
start when the non-stop carriage is ap-
plied.
5. Grasp the auxiliary pile support by the cross bar
(Fig. 142/1) and slide the auxiliary pile support up
to the front edge shaft.
● The main pile moves down the distance set
on the control station ("sheet catcher" de-
scending distance).
Fig. 142 Non-stop rake at the front edge shaft
SC.999.0020/01 B.10.125
Delivery
● The sheet catchers move into the pile ac-
cording to the angle, and hold the incoming
sheets.
● If the sheet catchers at the rear edge are
active, they will be inserted after the sheet
catchers at the front edge.
The delay depends on the selected inser-
tion time.
● The grippers at the inner sheet catchers
close and hold the first few sheets on the
sheet catchers.
● The movable rear edge moves to its working
position (towards the pile) if it is switched on.
The movable rear edge stabilizes the rear
edge of the pile underneath the auxiliary pile
support.
● The main pile moves down the distance set
on the control station ("auxiliary pile sup-
port" descending distance).
Tip
Do not insert the auxiliary pile support
until some air from the upper pile area
has escaped.
6. Push the auxiliary pile support evenly and slowly
into the delivery and up to the stop.
● The swing-down rear edge swings up when
inserting the support.
● Once the auxiliary pile support has been in-
serted all the way, the rear edge swings
back down again onto the auxiliary pile sup-
port.
● The grippers at the sheet catchers open and
the sheet catchers at the front and rear edge
move back.
● The sheets are deposited on the auxiliary
pile support.
Note
You cannot remove any sample sheets
while the front edge shaft is raised.
27.8 Performing non-stop operation with non-stop rake
1. Lower the full main pile down to the floor.
2. Remove the main pile from the delivery.
3. Put an empty grooved pile board onto the pile
support plate.
Align the pile board on the pile support plate.
4. Move the main pile upwards. The main pile stops
just before reaching the auxiliary pile. Clocking
down the main and auxiliary pile is interrupted for
approximately 10 sec.
B.10.126 SC.999.0020/01
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Caution - Risk of damaging the deliv-
ery!
The manual upwards and downwards
movement of auxiliary and main pile to
one another is not safeguarded. Keep an
eye on the piles constantly to check their
alignment.
The main pile cannot move up any further if one of the
two sheet joggers is raised.
To align the auxiliary pile and main pile the auxiliary
pile must then be lowered.
5. Move the main pile upwards until the auxiliary pile
and main pile are aligned to one another.
or
Move the auxiliary pile downwards until the aux-
iliary pile and main pile are aligned to one anoth-
er.
Caution - Risk of damaging the non-
stop rake and the grippers!
Make sure that the rods of the non-stop
rake rest in the recesses of the grooved
pile table. Only move the pallet / pile
board upward to such an extent that it
touches the non-stop rake but does not
lift it. There must be no objects (e.g.
wedges) on the pallet or pile.
6. Pull out the non-stop rake and swing it down-
wards.
The auxiliary pile frame automatically returns to the
upper end position.
27.9 Non-stop operation with rack board
1 Pile
SG.901.9900-002GRAUND_00
1 2 3 2 Insertion angles
3 Rack board
4 Size of standard board: 800 x 1220 x 18 mm
4 Heidelberg distance piece
5 Pile board, smooth
The non-stop device allows you to
a) change piles while the press is printing. While you
are exchanging a full pile table against an empty one,
the printed sheets are deposited on the rack board.
or
b) form small rack piles for jobs that are prone to block-
5 ing. Blocking is reduced due to the lower pile weight.
The non-stop device in the delivery consists of the rack
Fig. 143 Pile with rack board board, the non-stop carriage for the rack board, distant
pieces and inserting angles.
SC.999.0020/01 B.10.127
Delivery
Note
Use only Heidelberg rack boards or
boards of equally high quality. Unsuit-
able rack boards increase wear and may
cause press damage. Damaged rack
boards can cause malfunctions.
The maximum descending distance amounts to
300 mm. The press stops if the pile is not changed
before this height is reached.
The two enclosed inserting angles (Fig. 144/1) are
SG.901.9901-002GRAUND_00
used for stabilizing the pile. They prevent the top
sheets of the main pile from slipping forward towards
the operator. Prior to inserting the board, they should
be attached as far outwards as possible at the front
edge of the pile.
Fig. 144 Inserting angles at the front edge of the pile
27.10 Performing non-stop operation with rack board
1. The pile automatically moves down by the set
SG.901.9875-001GRAUND_00
"distant piece" descending distance.
2. Place the distance pieces (Fig. 143/1) onto the
rack board or the pile board. Align the distance
pieces. Ensure that the distance pieces are safe-
ly positioned.
Caution - Risk of collision with grip-
per bar and/or sheet joggers!
Unsuitable or incorrectly positioned dis-
1 tance pieces can damage the gripper
bar and/or the sheet joggers. Only use
Heidelberg distance pieces for rack
board operation.
3. Move the main pile upwards. The main pile stops
just before reaching the auxiliary pile. Clocking
down the main and auxiliary pile is interrupted for
Fig. 145 Distance piece
approximately 10 sec.
Caution - Risk of damaging the deliv-
ery!
The manual upwards and downwards
movement of auxiliary and main pile to
one another is not safeguarded. Keep an
eye on the piles constantly to check their
alignment.
The main pile cannot move up any further if one of the
two sheet joggers is raised.
B.10.128 SC.999.0020/01
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To align the auxiliary pile and main pile the auxiliary
pile must then be lowered.
4. Move the main pile upwards until the auxiliary pile
and main pile are aligned to one another.
or
Move the auxiliary pile downwards until the aux-
iliary pile and main pile are aligned to one anoth-
er.
Note
The distance pieces have to lift the rack
board completely out of the auxiliary pile
frame.
5. Pull out the non-stop carriage for rack board and
swing it downwards.
The auxiliary pile frame automatically returns to the
upper end position.
27.11 Non-stop pile changing with CleanStar
CleanStar reduces the pollution with dust and solvent
SG.901.9917-000GRAUND_00
vapors in the pressroom. Please refer to the chapter
"Press, delivery, CleanStar" for details about design
and function of CleanStar.
The deflector plate is supported flexibly. You may lift
up the deflector plate with your hand to view, for ex-
ample, the upper pile edge, or to put wedges into the
Fig. 146 Open/close the deflector plate button pile.
1. Open the deflector plate. Press the Open/close
deflector plate button (Fig. 146).
Note
The auxiliary pile support first raises the
deflector plate when the deflector plate
is closed. The deflector plate opens au-
tomatically when the auxiliary pile sup-
port presses the front edge shaft up-
wards.
2. Change the pile.
You cannot close the deflector plate as long as the
front edge shaft is lifted up by the auxiliary pile support.
An error message appears.
3. Close the deflector plate after the pile change.
Press the Open/close deflector plate button
(Fig. 146).
Note
The deflector plate does not close auto-
matically.
27.12 Elimination of malfunctions during non-stop pile changes
Prior to each troubleshooting:
SC.999.0020/01 B.10.129
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1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
Malfunction Possible cause Corrective measure
The sheet catchers do not swing to The auxiliary pile frame is not at the Press the Auxiliary pile up button until
the lower position. top end position. the upper end position is reached.
The sheet catchers are not inserted. The sheet catchers are not prese- Preselect the sheet catchers at the
lected at the control station. control station.
The sheet catchers move into the The "sheet catcher" descending dis- Adjust a larger "sheet catcher" de-
produced pile. tance is too small. scending distance.
The set drop height is too small. Increase the drop height. To do this,
readjust the pile height sensor at the
front edge.
The sheet catchers catch the print The sheet catchers in the middle Reduce the air supply above the pile.
sheets irregularly. catch the sheets. The outer sheet Equalize the pile. To do this, insert
catchers do not catch the sheets wedges into the front edge of the pile.
(roofing).
The external sheet catchers catch Reduce the air supply above the front
the sheets. The sheet catchers in the edge of the pile. Set the gripper open-
middle do not catch the sheets. ing to later.
Prior to inserting the auxiliary pile There is too much air in the pile area. Reduce the air supply above the pile.
support, the print sheet slide under-
The gripper opening time setting is Correct the gripper opening cam.
neath the stops at the front edge.
incorrect.
The "auxiliary pile support" de- Reduce the "auxiliary pile support"
scending distance is too great. descending distance.
The sheet decurler is not selected. Switch on the sheet decurler.
The inserting angles are not used. Use the inserting angles.
The print sheets on the auxiliary pile The rear sheet catchers are late Reduce the insertion time of the rear
support or on the main pile support when they are inserted. sheet catchers.
are shifted against the running direc-
tion of the paper.
The print sheets slide through the The main pile moves too far down. Reduce the descending distances of
stops at the rear edge of the pile. the main pile.
The rear edge stops are jammed in Clean the rear edge stops. Check
the upper position. their function.
The movable rear edge is jammed. Clean the guides of the movable rear
edge. Check their function.
The slide-in unit of the non-stop car- The guides of the non-stop carriage Clean the guides.
riage is tight. are soiled.
When the auxiliary pile support is in- The sheet catcher gripper unit does Check whether the grippers have
serted, the print sheets on it are car- not hold the sheets back. been switched on.
ried away.
The blast air above the front edge Reduce the air supply above the front
presses the sheets in front of the edge of the pile. Set the gripper open-
sheet catchers. The sheets fall onto ing to later.
the pile in front of the sheet catchers
instead of precisely onto them.
B.10.130 SC.999.0020/01
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Malfunction Possible cause Corrective measure
The "auxiliary pile support" de- Reduce the "auxiliary pile support"
scending distance is too great. descending distance.
The auxiliary pile support is being Insert the auxiliary pile support slower
inserted too slowly or too quickly. or faster, respectively.
The print sheets are wrapped around The rear sheet catchers are early Increase the insertion time of the rear
the tip of the auxiliary pile support. when they are inserted. sheet catchers.
The rolling inclination of the sheets is Provided it is tolerated by the subject,
too high. switch on the sheet decurler and/or
the rear sheet catchers.
The auxiliary pile support touches The "auxiliary pile support" de- Increase the "auxiliary pile support"
the main pile when it is inserted. scending distance is too small. descending distance.
The main pile is thicker in the middle Equalize the pile. To do this, insert
(roofing). wedges into the pile.
The rake rods hit the rake support rail The rake rods are bent. Straighten the rake rods.
or the rear edge during insertion.
The auxiliary pile support hits the The rear edge stops are jammed. Clean the rear edge stops. Check
rear edge stops. their function.
The auxiliary pile support is inserted Reduce the insertion speed of the
to quickly. auxiliary pile support.
The auxiliary pile frame does not low- The movable rear edge is not at its Clean the guides of the movable rear
er. home position. edge. Check their function. Check the
adjustment of the limit switches.
The feeder receives the "Paper stop" The maximum descent is reached. Accelerate the pile change.
signal.
The maximum number of sheets on Accelerate the pile change.
the auxiliary pile is reached.
The main pile cannot be raised. The movable rear edge is not at its Clean the guides of the movable rear
home position. edge. Check their function.
Tab. 14 Error messages
Following the troubleshooting:
2. Release the Emergency stop button. Close the
front guard on the delivery.
Note
You need some practice to change piles
properly and swiftly. At the beginning it is
sensible to reduce the printing speed to
ensure a smooth pile change.
SC.999.0020/01 B.10.131
Delivery
28 Automatic non-stop system
FS.901.9213-000UTKENU_05
28.1 Equipment
There are 2 variants:
FS.901.9219-001GRAUND_00
● Universal non-stop system with belt table
● Universal system with belt table and rack delivery
The auxiliary pile support is a belt table. The rack
delivery is equipped with additional guide rails to
allow a rack board to be inserted. Rack boards
and distance pieces are also supplied.
Note
You can use standard commercial pal-
lets or pile tables for the non-stop system
with belt table. Ensure that there are no
protruding parts (nails, screws) on the
surface of the pallets or pile tables.
Note
Only use rack boards and distance
Fig. 147 Automatic non-stop system pieces made by Heidelberg or of the
same quality. Unsuitable rack boards
and distance pieces increase wear and
can cause damage to the press. Dam-
aged rack boards can cause malfunc-
tions.
28.2 Specifications
Auxiliary pile
Maximum downward movement of the auxiliary
pile: 300 mm
Maximum weight of the auxiliary pile: 300 kg
Minimum format: 440 x 600 mm
Maximum number of sheets on the auxiliary pile (de-
pends on the grammage of the sheets):
Sheet thickness up to 0.06 mm: 4000 sheets.
Sheet thickness between 0.06 mm and 0.1 mm:
2400 sheets.
Sheet thickness above 0.1 mm: 1500 sheets.
Note
The paper supply stops once the maxi-
mum number of sheets or the maximum
height of the auxiliary pile has been
reached. The feeder is disconnected.
The press goes off impression.
B.10.132 SC.999.0020/01
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28.3 Determining the actual sheet size
Caution - Damage to the press due to
too large/small sheet size!
Make sure by directly measuring the
sheet size in the feeder pile that the
sheet size matches the input in the press
control system.
28.4 Delivery control console
Additional buttons on presses with automatic non-
FS.901.9210-000GRAUND_01
stop
● The Auxiliary pile support in work position button
(Fig. 148/1)
Pressing this button moves the auxiliary pile support to
work position or home position. The main pile is low-
1 2 3 ered.
Requirement
The signal lamp (Fig. 148/3) is green, the
auxiliary pile frame is in the upper posi-
tion and there is no malfunction that im-
pedes the automatic pile change.
● The Auxiliary pile support in rest position button
(Fig. 148/2)
The button flashes when the auxiliary pile support
stops in an undefined position.
Pressing this button moves the auxiliary pile support to
home position.
If a light curtain is interrupted while the auxiliary pile
support is moving, the auxiliary pile support stops
Fig. 148 Delivery control console moving and the changeover sequence is aborted. By
pressing the Auxiliary pile support in rest position but-
ton, the auxiliary pile support is returned to the rest
position.
Requirement
The auxiliary pile support only moves to
the rest position if the pile formation has
not yet begun or if it is possible to com-
bine the main pile and auxiliary pile.
Additional signal lamp on presses with automatic
non-stop
● The Light curtains signal lamp (Fig. 148/3)
The signal lamp displays the status of the light cur-
tains.
● Green: Automatic pile change is possible. The
light curtains are not interrupted.
● Green flashing: when piles are merged or sepa-
rated and approx. 5 sec. before an automatic pile
change starts.
● Red: Automatic pile change is not possible.
Check which light curtain is interrupted.
SC.999.0020/01 B.10.133
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28.5 Recommended settings
The following recommended adjustment values are
guide values. They shall help you in adjusting your
press to the print-related requirements of the individual
print jobs.
● Adjust the air in the pile area to the lowest level
possible. You avoid the tendency to build roofs.
● Adjust the gripper opening cam such that the
front edge of the print sheet lands shortly above
the pile level. The print sheet can thus be caught
by the sheet catchers.
● Position of pile height sensor
○ Paper setting: center
○ Cardboard setting: bottom
● It is only sensible to increase the descending dis-
tance slightly if the rear edge of the pile is 30 -
40 mm lower than the rest of the pile. Increase the
descending distance by as little as possible. De-
pending on the stock thickness, the descending
distance is automatically limited.
Note
Adjust the position of the lateral sheet
joggers according to the format to be
printed.
Sheet length 550 ... 750 mm: sheet jog-
ger at the rear stop.
Sheet length smaller than 550 mm:
sheet jogger at the front stop.
Note
Make sure that the delivery pile surface
is horizontal and even.
28.6 Overview of the functional sequence for an automatic pile change
Starting an automatic pile change
There are 2 ways to start the automatic pile change:
Manually with the Auxiliary pile support in work posi-
tion button or automatically when the preselected pile
height/number of sheets has been reached.
Note
The prerequisites for the automatic pile
change must be fulfilled (signal lamp of
the light curtain lights up green and aux-
iliary pile frame is in the upper end posi-
tion).
Starting a pile change manually
1. Press the Auxiliary pile support to work position
button on the delivery console or control station.
An automatic pile change starts immediately after
the button is pressed if all requirements are ful-
B.10.134 SC.999.0020/01
Delivery
filled (auxiliary pile frame at top, light curtain free,
DWBA free).
Starting a pile change automatically
Requirement
The Automatic non-stop pile change and
Non-stop operation buttons must be pre-
selected. A value for the pile height must
be entered.
The automatic pile change starts once the set number
of print sheets has been reached.
If a signal sounds and the pile change does not start
automatically: Check whether the Automatic non-stop
pile change button is preselected.
Functional sequence:
● The main pile moves downward until there is a
gap for the separator. The sheet catchers on the
front edge swing off. The movable rear edge
moves to the work position.
● The rear edge stops swing off. The separator
moves to the work position.
● The grippers at the rear edge secure the sheet.
● The sheet catchers at the front edge are inserted
and catch the falling sheets.
● The main pile moves downward until there is a
gap for the auxiliary pile support.
● The auxiliary pile support (belt table) moves to
the work position and picks up the auxiliary pile.
The separator and the sheet catchers move to
the rest position.
● The main pile moves downward to the floor.
● Automatically with a pallet conveying system or
manually by the operator: The main pile is moved
out of the press. An empty pallet is inserted.
● Automatically with a pallet conveying system:
The empty pallet moves upward until it is possible
to merge it with the auxiliary pile.
1. Manually by the operator: Press the Main pile up
button. The empty pallet moves upward until it is
possible to merge it with the auxiliary pile.
If the pallet does not move far enough upward, check
whether the Automatic non-stop pile change button is
preselected on the control station. If not, the pallet
stops 300 mm below the auxiliary pile support.
● The auxiliary pile support (belt table) moves to
home position, where the auxiliary pile and main
pile are merged.
If a light curtain is interrupted, the movement of the
auxiliary pile support stops. Check which light curtain
has been interrupted. Then press the Auxiliary pile
support in rest position button to end the procedure.
● The auxiliary pile frame moves upwards
SC.999.0020/01 B.10.135
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If a light curtain or a light beam of the DWBA is
interrupted or an Emergency stop is triggered,
the upward movement of the auxiliary pile frame
stops. Eliminate the cause of the fault. Then
press the Auxiliary pile up button to move the
auxiliary pile frame to the upper end position.
The changeover procedure is now complete.
28.7 Overview of the functional sequence for a rack change
Starting the rack change
There are 2 ways to start the rack change: Manually
with the Auxiliary pile support in work position button or
automatically when the preselected rack height/
number of sheets has been reached.
Note
The prerequisites for the rack change
must be fulfilled (signal lamp of the light
curtain lights up green and auxiliary pile
frame is in the upper end position).
Starting a rack change manually
1. Press the Auxiliary pile support to work position
button on the delivery console or control station:
A rack change starts immediately after the button
is pressed if all requirements are fulfilled (auxil-
iary pile frame at top, light curtain free, DWBA
free).
Starting a rack change automatically
Requirement
The Automatic non-stop pile change and
Rack delivery operation buttons must be
preselected. The values for the rack
height and rack pile must be entered.
● The rack change starts once the set number of
print sheets has been reached.
If a signal sounds and the rack change does not start
automatically: Check whether the Automatic non-stop
pile change button is preselected.
● The main pile moves downward until there is a
gap for the separator. The sheet catchers on the
front edge swing off. The movable rear edge
moves to the work position.
● The rear edge stops swing off. The separator
moves to the work position.
● The grippers at the rear edge secure the sheet.
● The sheet catchers at the front edge are inserted
and catch the falling sheets.
● The main pile moves downward until there is a
gap for the belt table.
● The auxiliary pile support moves to the work po-
sition and picks up the auxiliary pile. The sepa-
B.10.136 SC.999.0020/01
Delivery
rator and the sheet catchers move to the rest po-
sition.
● The main pile moves downward by the value set
for the Rack height.
The steps involved in the process up to now also apply
for the "Pile change in rack delivery operation".
1. Insert the distance pieces (Fig. 149/1).
FS.901.9206-000GRAUND_00
Ensure that the distance pieces are stable and
correctly aligned (long side in the direction of
sheet travel).
2. Slide in a rack board.
3. Press the Main pile up button.
The main pile moves upward until the distance
pieces take the weight off the empty rack board.
1 ● The auxiliary pile support moves to the rest po-
sition, thereby placing the auxiliary pile on the
rack board.
If a light curtain is interrupted, the movement of the belt
table stops. Check which light curtain has been inter-
rupted. Then press the Auxiliary pile support in rest
Fig. 149 Distance piece position button to end the procedure.
● The auxiliary pile frame moves upward.
If a light beam of the DWBA is interrupted or an
Emergency stop is triggered, the upward move-
ment of the auxiliary pile frame stops. Eliminate
the cause of the fault. Then press the Auxiliary
pile up button to move the auxiliary pile frame to
the upper end position.
The rack change is now complete.
Pile change in rack delivery operation
1. Perform the above steps as described in "Start-
ing a rack change automatically".
The belt table is then in the work position.
2. Press the Main pile down button. The main pile
moves downward to the floor.
3. Move the main pile out of the press. Insert an
empty pallet or an empty pile table.
4. Press the Main pile up button.
The empty pallet moves upward until it is possible
to merge it with the auxiliary pile.
If the pallet does not move far enough upward, check
whether the Automatic non-stop pile change button is
preselected on the control station. If not, the pallet
stops 300 mm below the belt table.
● The auxiliary pile support moves to the rest po-
sition, thereby placing the auxiliary pile on the
empty pallet/pile table.
If a light curtain is interrupted, the movement of the belt
table stops. Check which light curtain has been inter-
SC.999.0020/01 B.10.137
Delivery
rupted. Then press the Auxiliary pile support in rest
position button to end the procedure.
● The auxiliary pile frame moves upward.
If a light curtain or a light beam of the DWBA is
interrupted or an Emergency stop is triggered,
the upward movement of the auxiliary pile frame
stops. Eliminate the cause of the fault. Then
press the Auxiliary pile up button to move the
auxiliary pile frame to the upper end position.
The entire pallet change procedure is now complete.
28.8 Troubleshooting for an automatic non-stop pile change
Prior to troubleshooting
1. Secure the press against being started up: Press
the Emergency stop button on the delivery con-
trol panel. Open the front guard on the delivery.
Malfunction Possible cause Corrective measure
The sheet catchers do not swing to The auxiliary pile frame is not at the Press the Auxiliary pile up button until
the lower position. Automatic pile top end position. the upper end position is reached.
change does not start.
The sheet catchers or the separator The Pile descent path - separator is Set a larger pile descent path.
move into the pile that has been too small.
formed.
Prior to inserting the auxiliary pile There is too much air in the pile area. Reduce the air supply above the pile.
support, the print sheets slide un-
The gripper opening time setting is Correct the gripper opening cam.
derneath the stops at the front
incorrect.
edge.
The "auxiliary pile support" de- Reduce the "auxiliary pile support"
scending distance is too great. descending distance.
The sheet decurler is not selected. Switch on the sheet decurler.
The print sheets slide through the The rear edge stops are jammed in Clean the rear edge stops. Check
stops at the rear edge of the pile. the upper position. their function.
The movable rear edge is jammed. Clean the guides of the movable rear
edge. Check their function.
The auxiliary pile support touches The "auxiliary pile support" de- Increase the "auxiliary pile support"
the main pile when it is inserted. scending distance is too small. descending distance.
The main pile is thicker in the middle Equalize the pile. To do this, insert
(roofing). wedges into the pile.
The auxiliary pile frame does not low- The movable rear edge is not at its Clean the guides of the movable rear
er. home position. edge. Check their function. Check the
adjustment of the limit switches.
The feeder receives the "Paper stop" The maximum descent is reached. Change the pile more quickly.
signal.
The maximum number of sheets on Change the pile more quickly.
the auxiliary pile is reached.
The main pile cannot be raised. The movable rear edge is not at its Clean the guides of the movable rear
home position. edge. Check their function.
B.10.138 SC.999.0020/01
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Malfunction Possible cause Corrective measure
Auto non-stop: separating device Sensor on D.S. and/or transmitter on Clean the sensor on D.S. and the
does not detect a gap. O.S. is dirty/misaligned. LED flash- transmitter on O.S. using a clean, lint-
es. free cloth.
If the LED still blinks after cleaning,
please notify Heidelberg Service.
Auto non-stop: separating device Sensor on D.S. and/or transmitter on Clean the sensor on D.S. and the
does not detect a gap. O.S. is dirty, misaligned or defective. transmitter on O.S. using a clean, lint-
The LED is off. free cloth.
If the LED is still off or blinks after
cleaning, please notify Heidelberg
Service.
Auto non-stop: lateral sheet joggers If the sheet length of 550 mm or Manually push the sheet joggers on
not set to minimum format smaller is set, the sheet joggers D.S./O.S. to the minimum format.
must be in the minimum format po-
sition.
Tab. 15 Error messages
After troubleshooting
2. Release the Emergency stop button. Close the
front guard on the delivery.
Note
You need some practice to change piles
properly and swiftly. At the beginning it is
sensible to reduce the printing speed to
ensure a smooth pile change.
SC.999.0020/01 B.10.139
Delivery
29 Print-related information on the auto-non-stop system (optional)
FS.901.9212-000UTKENU_00
29.1 Function
Note
Caution - Risk of press damage!
If you did not set up the paper run cor-
rectly, an irregular delivery pile may be
the result. An irregular pile can cause
press damage during an auto-non-stop
pile change.
The automatic non-stop system can only function
smoothly if the paper run is set up correctly. For a cor-
rect setup, make sure that the following settings/
adjustments/components are correct:
● Sheet size
● Brake modules
● Sheet delivery
● Pile descent path
In addition, you must ensure that the relevant sensors
are working correctly:
● Gap sensor at the separating unit
● Pile height sensor
If the press control system detects a paper run mal-
function during the pile change, the pile change is
aborted.
29.2 Required checks before an automatic pile change
Item Items to check at the au- Remark Procedure
tomatic non-stop deliv- see the operating manual
ery
1 Did you measure the actu- The press control system automati- Pile change, determine the actual sheet
al width and length of the cally adjusts the sheet joggers and dimensions.
paper sheet? the rear edge stops based on your Call up the menu Delivery / Pile stops
specifications. If the actual sheet size
is bigger, the paper pile will bulge.
The sheet joggers and rear edge
stops must not exert pressure on the
pile.
2 Are the suction tapes at If the suction tapes are worn, the Check the suction tapes daily!
the sheet brake modules sheet will not be decelerated to deliv-
in good condition? ery speed. Good pile formation is not
possible. There may be overrunning
sheets.
3 Did you mount any com- You must not change the compo- Modular sheet brake system - component
ponents at the outermost nents at the outermost sheet brake versions for front and back printing/
stops within the suction modules. perfecting
tapes?
B.10.140 SC.999.0020/01
Delivery
Item Items to check at the au- Remark Procedure
tomatic non-stop deliv- see the operating manual
ery
4 Have the sheet brake If the sheet brake modules are not Modular sheet brake system - Handling
modules been uniformly symmetrical and uniformly inclined, the brake modules
adjusted? good pile formation is not possible.
Direction?
Inclination?
5 Is there a sufficiently The sheets must be placed neatly on- Place paper strips on all suction tapes and
strong vacuum at the to the suction tape. pull them off to ensure that the vacuum has
sheet brake modules? the same strength everywhere.
6 Are the friction wheels at If the friction wheels are worn, the Check the friction wheels monthly!
the sheet brake modules suction tapes will not follow the speed Replace the friction wheels
in good condition? profile of the press control system.
7 Have the sheet fall and Check the pile surface. Automatic non-stop system, recommend-
point of contact been ad- Make sure that the delivery pile sur- ed adjustments
justed optimally? face is horizontal and even. Gripper opening
8 Has the sensor of the au- The sensor should be positioned in Automatic non-stop system, recommend-
tomatic delivery pile height the middle; if cardboard is processed, ed adjustments
control been adjusted cor- the sensor should be positioned at the
rectly? bottom.
9 Is the pile descent path If the rear edge of the delivery pile is Call up the menu Delivery / Non-stop func-
correct? much lower than the highest point of tions
The pile descent path the pile, the upper sheets on the pile Automatic non-stop system, recommend-
should only be increased may be pushed together when the ed adjustments
slightly if the rear edge of delivery belt table is inserted.
the paper pile is Depending on the stock thickness,
30 ... 40 mm lower than the descending distance is automati-
the rest of the pile. cally limited.
Tab. 16
SC.999.0020/01 B.10.141
Delivery
30 Troubleshooting on the delivery
SC.901.9116-000UTKENU_03
30.1 Overview
The following table is intended to support you in locat-
ing and eliminating malfunctions that can occur in the
delivery area.
Contact your Heidelberg agency if you are unable to
eliminate the malfunction with the help of this table.
30.2 Sheet drop at front edge
Malfunction Possible cause Remedy
The corners of the sheet at the front Air escaping from the inside to the There is no malfunction. The "W
edge fold upwards during the sheet outside presses the corners of the shape" stabilizes the sheet during the
drop. sheet upwards. drop.
The sheets (cardboard, in particular) The gripper bar opens early. Set the gripper bar to open later
heavily hit the front edge. The slowed-down sheet is accelerat- (12% ... 18%) (see the "Gripper open-
ed again by the subsequent sheet. ing cam" chapter).
Increase speed of the sheet brake (to
a maximum of 40%) (see the "Sheet
brake" chapter).
Tab. 17 Sheet drop at front edge
30.3 Sheet drop at rear edge
Malfunction Possible cause Remedy
The rear corners of the sheet turn Incorrect positioning of the fan row. ● Position the penultimate fan row in
over during pile formation. front of the sheet slow-down de-
vice (seen from the delivery glass
guard).
● Place the outer fan of the penulti-
mate fan row above the rear cor-
ners of the sheet.
● Increase the air flow of the penul-
timate fan row to a maximum of
50 %.
See the "Air in the pile area" chapter.
The air volume that escapes from the Reduce the air stream of the 2nd fan
sheet center to the outside is too row (see the "Air in the pile area"
large. chapter).
The gripper bar opens early (exces- Correct the opening time of the grip-
sive shingling). per bar (see the "Gripper opening
cam" chapter).
The suction air at the sheet decurler is Reduce the suction air at the sheet
high. The sheet is decurled too much. decurler (see the "Air in the pile area"
chapter).
The rear edge of sheet drops irregu- The sheet drop is obstructed mechan- Remove the mechanical obstruction.
larly. ically, e.g. due to an oblique rear edge Please notify Heidelberg Service, if
or bent plates at the sheet slow-down necessary.
device.
B.10.142 SC.999.0020/01
Delivery
Malfunction Possible cause Remedy
The pile height varies at the rear Reduce the suction air of the outer
edge, and the corners of the are sheet brakes (see the "Sheet brake"
turned. chapter).
Folds and warps at the rear edges of The outer sheet slow-down devices Depending on printing material and
the sheet above the brake. are too far at the outside. motif, position the outer sheet brakes
as far inside as possible (see the
Excessive shingling scratching be-
"Sheet brake" chapter).
tween the brakes (wide mark).
In the case of slight paper creases The suction air at the sheet slow- Reduce the suction air of the sheet
and warps at the rear edge of the down device is high. brake (to a minimum of 85%) (see the
sheet above the sheet slow-down de- "Sheet brake" chapter).
vice.
Tab. 18 Sheet drop at rear edge
30.4 Excessive shingling
Malfunction Possible cause Remedy
The sheets tear at the front edge. Collision with the preceding sheet on Position the sheet brake modules on
the sheet slow-down device. D.S. and O.S. further inside the sheet
(see the "Sheet brake" chapter).
Reduce the suction air of the sheet
brake (see the "Sheet brake" chap-
ter).
"Excessive shingling scratching" - The gripper bar opens early. Set the gripper bar to open later (see
marks in the printed image at the rear the "Gripper opening cam" chapter).
edge of sheet (small dot marks).
The speed of the sheet slow-down Increase speed of the sheet brake (to
device is low. a maximum of 40%) (see the "Sheet
brake" chapter).
Tab. 19 Excessive shingling
30.5 Marks
Malfunction Possible cause Remedy
Point set-off. Sheets become electrostatically ● Switch off the sheet decurler or re-
Set-off stripes in the area of the suc- charged due to friction when rubbing duce the suction air volume of the
tion tapes. against the sheet decurler or the sheet decurler.
sheet guide plates. ● Reduce the blast air volume of the
sheet guide plates in the delivery.
Please refer to the "Suction air/blast
air sheet guide system" chapter for
further information.
Low powder volume. Increase the powder volume (see the
"Powder spray device" chapter).
Nonuniform powder distribution due Use calcium carbonate powder.
to electrostatic charge of the sheets.
Individual powder spray nozzles Clean the blocked powder spray noz-
blocked. zles.
SC.999.0020/01 B.10.143
Delivery
Malfunction Possible cause Remedy
Set-off scratches in the rear corners Excessive jogging movement. Switch off the jogging movement on
of the sheet. one or on both lateral sheet joggers
(see the "Sheet jogger" chapter).
Marks in the coating or in the printed Unsuitable suction tapes. Use gray suction tapes (made of sili-
image on the underside of the sheet. cone) (see the "Suction tapes" chap-
ter).
Reduce the negative pressure at the
sheet brake and set the gripper bar to
open earlier (see the "Sheet brake
and gripper opening cam" chapter).
Tab. 20 Marks
30.6 Pile formation
Malfunction Possible cause Remedy
The gripper bar must open significant- The surface of the suction tape is too Replace the suction tapes (see the
ly earlier than usual. smooth, due to wear of inking. "Sheet brake" and "Suction tapes"
chapters).
The vacuum at the manual valve of Filter in the air removal line of the Clean the filter (see the maintenance
the sheet slow-down device is below sheet slow-down device is soiled, de- and cleaning (customer) manual).
0.35 bars without sheet travel (all fective, or incorrectly installed.
Check the correct fitting location and
levers of the manual valve are fully
seal of the filter case (see the main-
open; sheet slow-down device vacu-
tenance and cleaning (customer)
um = 100 %).
manual).
Unstable pile formation with heavy The chamber pressure of the upper Increase the chamber pressure of the
and flexible paper (250 ... 350 g/m ). deflection of the sheet guide plate as- upper deflection of the sheet guide
2
cent is low. plate ascent (see the "Suction air/
blast air sheet guide system" chap-
ter).
Individual oblique sheet. The suction tapes are worn out. Replace the suction tapes set by set
Different sheet arrival at the front (see the "Sheet brake" and "Suction
edge. tapes" chapters).
Guide roll on the brake module is Check and, if necessary, clean the
tight. sheet brake module (see the "Sheet
brake" chapter).
Occasional overpiling despite stable Individual sheets were damaged dur- Check the sheet guide in the feeder
pile formation process. ing the printing process. and between the printing units.
Damaged sheets (with dog's ears at
the rear edge, for example) cannot be
delayed safely.
Tab. 21 Pile formation
B.10.144 SC.999.0020/01
Delivery
30.7 Sheet guide
Malfunction Possible cause Remedy
The sheet collapses underneath the The air stream of zone A is too strong. Reduce the air stream of zone A to
sprocket wheel shaft. approximately 10 % (see "Suction air/
blast air sheet guide system").
The air stream from the blast tubes on Increase the air stream from the blast
the sprocket wheel shaft is weak. tubes on the sprocket wheel shaft to
approximately 60 %.
Line-shaped powder traces on the un- The powder spray nozzles in the Clean the powder spray nozzles.
derside of the sheet. guide plate are soiled.
Tab. 22 Sheet guide
SC.999.0020/01 B.10.145
Delivery
B.10.146 SC.999.0020/01
Coating unit
Coating unit
unit
Coating
1 Coating unit - safety instructions ........................................................................................ B.11.5
1.1 To be observed when performing work .......................................................................... B.11.5
2 Coating unit - overview .......................................................................................................... B.11.9
2.1 Coating unit ................................................................................................................... B.11.9
2.2 Varnish circulation ......................................................................................................... B.11.9
3 Print-related notes on coating ............................................................................................. B.11.11
3.1 Pressure ......................................................................................................................... B.11.11
3.2 Jacket ............................................................................................................................. B.11.11
3.3 Print length adjustments ................................................................................................ B.11.11
3.4 Varnish application ......................................................................................................... B.11.11
3.5 UV varnish ..................................................................................................................... B.11.11
3.6 Powder ........................................................................................................................... B.11.12
4 Coating blanket cylinder with combination clamping rails ............................................... B.11.13
4.1 Coating blanket/coating plate and packing sheet .......................................................... B.11.13
4.2 Preparing packing sheet ............................................................................................... B.11.15
4.3 Selecting a control panel and throwing on the pressing roller ....................................... B.11.17
4.4 Mounting/demounting the coating blanket .................................................................... B.11.18
4.5 Mounting/demounting the coating plate ........................................................................ B.11.24
5 Positioning corrections on the coating blanket cylinder with combination clamping rails
................................................................................................................................................. B.11.31
5.1 Print length adjustment for coating plates ...................................................................... B.11.31
5.2 Positioning corrections on the coating plate .................................................................. B.11.31
6 Pressing roller ....................................................................................................................... B.11.36
6.1 Place of installation / function ........................................................................................ B.11.36
6.2 Removing/fitting the pressing roller ................................................................................ B.11.37
6.3 Cleaning ........................................................................................................................ B.11.38
7 Notes on treatment of the screen roller .............................................................................. B.11.39
7.1 Bearing .......................................................................................................................... B.11.39
7.2 Transport ....................................................................................................................... B.11.39
7.3 Cleaning ........................................................................................................................ B.11.39
8 Screen roller .......................................................................................................................... B.11.40
8.1 Function ......................................................................................................................... B.11.40
8.2 Notes on cleaning the screen roller .............................................................................. B.11.40
8.3 Removing screen roller ................................................................................................. B.11.41
8.4 Installing screen roller ................................................................................................... B.11.46
SC.999.0020/01 B.11.1
Coating unit
9 Fitting/removing rolling bearings ........................................................................................ B.11.51
9.1 Changing bearings on screen rollers and metering rollers ........................................... B.11.51
9.2 Removing the rolling bearing from the trunnion ............................................................. B.11.51
9.3 Fitting the rolling bearings on the trunnion ..................................................................... B.11.52
10 Chambered blade and pressurized chambered blade ....................................................... B.11.53
10.1 Overview ........................................................................................................................ B.11.53
10.2 Function ........................................................................................................................ B.11.54
10.3 Preparing the chambered blade .................................................................................... B.11.57
10.4 Installing the coating pan .............................................................................................. B.11.61
10.5 Fitting the chambered blade ......................................................................................... B.11.63
10.6 Coating operation .......................................................................................................... B.11.63
10.7 Cleaning the chambered doctor blade and the coating unit .......................................... B.11.66
10.8 Removing the chambered blade ................................................................................... B.11.68
10.9 Cleaning the chambered blade ..................................................................................... B.11.68
10.10 Removing the coating pan ............................................................................................ B.11.69
10.11 Outlet tube on the pressurized chambered blade ......................................................... B.11.70
10.12 Adjusting the chambered blade to the screen roller ...................................................... B.11.70
11 Screen rollers of spraying device (option) ......................................................................... B.11.78
11.1 Function/Task ................................................................................................................ B.11.78
11.2 Activating/deactivating the spraying device ................................................................... B.11.78
11.3 Cleaning ......................................................................................................................... B.11.79
11.4 Installation location and function .................................................................................... B.11.79
11.5 Components ................................................................................................................... B.11.80
11.6 Requirements of the water ............................................................................................. B.11.80
11.7 Replacing canister ........................................................................................................ B.11.80
11.8 Commissioning ............................................................................................................. B.11.82
12 CoatingStar varnish supply unit .......................................................................................... B.11.83
12.1 Features ........................................................................................................................ B.11.83
12.2 Varnish circulation ......................................................................................................... B.11.83
12.3 Control panels ............................................................................................................... B.11.84
12.4 Setting the pumping capacity (flow rate) ....................................................................... B.11.84
12.5 Tips on optimum cleaning results ................................................................................. B.11.84
12.6 Manual cleaning with washing fluid only ....................................................................... B.11.86
12.7 Manual cleaning with washing fluid and fresh water ..................................................... B.11.87
12.8 Automatic cleaning process with a cleaning program ................................................... B.11.88
12.9 Interrupting/aborting the cleaning process .................................................................... B.11.88
12.10 Recording a cleaning program using the recorder function .......................................... B.11.89
B.11.2 SC.999.0020/01
Coating unit
13 CoatingStar Compact varnish supply unit ......................................................................... B.11.90
13.1 Features ........................................................................................................................ B.11.90
13.2 Varnish circulation ......................................................................................................... B.11.90
13.3 Control panels ............................................................................................................... B.11.91
13.4 Setting the pumping capacity (flow rate) ....................................................................... B.11.92
13.5 Tips on optimum cleaning results ................................................................................. B.11.93
13.6 Manual cleaning with washing fluid ............................................................................... B.11.94
13.7 Semi-automatic cleaning with cleaning program .......................................................... B.11.94
13.8 Interrupting/aborting the cleaning process .................................................................... B.11.95
14 Coating unit with 2 varnish circulation systems (optional) .............................................. B.11.96
14.1 Varnish separation ......................................................................................................... B.11.96
SC.999.0020/01 B.11.3
Coating unit
B.11.4 SC.999.0020/01
Coating unit
1 Coating unit - safety instructions
SF.901.1000-000UTKENU_01
1.1 To be observed when performing work
Warning - Risk of injury from falling
screen roller!
Use the lifting device provided and a
crane. Also watch other persons dur-
ing installation and removal. Standing
or walking under suspended loads is
strictly forbidden.
Warning - Risk of cutting on sharp
doctor blades!
Proceed with the utmost caution and
great care when removing and fitting
the blade equipment (e.g. chambered
blades, washup blades, blade holders)
and when changing the doctor blades.
Wear cut-resistant protective gloves
for all work on the blade equipment.
Only transport the blade equipment in
safe places and with the protective
bars on the doctor blade. Always take
other people into consideration when
handling the blade equipment.
Warning - Risk of injury from rotat-
ing rollers and cylinders!
When cleaning the rollers and cylin-
ders, the ball of your thumb must point
in the direction of the infeed gap and
your fingers in the direction of the out-
let gap. Select the corresponding di-
rection of rotation.
Warning - Risk of injury from rotat-
ing rollers and cylinders!
Use the gap covers of the blanket
cylinders, plate cylinders and coating
blanket cylinders in order to avoid in-
juries.
Warning - Risk of injury from rotat-
ing rollers and cylinders!
Soiling can impair the function of the
finger protecting bar. You should
therefore regularly check the function
of the finger protection devices on the
coating unit.
SC.999.0020/01 B.11.5
Coating unit
Warning - Hot surfaces!
After dryer use, wait until all accessible
parts have cooled down and are no
more than lukewarm (approximate-
ly 40 °C).
Warning - Explosion hazard due to
evaporating solvents!
Before the use of cleaning agents, wait
until the cylinders and press compo-
nents to be cleaned have cooled down
and are just warm to the touch (ap-
proximately 40 °C).
Warning - Explosion hazard due to
evaporating solvents!
When using dryers, only use inks and
varnishes that do not create any ex-
plosive atmosphere when heated in
the dryer. This is specified in the cor-
responding safety data sheets.
Ensure that no solvents can enter into
the dryer area when using cleaners on
the press. Never use and store sol-
vents in the vicinity of the dryer.
When using an automatic washup de-
vice, set the wash program so that the
blankets and impression cylinders are
dry before you continue with the pro-
duction. This ensures that no solvent
can enter into the dryer area.
B.11.6 SC.999.0020/01
Coating unit
Warning - Danger of death from
electrical voltage!
Dryers work with very high operating
voltages. Ensure that the machine and
the dryers cannot be switched on be-
fore starting any maintenance work on
the dryer:
Switch the main switch to 0/Off and
lock it in this position with a padlock.
Leave a sign with the name of the per-
son authorized to switch on the main
switches.
Never touch any plugs of the electrical
connections or disconnect them when
the dryer is in operation. Protect all
plugs of electrical connections against
moisture, contamination and damage.
Faulty cables, plugs and insulation
should be repaired by skilled person-
nel only, using original spare parts.
Warning - Risk of injury from falling!
There is a risk of falling and thus suf-
fering serious bodily injuries when
climbing on or off in the area of the
white sheet metal.
Only step on the designated foot-
boards (gray bulb plate) from the drive
side.
Caution - Unsecured clamps can
damage metering roller or screen
roller!
When using the printing press without
coating blanket or coating plate, you
must crank down the clamp at front edge
and rear edge until it hits the stop.
Caution - Damage to the press caused
by improperly mounted sheet guide
plates!
Never remove the sheet guide plates
near the transfer drums and impression
cylinders. The sheet guide plates must
only be removed and fitted by Heidel-
berg service staff. Inching the transfer
drums to a vertical position will allow you
to clean the sheet guide plates.
SC.999.0020/01 B.11.7
Coating unit
Caution - Malfunction due to not per-
forming the necessary cleaning work!
Working with coating requires great care
and cleanliness. The coating can be re-
moved very easily as long as it has not
yet dried off. To guarantee trouble-free
operation the coating unit and the corre-
sponding safety devices must be kept
very clean.
B.11.8 SC.999.0020/01
Coating unit
2 Coating unit - overview
SG.901.1001-000UTKENU_07
2.1 Coating unit
Chambered blade metering
SG.901.1010-001GRAUND_00
● Collecting trough (Fig. 1/1)
● Chamber doctor blade (Fig. 1/2)
3
4 ● Screen roller (Fig. 1/3)
● Coating blanket cylinder (Fig. 1/4)
5 2 ● Impression cylinder (Fig. 1/5)
1
Fig. 1 Chambered blade metering diagram
2.2 Varnish circulation
Note
The varnish circulation is shown using
CoatingStar as an example. A cham-
bered blade can also be used with other
varnish supply units.
SC.999.0020/01 B.11.9
Coating unit
Chambered blade metering
LS.901.6081-002GRAUND_00
13 12 11 10
● Suction set 1 and varnish tank (Fig. 2/1)
● Suction set 2 and container for rinsing solution
(Fig. 2/2)
● Fresh water supply (Fig. 2/3)
9
● Varnish supply unit (Fig. 2/4)
8 ● Supply hose and varnish pipes (Fig. 2/5)
15
14 7 ● Flow sensor (Fig. 2/6)
● Varnish return flow tube, return flow hose and
6 varnish pipes (Fig. 2/7) (Fig. /28)
● Collecting trough (Fig. 2/9)
5 ● Screen roller (Fig. 2/10)
● Chambered blade (Fig. 2/11)
4 ● Manual control unit (Fig. 2/12)
1 2 ● Control panel O.S. (Fig. 2/13)
3 ● Connection to the press control station (Fig. 2/14)
● Distribution box (Fig. 2/15)
Fig. 2 Varnish circulation chambered blade meter-
ing
Flexokit
SG.901.1099-000GRAUND_00
13 12 11 10 9 ● Suction set 1 and varnish tank (Fig. 3/1)
8 ● Suction set 2 and container for rinsing solution
7 (Fig. 3/2)
● Varnish pump H2 (Fig. 3/3)
14
● Collecting vessel (Fig. 3/4)
● Supply hose (Fig. 3/5)
● Varnish return line (Fig. 3/6)
6
● Collecting trough (Fig. 3/7)
● Chambered blade Flexokit (Fig. 3/8)
● Pressure sensor (Fig. 3/9)
5 ● Fill level sensor (Fig. 3/10)
● Return flow hose (Fig. 3/11)
4 ● Manual control unit (Fig. 3/12)
1 2 3 ● Control panel O.S. (Fig. 3/13)
● Connection to the control station (Fig. 3/14)
Note
Fig. 3 Flexokit varnish circulation
Additional information is available in the
manufacturer's documentation.
B.11.10 SC.999.0020/01
Coating unit
3 Print-related notes on coating
SG.901.1007-000UTKENU_04
3.1 Pressure
Set the pressure as low as possible. Excessive pres-
sure generates squeeze edges at the subject being
coated.
3.2 Jacket
The cylinder undercut of the coating blanket cylinder is
3.2 mm. To keep the pressure low, you should use soft
packing with a special compressible underlay blanket.
The dimensions of the coating blanket are
800 mm x 1048 mm, the dimensions of the coating
plate are 780 mm x 1030 mm. The lead edge of print is
43 mm in both cases.
3.3 Print length adjustments
Coating plates have a larger layer thickness than stan-
dard offset plates and should therefore be exposed in
a special round form imagesetter. If no round form im-
agesetter is available, the master for copying should
be correspondingly optically distorted.
Smaller corrections can be carried out by changing the
shims under the coating plate:
● To reduce the thickness of the underlays: the
print image of the coating form becomes longer.
● Increase the thickness of the underlays: the print
image of the coating form becomes shorter.
Note
The impression pressure must be cor-
rected appropriately in order to achieve
the optimum printing pressure again.
3.4 Varnish application
The minimum quantity of varnish for a wet coating lay-
er covering the whole surface is approximately 3 - 4 g/
m2. The maximum applied quantity of varnish is 8 -
10 g/m2. Measurably more varnish should not be ap-
plied, since this only increases the gloss slightly.
Too much coating causes problems with drying. The
sheets can stick together (causing blockages).
3.5 UV varnish
The ink film should be dry/cured before the UV varnish
is applied. That is why the prints should always be
pinned before being coated with UV varnish.
SC.999.0020/01 B.11.11
Coating unit
3.6 Powder
Most dispersion coatings, particularly matt coatings,
allow the powder volume to be reduced.
Use powders that are suitable for dispersion varnish
(WS powder). These powders are water-repellent.
They also improve the sliding of the sheets in the de-
livery. Consult your varnish or powder supplier.
Even with glossy varnishes, you should use as little
powder as possible, since glossiness and abrasion re-
sistance can be diminished by powdering. If neces-
sary, keep the delivery pile smaller or use a rack de-
livery.
B.11.12 SC.999.0020/01
Coating unit
4 Coating blanket cylinder with combination clamping rails
SC.B01.1301-000UTKENU_01
4.1 Coating blanket/coating plate and packing sheet
SC.B01.1300-001GRAUND_00
3 4 5 3 1 3 4 5 3
6 2 7 6
Fig. 4 Coating blanket cylinder: clamping elements for the coating plate
Main components
1 Spindle, tensioning the rear edge
2 Spindle, tensioning the front edge
3 Pulling the rear edge of the coating plate (4x)
4 Clamping the rear edge of the coating plate (2x)
5 Spreading/compressing the spindle for the rear
edge of the coating plate (2x)
6 Clamping the front edge of the coating plate (2x)
7 Indicator, lead edge of print
SC.B01.1301-001GRAUND_00
3 3 1 3 3
4 4 2 4 4
Fig. 5 Coating blanket cylinder: clamping elements for the coating blanket
SC.999.0020/01 B.11.13
Coating unit
Main components
1 Spindle, tensioning the rear edge
2 Spindle, tensioning the front edge
3 Closing the clamping eccentric at the rear edge of
the coating blanket (4x)
4 Closing the clamping eccentric at the front edge
of the coating blanket (4x)
Clamping device
The clamping device of the coating blanket cylinder is
designed as a combination clamping system for all
conventional coating plates and coating blankets pre-
assembled with rails.
One spindle each clamps the front edge or the rear
edge of the coating blanket/coating plate.
Required tools
SC.B01.1343-000GRAUND_00
You need the following tools to change the coating
2 1
plate/coating blanket:
● Pin wrench (Fig. 6/1 and 2)
● Pin wrench with T-handle, (6 mm Allen key)
(Fig. 6/3)
● Torque wrench with extension (Fig. 6/4)
3
The tools are included in the press items supplied.
Fig. 6 Tools
Clamping principle for coating blanket
SC.B01.1302-000GRAUND_00
1 2
The front edge of the coating blanket (Fig. 7/2) is in-
serted into the groove of the clamping device.
The clamping eccentric (Fig. 7/1) holds the coating
blanket clamping bar in place in the clamping device.
The rear edge of the coating blanket is clamped ac-
cording to the same principle.
Fig. 7 Principle of rear edge clamping for coating
blanket
B.11.14 SC.999.0020/01
Coating unit
Clamping principle of coating plate
SC.B01.1303-000GRAUND_00
1 2 3 4 The coating plate (Fig. 8/4) is held in the gap between
the upper clamping bar (Fig. 8/2) and the lower clamp-
ing bar (Fig. 8/3). Two clamping eccentrics (Fig. 8/1) at
the rear edge press the clamping bars together.
Clamping area between the clamping bars:
0.19 mm ... 0.4 mm
The front edge of the plate is clamped according to the
same principle.
Fig. 8 Principle of rear edge clamping of coating
plate
Usable coating blankets and coating plates
The undercut of the blanket cylinder is 3.2 mm. The
coating blanket and packing sheet must have a com-
bined thickness of 3.2 mm.
You can use the following coating plates or coating
blankets in the coating unit:
● metal-barred coating blankets and blankets
● Metal or plastic-based coating plates
Note
When using coating plates:
Make sure that the front edge and rear
edge of the plate are washed out so that
the plate can be securely clamped.
The coating blankets and packing sheets have a dif-
ferent format than the blankets and packing sheets
used on the printing unit.
4.2 Preparing packing sheet
Pile edges may stick together. This is why the coating
area may not protrude beyond the sheet size on any
side. The packing must therefore be approximately
2 mm shorter than the sheet in circumferential direc-
tion and approximately 5 mm shorter in lateral direc-
tion.
Tools required
To change the packing sheet you need the small pin
wrench (separate parts set).
SC.999.0020/01 B.11.15
Coating unit
Clamping the packing sheet
SC.B01.1304-000GRAUND_00
2
1. Cut the packing sheet to the required sheet size.
Note
2 If you are processing stocks of
700 x 1000 mm, for instance:
3 Pack the coating blanket cylinder with 2
2 packing sheets of 698 x 990 mm and
0.4 mm thickness. Use full-size sheets to
make up the remaining packing height.
2. Insert the pin wrench (Fig. 9/4) into the borehole
and open all clamping bars (Fig. 9/2). Turn up to
the stop.
2
3. Push the packing sheets (Fig. 9/1) into the clamp-
ing bar up to the stop.
Note
There is a mark in the center of the
clamping bar (Fig. 9/3). You can center
1
align the sized packing sheet using the
mark.
4. Close all clamping bars.
The packing sheets are fixed in place in the
clamping bar.
Fig. 9 Clamping bar with sized packing sheet
Installing the clamping bar
SC.B01.1305-000GRAUND_00
1 1. Insert the prepared clamping bar with the packing
sheet into the recess on the front edge cylinder
gap.
● First on D.S. (Fig. 10/1),
● then on O.S. (Fig. 11/1).
Fig. 10 Clamping bar on D.S.
B.11.16 SC.999.0020/01
Coating unit
SC.B01.1306-000GRAUND_00
1
Fig. 11 Clamping bar on O.S.
4.3 Selecting a control panel and throwing on the pressing roller
When working on a coating unit:
SC.B01.1321-000GRAUND_00
1 1. Select the control panel at the coating unit.
Press the Control panel selection button
(Fig. 12/1).
The LED in the button lights up. The control panel
0,01mm 0,01mm is selected.
Note
Leave the coating unit selected during
the entire coating blanket / coating plate
change.
To turn the coating blanket cylinder:
2
2. Press the Positioning button (Fig. 12/2).
The LED lights up. The cylinder turns to the next
3 clamping position. The pressing roller is en-
gaged.
Fig. 12 Coating unit control panel, on O.S.
Note
If the pressing roller was manually dis-
engaged during the clamping/releasing
process, this condition is retained
throughout the entire clamping process.
It may be necessary to re-select the
pressing roller.
3. To do so, push the button Pressing roller on/off
(Fig. 12/3).
SC.999.0020/01 B.11.17
Coating unit
4.4 Mounting/demounting the coating blanket
4.4.1 Removing the coating blanket
Requirement
SC.B01.1350-000GRAUND_00
1 The coating blanket is washed.
1. Open the coating unit guard (Fig. 13/1) on the
delivery side.
Fig. 13 Opening the guard
2. Press the Positioning button.
SC.B01.1307-000GRAUND_00
1
The coating blanket cylinder turns until the rear
edge is easily accessible.
3. Turn the spindle for the rear edge (Fig. 14/1) until
you hit the stop. This slackens off the tension on
the coating blanket.
Turning direction: counterclockwise.
Fig. 14 Slackening the coating blanket at the rear
edge
4. Open the four clamping bars (Fig. 15/1).
SC.B01.1308-000GRAUND_00
1 1
The clamping eccentrics release the rear edge.
Fig. 15 Opening the clamping bars
B.11.18 SC.999.0020/01
Coating unit
5. Pull the rear edge of the coating blanket
SC.B01.1309-000GRAUND_00
1 (Fig. 16/1) out of the groove in the rear clamping
device.
6. Grasp the coating blanket and packing sheet.
Note
Hold the coating blanket and packing
sheet under constant tension when
pulling out.
7. Press the Positioning button.
The cylinder turns backward until it reaches the
front edge.
Fig. 16 Grasping the coating blanket at the rear
edge
8. Guide the coating blanket (Fig. 17/1) and packing
SC.B01.1310-000GRAUND_00
1 sheet out of the coating unit.
Fig. 17 Guiding out the coating blanket
9. Turn the spindle for the front edge (Fig. 18/1) until
SC.B01.1338-000GRAUND_00
you hit the stop.
Turning direction: counterclockwise.
Fig. 18 Relaxing the front edge
SC.999.0020/01 B.11.19
Coating unit
10. Open the four clamping bars (Fig. 19/1).
SC.B01.1339-000GRAUND_00
The clamping bars release the front edge.
Fig. 19 Opening the clamping bars
SC.B01.1311-000GRAUND_00
11. Pull the front edge of the coating blanket
1 (Fig. 20/1) out of the groove of the front clamping
device.
12. Place the coating blanket in a clean, protected
location.
Fig. 20 Taking out the coating blanket
13. Remove the clamping bar (Fig. 21/1) with the
SC.B01.1312-000GRAUND_00
1 sized packing sheets from the coating blanket
cylinder.
● To do so, slide the clamping bar towards
D.S. - the clamping bar then compresses.
● Lift the clamping bar on O.S. out of the re-
cess on the coating blanket cylinder.
It may be necessary to turn back the clamp shaft
slightly.
14. Place the packing sheet onto a clean, safe place.
15. Close all clamping bars if they were open.
16. Close all guards.
17. Deselect the control panel at the coating unit
again.
The LED in the button Control panel selection
Fig. 21 Removing clamping bar with packing sheet goes dark.
4.4.2 Installing the coating blanket
If you removed the coating blanket in the previous
step, you can proceed directly with the installation of
the coating blanket.
B.11.20 SC.999.0020/01
Coating unit
Otherwise:
1. Select the control panel at the coating unit.
2. Open the coating unit guard on the delivery side.
3. Press the Positioning button.
The LED lights up.
The coating blanket cylinder turns. The pressing
roller is engaged.
Continue with the installation:
SC.B01.1342-001GRAUND_00
1 4. Turn the spindle at the rear edge (Fig. 22/1) and
the spindle at the front edge (Fig. 22/2) up to the
stop in each case.
Direction of rotation: counterclockwise
in each case.
5. Open the four clamping bars (Fig. 23/1) at the
rear edge.
6. Press the Positioning button.
The coating blanket cylinder turns until the front
edge is accessible.
2
Fig. 22 Releasing rear edge and front edge
SC.B01.1345-000GRAUND_00
1 1
Fig. 23 Opening the four clamping bars at the rear
edge
SC.999.0020/01 B.11.21
Coating unit
7. Open the four clamping eccentrics at the front
SC.B01.1312-000GRAUND_00
1 edge.
8. Plug the clamping bar (Fig. 24/1) with the packing
sheets into the recesses on the cylinder, first on
D.S., then on O.S.
Fig. 24 Inserting the clamping bar: O.S.
9. Place the coating blanket on the packing sheet
SC.B01.1313-000GRAUND_00
1 and insert the reinforced part of the coating blan-
ket (Fig. 25/1) into the groove of the front clamp-
ing device.
10. Push down the coating blanket in the middle be-
tween D.S. and O.S.
11. Make sure that the coating blanket is centered in
the clamping bar.
Fig. 25 Inserting coating blanket
12. Close the four clamping eccentrics (Fig. 26/1).
SC.B01.1339-000GRAUND_00
Fig. 26 Closing the clamping bars
B.11.22 SC.999.0020/01
Coating unit
Note
SC.B01.1310-000GRAUND_00
1 Hold the coating blanket and packing
sheet when pulling in under constant
tension.
13. Press the Positioning button.
The pneumatic trolley is brought into contact with
the coating blanket cylinder.
The coating blanket cylinder pulls in the coating
blanket (Fig. 27/1) and the packing sheet up to
the rear edge.
Fig. 27 Inserting the coating blanket
14. Open all four clamping eccentrics at the rear
SC.B01.1309-000GRAUND_00
1 clamping device if necessary.
15. Push the rear edge of the coating blanket
(Fig. 28/1) into the groove of the rear clamping
device.
Fig. 28 Inserting the rear edge of the coating blanket
16. Close all four clamping eccentrics (Fig. 29/1) at
SC.B01.1308-000GRAUND_00
1 1 the rear edge.
Fig. 29 Closing the clamping bars
SC.999.0020/01 B.11.23
Coating unit
Clamping the coating blanket
SC.B01.1342-001GRAUND_00
1
Caution - Damage to the coating blan-
ket if torque is too great!
Use the torque wrench supplied with the
press to clamp the coating blanket.
Clamp the coating blanket by applying
the specified tightening torque.
Direction of rotation: clockwise in each
case.
1. First clamp the coating blanket using the spindle
at the front edge (Fig. 30/2).
2
Tightening torque: 40 Nm
Fig. 30 Clamping front edge and rear edge 2. Then clamp the coating blanket using the spindle
at the rear edge (Fig. 30/1).
Tightening torque: 40 Nm
3. Close all open guards.
4. Deselect the control panel at the coating unit
again.
The LED in the button Control panel selection
goes dark.
4.5 Mounting/demounting the coating plate
4.5.1 Removing the coating plate
Requirement
SC.B01.1350-000GRAUND_00
1 The coating plate has been cleaned.
1. Select the control panel at the coating unit.
2. Open the coating unit guard (Fig. 31/1) on the
delivery side.
3. Press the Positioning button.
The LED lights up.
The coating blanket cylinder turns to the removal
position. The pressing roller is engaged.
Fig. 31 Opening the guard
B.11.24 SC.999.0020/01
Coating unit
4. Turn the spindle for the rear edge (Fig. 32/2) until
SC.B01.1347-001GRAUND_00
1 2 you hit the stop. This slackens off the tension on
the coating plate.
Turning direction: counterclockwise.
Fig. 32 Releasing rear edge and front edge
SC.B01.1315-000GRAUND_00
5. Open the clamping on the rear edge. To do so,
1 1 open the two clamping bars at the rear clamping
device (Fig. 33/1) using the pin wrench.
Fig. 33 Loosening the clamping
The clamping bars (Fig. 34/1) release the rear edge of
SC.B01.1336-000GRAUND_00
1 the coating plate.
Fig. 34 Removing the rear edge of the coating plate
SC.999.0020/01 B.11.25
Coating unit
6. Grasp the coating plate (Fig. 35/1) and the pack-
SC.B01.1316-000GRAUND_00
1 ing sheet.
Note
Hold the coating plate and the packing
sheet under constant tension when re-
moving them.
7. Press the Positioning button.
The cylinder turns backward until it reaches the
front edge.
8. Guide the coating plate and the packing sheet out
of the coating unit.
Fig. 35 Guiding out the coating plate
9. Open the clamping at the front edge. To do so,
SC.B01.1334-000GRAUND_00
1 open the two clamping bars at the front clamping
device (Fig. 36/1).
Fig. 36 Releasing front edge clamping
10. Turn the spindle for the front edge (Fig. 37/1) until
SC.B01.1347-001GRAUND_00
1 2 you hit the stop. This slackens off the tension on
the coating plate.
Turning direction: counterclockwise.
11. Remove the collecting plate.
12. Place the coating plates in a clean, protected lo-
cation.
Fig. 37 Releasing rear edge and front edge
B.11.26 SC.999.0020/01
Coating unit
13. Remove the clamping bar with the packing sheet.
SC.B01.1312-000GRAUND_00
1 To do so, slide the clamping bar (Fig. 38/1) to-
wards D.S. - the clamping bar then compresses
slightly.
Lift the clamping bar on O.S. out of the recess on
the coating blanket cylinder.
14. Place the packing sheet onto a clean, safe place.
15. Close all clamping bars, if they were open.
16. Close all guards.
17. Deselect the control panel at the coating unit
again.
The LED in the button Control panel selection
goes dark.
Fig. 38 Taking out packing sheets
4.5.2 Installing the coating plate
If you have removed the coating plate in the previous
section, you can proceed immediately with clamping of
the coating plate.
Otherwise:
1. Select the control panel at the coating unit.
2. Open the coating unit guard on the delivery side.
3. Press the Positioning button.
The LED lights up.
The coating blanket cylinder turns. The pressing
roller is engaged.
Continue with the installation:
4. Open all clamping bars:
5. Loosen the spindle at the rear edge (Fig. 39/1)
SC.B01.1342-001GRAUND_00
1 and the spindle at the front edge (Fig. 39/2) up to
the stop in each case.
Direction of rotation: counterclockwise in
each case.
6. Press the Positioning button.
The coating blanket cylinder turns until the front
edge is accessible.
Fig. 39 Releasing rear edge and front edge
SC.999.0020/01 B.11.27
Coating unit
7. Plug the clamping bar (Fig. 40/1) with the packing
SC.B01.1312-000GRAUND_00
1 sheets into the recesses on the cylinder, first on
D.S., then on O.S.
Fig. 40 Inserting the underlay sheets
8. Place the coating plate on the packing sheet.
SC.B01.1318-000GRAUND_00
2 1 2 Insert the front edge of the coating plate into the
gap of the opened front clamping bars (Fig. 41/1).
9. Make sure the coating plate rests correctly
against the two register pins (Fig. 41/2).
Fig. 41 Coating plate at front edge
Clamping the front edge
SC.B01.1334-000GRAUND_00
1 1. Move the two clamping bars of the front clamping
device (Fig. 42/1) down and close them.
2. Remove the pin wrench.
Fig. 42 Closing the clamping bars
B.11.28 SC.999.0020/01
Coating unit
Note
SC.B01.1335-000GRAUND_00
1 Hold the coating plate and packing sheet
under a constant tension.
3. Press the Positioning button.
The pressing roller is laid on the coating plate.
The coating blanket cylinder turns up to the rear
edge and pulls in the coating plate (Fig. 43/1) with
the packing sheet.
Fig. 43 Pulling in the coating plate
SC.B01.1336-000GRAUND_00 Clamping the rear edge
1
1. Push the rear plate edge (Fig. 44/1) into the rear
clamping device.
Fig. 44 Press in rear edge of plate
2. Close the two clamping bars at the rear clamping
SC.B01.1315-000GRAUND_00
1 1 device (Fig. 45/1).
3. Remove the pin wrench.
Fig. 45 Closing the rear clamping bars
SC.999.0020/01 B.11.29
Coating unit
4. Disengage the pressing roller.
SC.B01.1357-000GRAUND_00
Press the Pressing roller ON/OFF button
(Fig. 46/1).
0,01mm 0,01mm
Fig. 46 Disengaging the pressing roller
Clamping the coating plate
SC.B01.1362-000GRAUND_00
1 2
Caution - Damage to the coating plate
if torque is too great!
Use the torque wrench supplied with the
press to tension the coating plate. Ten-
sion the coating plate with the specified
tightening torque.
Direction of rotation: clockwise in each
case.
1. First clamp the coating plate using the spindle at
3 the rear edge (Fig. 47/2).
2. Then clamp the coating plate using the spindle at
Fig. 47 Clamping rear edge and front edge the front edge (Fig. 47/1).
Tightening torque
● Coating plate with aluminum base: 30 Nm
● Coating plate with polyester base (PET base):
30 Nm. (Guide value for coating plates with
0.4 mm PET base).
Note
The pointer for the lead edge of print
(Fig. 47/3) should now be positioned in
the middle (mark).
3. Close all open guards.
4. Deselect the control panel at the coating unit
again.
The LED in the button Control panel selection
goes dark.
B.11.30 SC.999.0020/01
Coating unit
5 Positioning corrections on the coating blanket cylinder with combination
SC.B01.1302-000UTKENU_00
clamping rails
5.1 Print length adjustment for coating plates
Coating plates have a larger layer thickness than stan-
dard offset plates For this reason, expose the coating
plate in a special drum-type image setter. If no drum-
type image setter is available, the master must be op-
tically distorted as required.
You can carry out smaller corrections by changing the
packing beneath the coating plate:
● To reduce the thickness of the underlays: the
print image of the coating form becomes longer.
● To increase the thickness of the underlays: the
print image of the coating form becomes shorter.
This requires that you remove the coating plate and
remove or add packing sheets and then mount the
coating plate again.
● A packing thickness of 0.05 mm represents a
print length of roughly 0.25 mm with maximum
sheet size.
● To obtain an optimal printing pressure again, you
need to adjust the impression and cylinder-to-
cylinder pressure as required.
5.2 Positioning corrections on the coating plate
Arrow markings
SC.B01.1358-000GRAUND_00
2 The arrow markings on the permanently mounted red
guard (Fig. 48) show the direction of rotation in which
the hexagon must be turned to shift the coating plate/
coating blanket in the circumferential direction.
1. Turn the hexagon clockwise in each case
.
● Pull rear edge (Fig. 48/1)
● Pull front edge (Fig. 48/2)
Fig. 48 Arrow markings
SC.999.0020/01 B.11.31
Coating unit
5.2.1 Tensioning/buckling the rear edge of the coating plate
Zonal corrections of the coating plate
SC.B01.1361-000GRAUND_00
1 Zonal corrections can only be performed at the rear
edge of the coating plate in the lateral direction and in
the circumferential direction. As the rear clamping bar
is divided into two segments, all zones can be adjusted
independently of one another.
Zonal corrections can only be carried out on coating
plates. Coating blankets do not permit zonal correc-
tions.
If the rear edge of the plate is to be tensioned or buck-
led, shift the corresponding segment (Fig. 49/1). To do
Fig. 49 Shifting the segment this, turn the related hexagon (Fig. 49/2).
To do this, use the pin wrench with T-handle, 10 mm
width across flats.
SC.B01.1360-000GRAUND_00
1 2
Fig. 50 Tensioning and buckling the rear edge
Caution - The coating plate can be
damaged during stretching or buck-
ling!
Only carry out zonal corrections carefully
and in small steps.
Direction of rotation on hexagon:
● Hexagon left of center (Fig. 50/1):
○
Counterclockwise : the plate is ten-
sioned.
○
Clockwise : the plate is buckled.
● Hexagon right of center (Fig. 50/2):
○
Clockwise : the plate is tensioned.
○
Counterclockwise : the plate is
buckled.
B.11.32 SC.999.0020/01
Coating unit
5.2.2 Zonal corrections in the circumferential direction
The clamping bar of the rear edge is divided on D.S.
SC.B01.1365-000GRAUND_00
(Fig. 51/1) and on O.S. (Fig. 51/2) into two individual
segments each. The coating plate can be zonally
clamped with the individual segments. Two hexagon-
head screws (Fig. 51/2) per segment are provided for
1
pulling the plate.
Carry out the zonal corrections in the circumferential
direction by turning the hexagon-head screws.
Use the pin wrench with a fork wrench for this purpose.
Direction of rotation on hexagon-head screw:
●
Clockwise : The hexagon-head screw
pulls the corresponding segment with the rear
edge of the plate in the circumferential direction.
2
●
Counterclockwise : The hexagon-head
screw releases the corresponding segment.
Turn the hexagon-head screw counterclockwise
up to the stop.
Fig. 51 Zonally clamping the coating plate
Zero position
Note
In order to be able to make use of the
maximum pull distance when tensioning
the next coating plate, the four hexagon-
head screws must be turned back into
the zero position after removing the
coating plate.
1. Turn the four hexagon-head screws (Fig. 51/2)
counterclockwise until the screws are loose.
Then tighten the screws slightly again.
SC.999.0020/01 B.11.33
Coating unit
5.2.3 Shifting the coating plate in the circumferential direction - Manual circumferential
register
Displaying the print start
SC.B01.1363-000GRAUND_00
Depending on the print job, it may be necessary to
move the print start of the plate in circumferential di-
rection. With the coating blanket cylinder, the front
edge of the plate can be adjusted within a range of
approx. ± 1 mm.
The pointer (Fig. 52/2) is set to the basic "zero" posi-
tion ex factory. If necessary, the print start can be
changed using the spindle (Fig. 52/1):
Direction of rotation of the spindle
●
Clockwise : The print start moves to-
wards the cylinder gap.
or
●
Counterclockwise : The print start moves
1 towards the rear edge.
Fig. 52 Changing the print start on the coating The pointer (Fig. 52/2) indicates the current position.
plate
Changing the print start
SC.B01.1362-000GRAUND_00
1 2 1. Loosen the coating plate at the spindle at the rear
edge (Fig. 53/2).
The central spindle (Fig. 53/1) does not need to
be loosened.
2. Turn the spindle at the front edge until the pointer
(Fig. 53/3) is set to the desired position (mark).
The pointer moves and points with the flat side to the
actual position of the lead edge of the plate.
Fig. 53 Loosen the spindles
Clamping the coating plate
SC.B01.1342-001GRAUND_00
1
Caution - Damage to the coating plate
if torque is too great!
Use the torque wrench supplied with the
press to tension the coating plate. Ten-
sion the coating plate applying the spec-
ified tightening torque.
Direction of rotation: clockwise in each case
3. First clamp the coating plate using the spindle at
the rear edge (Fig. 54/1).
4. Then clamp the coating plate using the spindle at
2
the front edge (Fig. 54/2).
Fig. 54 Clamping the front edge/rear edge Tightening torque
Aluminum base: 30 Nm
Polyester base (PET base): 30 Nm
B.11.34 SC.999.0020/01
Coating unit
Note
Recommended value for coating plates
with 0.4 mm PET base.
SC.999.0020/01 B.11.35
Coating unit
6 Pressing roller
SC.B01.1303-000UTKENU_00
6.1 Place of installation / function
Place of installation
SC.B01.1353-000GRAUND_00
1 2 The pressing roller (Fig. 55/2) is located behind the
black guard (Fig. 55/1) above the cylinder.
Function
The pressing roller presses the plate onto the cylinder
during the mounting procedure. This guarantees an
axially parallel mounting of the plate.
Fig. 55 Place of installation for the pressing roller
Selecting the pressing roller
SC.B01.1357-000GRAUND_00
1. Press the Pressing roller ON/OFF button
(Fig. 56/1).
The Pressing roller ON/OFF button lights up.
2. Press the Positioning button.
0,01mm 0,01mm The pressing roller is thrown onto the cylinder.
Note
The pressing roller is not thrown on if it is
positioned above the cylinder gap. How-
ever, the button Pressing roller ON/OFF
is lit. The pressing roller is thrown on au-
tomatically when the press is inched for-
ward.
Fig. 56 Coating unit control panel on O.S., prese-
lecting the pressing roller
B.11.36 SC.999.0020/01
Coating unit
6.2 Removing/fitting the pressing roller
Note
SC.B01.1355-000GRAUND_00
1
Make sure the pressing roller is thrown
off before removal/installation. The but-
ton Pressing roller ON/OFF (Fig. 56/1) is
not lit.
Removal
1. Open the guard in front of the pressing roller.
2. Push the pressing roller (Fig. 57/1) towards D.S.
(Fig. 57/arrow) against the spring force.
3. Take the pressing roller out of the press, first on
O.S., then on D.S.
Fig. 57 Removing the pressing roller
Installation
SC.B01.1356-000GRAUND_00
1 2
When inserting the pressing roller, make sure that:
● the spring-loaded ball stud (Fig. 58/1) is on D.S.,
● the rigid stud (Fig. 58/2) is on O.S.
Fig. 58 Pressing roller, mounting position
1. Insert the spring-loaded ball stud of the pressing
SC.B01.1355-000GRAUND_00
1 roller (Fig. 59/1) into the borehole on D.S.
2. Push the pressing roller towards D.S. and insert
the rigid bearing stud into the borehole on O.S.
Note
Make sure that both bearing bolts have
properly locked in place.
Fig. 59 Installing the pressing roller
SC.999.0020/01 B.11.37
Coating unit
Fig. 60 shows a correctly installed pressing roller.
SC.B01.1354-000GRAUND_00
A.S. B.S.
D.S. O.S.
C.E. C.S.
L.I. L.S.
L.V. L.M.
Fig. 60 Pressing roller installed
3. Close the guard (Fig. 61/1) in front of the pressing
SC.B01.1353-000GRAUND_00
1 2 roller (Fig. 61/2).
Fig. 61 Closing the guard
6.3 Cleaning
Keep the guard clean so that its protection function can
be guaranteed at all times.
Clean the pressing roller regularly. You will find notes
on this in the separate "Maintenance and cleaning,
customer" manual.
Remove the pressing roller from the unit for cleaning.
Please refer to the section "Removing/fitting the press-
ing roller" for more information.
B.11.38 SC.999.0020/01
Coating unit
7 Notes on treatment of the screen roller
SG.901.1713-000UTKENU_05
7.1 Bearing
The screen roller is a sensitive precision component
and requires careful treatment. The following must be
observed:
● Store and transport the screen roller in the case
provided or in a corresponding device.
● Never use a felt pen or anything similar to mark
the surface.
● Protect the surface against soiling, e.g. by means
of oil or grease.
● Keep the screen roller dry for packing and stor-
age.
● Protect the screen roller against large tempera-
ture fluctuations.
7.2 Transport
● Never touch the surface.
● The screen roller should not be exposed to
shocks or blows during transport, removal or in-
stallation. The edges of the screen roller are par-
ticularly sensitive.
● Always use the mounting tool and the hook-
shaped handle for installing and removing the
screen roller.
● Always pack the screen roller for transport. Se-
cure the screen roller inside the transport crate.
7.3 Cleaning
Clean the screen roller while the coating is still fresh, is
in solution with water and can still be thinned. This is
the only way to remove varnish residues which are
even deep in the cups. Once the coating has started to
dry in the cavities, the scoop volume of the screen
roller is reduced.
In this case it is necessary to clean them with chemi-
cals or by mechanical or ultrasonic means. This caus-
es increased work and costs.
Detailed instructions on cleaning are available in the
Customer Maintenance and Cleaning manual.
SC.999.0020/01 B.11.39
Coating unit
8 Screen roller
SC.B01.1306-000UTKENU_01
8.1 Function
There are numerous small recesses (cells) on the sur-
SC.B01.1381-000GRAUND_00
2 1 face of the screen roller (Fig. 62/2). The cells fill up with
varnish in the chambered doctor blade (Fig. 62/1). The
doctor blades on the chambered doctor blade dis-
tribute the varnish evenly between the cells and
scrape off any excess varnish from the raised sections
of the screen roller.
The number and size of the cells determine the cell
volume of the screen roller.
The metering of the varnish volume is controlled by
using different screen rollers.
Fig. 62 Screen roller, chambered blade
8.2 Notes on cleaning the screen roller
1. Clean the screen roller.
You need to clean the screen roller while the varnish is
still fresh and can be solubilized and thinned with water
or cleaning agent (UV varnish). Only then can you re-
move residual varnish from the bottom of the cells.
Once the coating has started to dry in the cavities, the
scoop volume of the screen roller is reduced.
If the varnish is dried on, you have to clean the screen
roller using chemical or mechanical means or by ul-
trasound.
Note
Further information and notes on clean-
ing the screen rollers can be found in the
"Coating unit, Notes on handling screen
rollers" chapter.
B.11.40 SC.999.0020/01
Coating unit
8.3 Removing screen roller
Required tools
SC.B01.1322-000GRAUND_00
You need the following tools to change the screen
roller:
● Operator tool
● Lifting sling (Fig. 63)
The lifting sling is not suitable for use with a
crane.
To open and close the bearing shells, us the operator
tool provided only. Other tools may damage the
hexagon.
The tools are included in the press items supplied.
Preparation for removal
Fig. 63 Lifting sling ● You can have the chambered blade installed.
If you want to remove the chambered blade, you
can find information on this in the "Coating unit,
chambered blade and pressurized chambered
blade" chapter. Observe, in particular, the warn-
ings and safety instructions for handling the
chambered blade.
● Prepare the crate provided for laying down the
screen roller.
● Lay out the lifting sling (Fig. 63) provided.
Caution - Improper handling can dam-
age the screen roller!
The screen roller is a precision compo-
nent which may become damaged by
impact. Read the "Notes on handling
screen rollers" before removing the
screen roller.
SC.999.0020/01 B.11.41
Coating unit
1. Select the control panel (Fig. 64/1).
SC.B01.1320-000GRAUND_00
1 Press the Control panel selection button twice in
quick succession.
The LED in the button lights up. The control panel
is selected.
0,01mm 0,01mm Note
Leave the coating unit selected during
the entire screen roller change.
Fig. 64 Control panel selection
2. Push back the guard above the screen roller by
SC.B01.1323-000GRAUND_00
1 the handle (Fig. 65/1).
The screen roller is now easily accessible from above.
Fig. 65 Opening the guard
B.11.42 SC.999.0020/01
Coating unit
3. Turn the screen roller by hand until the driver
SC.B01.1328-000GRAUND_00
1 (Fig. 66/1) is positioned so that you can lift out the
screen roller towards the top.
Fig. 66 Driver is vertical
Functioning principle of the roller lock
SC.B01.1332-000GRAUND_00
1 2 The position of the lock is indicated by a white mark.
Opening the lock:
1. Push down the latch (Fig. 67/1) with the operator
tool. The lock deflects by about 3 mm.
2. Turn the latch approx. 180° (Fig. 67/2).
The latch engages in this position.
On D.S.: Turn clockwise .
On O.S.: Turn counterclockwise .
Closing the lock:
1. Turn the latch approx. 180°.
Fig. 67 Lock: D.S. On D.S.: Turn counterclockwise .
On O.S.: Turn clockwise .
The latch is lifted by spring pressure.
2. Make sure the latch is pressed up correctly
against the journal box (Fig. 67/1).
SC.999.0020/01 B.11.43
Coating unit
Opening the locking device
SC.B01.1325-000GRAUND_00
On D.S.:
1. Push down the latch (Fig. 68/1) with the operator
tool and turn the latch.
Turning direction: clockwise
The latch engages.
Fig. 68 Locking device on D.S. closed
On O.S.:
SC.B01.1326-001GRAUND_00
2. Push down the latch (Fig. 69/1) with the operator
tool and turn the latch.
Turning direction: counterclockwise
The latch engages.
Fig. 69 Locking device on O.S. closed
B.11.44 SC.999.0020/01
Coating unit
Fitting the hook lugs
SC.B01.1331-000GRAUND_00
1
Note
The screen roller weighs approximately
23 kg. To remove/install the screen
roller, enlist the help of a second opera-
tor if necessary.
Use the lifting sling provided to lift the
screen roller out of the coating unit.
The lifting sling is not suitable for use
with a crane.
Make sure that you do not knock any ad-
jacent press parts with the screen roller
when you lift it out.
3. If necessary, correct the removal position of the
screen roller until the flat section (Fig. 70/arrow)
is at the top.
There are two flat sections on the ring that are
offset by 180°.
4. Fit the hook lugs (Fig. 72/1) into the ring from be-
low on D.S. and O.S.
5. Make sure the plate spring (Fig. 70/1) engages
correctly above the flat section.
Fig. 70 Attaching the hook correctly: O.S.
6. Make sure the two yellow marks (Fig. 71/1) are
SC.B01.1333-000GRAUND_00
visible as shown.
Now you can lift the screen roller up and out of the
coating unit.
Fig. 71 Yellow mark
SC.999.0020/01 B.11.45
Coating unit
Removing the screen roller
SC.B01.1327-000GRAUND_00
1. Carefully lift the screen roller up and out of the
coating unit, with the assistance of a second op-
erator if necessary.
Caution - Damage to the screen roller
caused by incorrect storage
Contact with the floor can damage the
roller surface. Place the screen roller on-
to the journal only.
2. Place the screen roller into the prepared crate or
on the support on the coating unit (Fig. 72/1).
1 1
Fig. 72 Carefully setting down the screen roller
8.4 Installing screen roller
Note
SC.B01.1322-000GRAUND_00
Ensure that everything is clean. Soiling
will cause concentricity errors and mal-
functions.
Preparing for installation
● The chambered blade is removed.
● The roller locks on D.S. and O.S. in the coating
unit must be open.
Open the locks, if necessary.
● The driver on the screen roller should be covered
with a thin film of grease.
If necessary, spread a thin, even layer of grease
onto the driver on the screen roller. Information
Fig. 73 Lifting sling
on approved lubricants is available in the "Main-
tenance and cleaning, customer" manual.
● Turn the screen roller so that the flat sections at
the face-side rings are at the top (mounting po-
sition).
Note
Use the lifting sling provided (Fig. 73) to
lift the screen roller into the coating unit.
Make sure that you do not knock adja-
cent press parts with the screen roller
when you lift it in.
B.11.46 SC.999.0020/01
Coating unit
1. Select the control panel.
SC.B01.1320-000GRAUND_00
1 Press the Control panel selection button twice in
quick succession.
The LED in the button lights up. The control panel
is selected.
0,01mm 0,01mm Note
Leave the coating unit selected during
the entire screen roller change.
2. Inch the press, if necessary, to move the seat of
the driver to the vertical position.
Fig. 74 Control panel selection
Installing the screen roller
SC.B01.1331-000GRAUND_00
1
Note
The screen roller weighs approximately
23 kg. To remove/install the screen
roller, enlist the help of a second opera-
tor if necessary.
1. Fit the hook lugs correctly on D.S. and O.S. The
plate spring (Fig. 75/1) has engaged.
Fig. 75 Fitting the hook lug correctly
SC.999.0020/01 B.11.47
Coating unit
2. Make sure the two yellow marks (Fig. 76/1) are
SC.B01.1333-000GRAUND_00
visible as shown.
Fig. 76 Yellow mark
Note
SC.B01.1327-000GRAUND_00
The driver is positioned on D.S.
3. Carefully lift the screen roller into the bearing
shells on D.S. and O.S., ensuring it is in the cor-
rect mounting position; enlist the help of second
operator if necessary.
1 1
Fig. 77 Lifting the screen roller into the coating unit
B.11.48 SC.999.0020/01
Coating unit
4. Remove the hook lugs (Fig. 78/1) on D.S. and
SC.B01.1330-000GRAUND_00
1 2 3 O.S. from the screen roller.
● Push the hook lug firmly down.
● The plate spring (Fig. 78/2) rebounds and
you can detach the hook lug from the ring
(Fig. 78/3).
Fig. 78 Removing the hook lug: O.S.
On D.S.:
SC.B01.1325-000GRAUND_00
5. Turn the latch (Fig. 79/1) 180° using the operator
tool.
The latch disengages and springs up about
3 mm.
Turning direction: counterclockwise
6. Keep turning the latch until you hit the stop.
Watch the white mark.
1
Fig. 79 D.S. lock closed correctly
SC.999.0020/01 B.11.49
Coating unit
On O.S.:
SC.B01.1326-001GRAUND_00
7. Turn the latch (Fig. 80/1) 180° using the operator
tool.
The latch disengages and springs up about
3 mm.
Turning direction: clockwise
8. Keep turning the latch until you hit the stop.
Watch the white mark.
1
Fig. 80 O.S. lock closed correctly
Finally:
SC.B01.1324-000GRAUND_00
1 9. Close the guard above the screen roller by the
handle (Fig. 81/1).
Fig. 81 Closing the guard
B.11.50 SC.999.0020/01
Coating unit
9 Fitting/removing rolling bearings
SF.901.6015-000UTKENU_00
9.1 Changing bearings on screen rollers and metering rollers
Caution - Damage to the rolling bear-
ing caused by washing fluid!
Remove the two rolling bearings from
the metering roller or screen roller before
placing the roller into a cleaning bath.
The press is supplied with an extractor (Fig. 82) for
SF.901.0052-000GRAUND_00
removing rolling bearings from the screen roller or me-
tering roller. This extractor is also used to fit new rolling
bearings to rollers.
Requirement
The roller has been removed and is
clean.
The drive cup on D.S. and the roller cov-
er on O.S. have been removed.
Fig. 82 Extractor
9.2 Removing the rolling bearing from the trunnion
Follow the steps below to remove the rolling bearing
SF.901.0053-000GRAUND_00
from the trunnion:
1. Push the extractor from the side onto the rolling
bearing on the trunnion (Fig. 83).
2. Screw the threaded rod with the larger diameter
into the thread until the threaded rod has con-
tract.
Use a fork wrench with a width across flats of 17 to
perform the next step.
3. Using the fork wrench, turn the threaded rod
clockwise at the wrench flat.
The blanket extractor moves away from the trun-
nion. The claws pull the rolling bearing off the
trunnions.
Fig. 83 Removing the rolling bearing
SC.999.0020/01 B.11.51
Coating unit
9.3 Fitting the rolling bearings on the trunnion
Follow the steps below to fit the rolling bearing on the
SF.901.0054-000GRAUND_00
trunnion:
1. Clean the trunnion thoroughly and grease it light-
ly before fitting the rolling bearing on the trunnion.
2. Insert the rolling bearing into the extractor.
Note
Make sure that the extractor and rolling
bearing are properly aligned.
3. Slide the extractor onto the trunnion by hand as
far as it will go.
4. Insert the threaded rod with the small diameter
through the hole in the extractor (Fig. 84).
The trunnion has a thread into which you can screw the
threaded rod.
5. Screw the threaded rod into the trunnion by hand
as far as it will go.
Use a fork wrench with a width across flats of 17 to
perform the next step.
6. Use the fork wrench to screw the threaded rod
Fig. 84 Fitting the rolling bearings into the trunnion.
The rolling bearing is moved onto the trunnion.
The rolling bearing is properly fitted when it is in con-
tact with the shoulder of the trunnion. It is not possible
to screw in the threaded rod any further.
7. Screw the drive clutch and bearing cap of the
metering roller or screen roller back on.
B.11.52 SC.999.0020/01
Coating unit
10 Chambered blade and pressurized chambered blade
SC.B01.3050-000UTKENU_02
10.1 Overview
This chapter contains a description of the standard
chambered blade operated in volume flow control
mode and of the pressurized chambered blade oper-
ated with pressure control.
You can use the chambered blade in connection with a
standard varnish supply unit, with CoatingStar or
CoatingStar Compact.
The pressurized chambered blade requires a varnish
supply unit which is able to operate pressure control
and suction with separate pumps. The pressurized
chambered blade is only available in connection with
CoatingStar or CoatingStar Compact.
The standard chambered blade and the pressurized
chambered blade only have minor differences in their
design. The differences in the settings are described in
the following sections.
If a text refers to both blade versions, then the term
"chambered blade" will be used synonymously for both
blade versions.
Standard chambered blade
SC.B01.1375-000GRAUND_00
The standard chambered blade (Fig. 85/1) is part of
the standard equipment.
Only the varnish volume which is circulated without
pressure (volume flow control) can be set.
Fig. 85 Standard chambered blade (unpressurized)
Pressurized chambered blade
SC.B01.1372-000GRAUND_00
The pressurized chambered blade is special equip-
ment.
If you want to operate the coating unit with pressure
control you need to use the pressurized chambered
blade.
The pressurized chambered blade requires a varnish
supply unit that is able to regulate pressure and suc-
tion via separate pumps (CoatingStar or CoatingStar
Compact).
Fig. 86 Pressurized chambered blade
SC.999.0020/01 B.11.53
Coating unit
Note
The standard varnish supply unit in-
cludes 2 independent varnish pumps.
When varnish or cleaner is pumped back
into the unit, both pumps work simulta-
neously. This considerably reduces the
quantity of varnish or cleaner remaining
in the varnish circuit compared to earlier-
model varnish supply units.
On the pressurized chambered blade (Fig. 87/1) de-
SC.B01.1376-000GRAUND_00
3 fined pressure is generated in the varnish return flow
2 through a reducing valve fitted inside (Fig. 87/3). The
varnish can flow off into the coating pan through the
reducing valve.
The varnish is pumped back from the coating pan into
the varnish tank. The pressure in the chamber must be
kept at a constant level. To this end there is a pressure
sensor installed in the varnish supply line that is used
to control the pressure in the chamber. The pressure
1 sensor is read directly by the control system of the
varnish supply unit.
Fig. 87 Pressurized chambered blade To ensure the durable functioning of the relief valve
(Fig. 87/2) you must remove and clean the relief valve
at regular intervals. You can find notes on this in the
"Maintenance and cleaning, customer" manual.
You can also operate the pressurized chambered
blade as a chambered blade without modifying it. You
can find notes on this in the section "Setting the pres-
sure".
If the coating unit is to be operated on a press with
volume flow control, a standard chambered blade
should ideally be used.
10.2 Function
The components of the chambered blade (Fig. 88/1)
SC.B01.1381-000GRAUND_00
2 1 and the screen roller (Fig. 88/2) form a closed varnish
chamber.
The chambered doctor blade ensures an even distri-
bution of the varnish in the cells of the screen roller. It
wipes off excess varnish on the cell walls.
Fig. 88 Principle design
B.11.54 SC.999.0020/01
Coating unit
Fig. 89 and Fig. 90 show the principle differences of
SC.B01.1373-000GRAUND_00
the flow routes of the varnish.
The varnish is pumped from the varnish supply unit
through the supply hoses into the chambered blade/
pressurized chambered blade.
● Standard chambered blade (Fig. 89)
After the varnish has run though the varnish
chamber any excess varnish flows without pres-
sure into the coating pan.
Fig. 89 Schematic diagram of the varnish flow in the
standard chambered blade
● Pressurized chambered blade (Fig. 90)
SC.B01.1374-000GRAUND_00
1 The adjustable reducing valve (Fig. 90/1) in the
varnish return flow ensures that a sufficient pres-
sure is generated in the varnish chamber.
Fig. 90 Schematic diagram of the varnish flow in the
pressurized chambered blade
SC.999.0020/01 B.11.55
Coating unit
Design
SC.B01.1382-000GRAUND_00
B.S. 1 Working blade
1 2 3
O.S. 2 Working blade holder
C.S.
L.S. 3 Eccentric shaft, operable from D.S.
L.M.
4 Closing blade
5 Closing blade holder
6 Eccentric shaft, operable from D.S.
7 Doctor blade housing
7 8 2 retaining springs
9 2 gaskets
8
9
4 5 6
Fig. 91 Design of chambered blade
The "Chambered blade ON/OFF" function
SC.B01.1368-000GRAUND_00
The chambered blade is engaged and disengaged by
2 pneumatic cylinders (Fig. 92/1) via a toggle lever
mechanism (Fig. 92/2).
Note
The two pneumatic cylinders are under
1 pressure during the switching operation.
When the chambered blade is engaged,
the pressure is 0 bar.
When the chambered blade is disen-
gaged, the pressure is 6 bars.
Fig. 92 Toggle lever mechanism "Chambered blade
on/off," here O.S.
B.11.56 SC.999.0020/01
Coating unit
1. Press the Chambered blade on/off button
SC.B01.1367-004GRAUND_00
+
(Fig. 93/1) on the feeder side control panel on
O.S. twice in quick succession.
1
10.119.9299
Fig. 93 Control panel coating unit O.S., feeder side
10.3 Preparing the chambered blade
To prepare the chambered blade you need the follow-
SC.B01.1383-000GRAUND_00
3 ing:
● 2 gaskets (Fig. 94/1)
● 2 retaining springs (Fig. 94/2)
2 ● doctor blade housing (Fig. 94/3) with doctor blade
supports
1
● one roll of continuous doctor blade or prepared
doctor blade
Fig. 94 Preparing the O.S. chambered blade
SC.999.0020/01 B.11.57
Coating unit
Blade variants
SC.B01.1384-000GRAUND_00
You can use 2 blade versions in your chambered
blade:
● Steel - steel
or
● Steel - plastics
1
Working blade
The working blade (Fig. 95/1) must always be made of
steel.
Closing blade
The closing blade can either be made of plastic
(Fig. 95/2) or steel (Fig. 95/3).
Whether you use the closing blade made of plastic or
steel depends on several parameters such as varnish
type, viscosity etc. It is therefore impossible to make
specifications across the board. We recommend using
the steel closing blade with UV varnishes. The plastic
closing blade can be preferably used when processing
dispersion varnishes.
When inserting the blades pay attention to the follow-
ing:
● The ground blade edge of the steel blades
(Fig. 95/1, 95/3) is located on the inside (Fig. 95/
arrow).
● The plastic closing blade (Fig. 95/2) has a large
chamfer surface which is visible from the outside.
● The blades must rest against the rear edge of the
2 groove so that the front edge is parallel to the
blade holder. Remove any varnish residue or im-
purities from the blade holders if necessary.
3 Note
Always use 2 steel blades to adjust the
chambered blade.
Fig. 95 Steel blade and plastic blade
Wear and tear of the blade
You should replace the blade when the sharpened
blade is worn or shows signs of damage. You also
need to replace defective gaskets.
B.11.58 SC.999.0020/01
Coating unit
Required tools
FS.901.1060-000GRAUND_00
● Vise-grip pliers (Fig. 96/1)
3
● Tin shears (Fig. 96/2)
● Operating key for eccentric shaft (Fig. 96/3)
● Protective gloves
2
1
Fig. 96 Required tools
1 Working blade
1 LS.901.1062-000GRAUND_00
2 Closing blade
● The corner section on the closing blade (Fig. 97/
A) always starts in the center of the gaskets.
2 ● Gasket width (Fig. 97/B)
1 Cutting the blade to size
1. Put on protective gloves.
2. Using the sheet metal snips, cut off 2 pieces,
each with a length of 1066 mm from the contin-
uous blade (one working blade and one closing
blade).
Note
The working blade will not have to be cut
B at the corners and can thus be inserted
45° directly into the chambered blade.
2 Cutting the closing blade to size
A Note
Cropping the corners prevents the build-
up of varnish in the corners of the cham-
Fig. 97 Corner section on the closing blade bered blade.
1. Hold the cut-off blade knife against the cham-
bered blade and align it centrally.
2. On the closing blade, mark the center of the gas-
kets (Fig. 97/A).
3. Cut off the two corners of the closing blade at an
angle of approx. 45°.
The built-in doctor blades may not protrude on the side
over the blade housing.
SC.999.0020/01 B.11.59
Coating unit
Inserting the doctor blades
SC.B01.1385-000GRAUND_00
A.S. 1. Loosen the eccentric shafts (Fig. 98/4) using the
D.S. operator tool (Fig. 98/1).
C.E. 2. Slide the doctor blade (Fig. 98/2) under the doc-
L.I. tor blade holder (Fig. 98/3).
L.V.
Insert both doctor blades laterally into the doctor blade
1 housing so that they are flush with the edge.
Note
Pay attention to the position of the cham-
fer on the two doctor blades.
3. Lock the eccentric shafts with the operator tool to
secure the two doctor blades.
4
2 3 4
Fig. 98 Installing and clamping doctor blade, here
on D.S.
Inserting the gaskets
SC.B01.1386-000GRAUND_00
B.S. 1. Moisten the gasket (Fig. 99/2) with water. This
O.S. will facilitate fitting and ensure that the seal is ly-
C.S. ing properly on the blade mounting.
L.S. 2. Press the gasket slightly together. Guide the gas-
L.M. ket with the closed side outwards into the blade
mounting.
Using the vise-grip wrench, push the gasket care-
fully towards the outside until it is positioned in
the doctor blade holder such that it is flush with
the outer edge.
3. Pick up the retaining spring (Fig. 99/1) with the
pliers and insert the spring into the doctor blade
holder.
Slide the retaining spring outward until it is in
contact with the gasket.
1
2
Fig. 99 Inserting the gasket
B.11.60 SC.999.0020/01
Coating unit
10.4 Installing the coating pan
Note
SC.B01.1387-000GRAUND_00
The coating pan must be installed be-
fore the chambered blade is installed.
1. Open the coating unit guard on the feeder side.
2. Connect the drain hose of the coating pan to the
1 coupling of the coating unit.
3. Place the short journals (Fig. 100/1) of the coat-
ing pan onto the rails on both sides (Fig. 100/2).
4. Slide the pan along the rails into the coating unit.
2
5. Allow the long journals to engage in the retaining
springs from above (Fig. 100/3).
6. Check the proper seat of the coating pan.
Fig. 100 Installing the coating pan
Baffle plate
SC.B01.1388-000GRAUND_00
If you operate the coating unit on your machine with a
1 standard varnish supply unit, you can fit the baffle plate
(Fig. 101/1).
If varnish pressure control is used (only with
CoatingStar and CoatingStar Compact), the baffle
plate must not be fitted.
1. Attach the baffle plate from above onto the coat-
ing pan.
The baffle plate is held in place by the spring
shackle.
Fig. 101 Fitting the baffle plate 2. Close the feeder-side guard on the coating unit.
SC.999.0020/01 B.11.61
Coating unit
Sensor
SC.B01.1393-000GRAUND_00
1
If liquid collects under the coating pan in the splash
guard (Fig. 102/1), this is recorded by a sensor
(Fig. 102/2).
The message "Varnish level not OK" appears on the
control station. Then you have to clean the splash
guard.
You can find further notes on this in the "Maintenance
and cleaning, customer" manual.
A.S.
D.S.
C.E.
L.I.
L.V.
2
Fig. 102 Sensor
B.11.62 SC.999.0020/01
Coating unit
10.5 Fitting the chambered blade
Note
SC.B01.1377-001GRAUND_00
A.S. The chambered blade must be disen-
D.S. gaged for installation.
C.E.
L.I. 1. Put on protective gloves.
L.V.
2. Open the coating unit guard on the feeder side.
7 3. Swing up the latches on D.S. (Fig. 103/2) and
O.S.
2
4. Grasp the chambered blade by the profiles on
both sides (Fig. 103/3).
Attach the chambered blade in the mounting fix-
tures on D.S. (Fig. 103/1) and O.S.
1 5. Swing down the latches on D.S. (Fig. 103/2) and
O.S.
2
6. Make sure that both latches have properly locked
in place.
3
7. Make sure the locking bolts on D.S. (Fig. 103/7)
and O.S. have moved over the guide bolts of the
4 chambered blade.
8. Connect the supply hose (Fig. 103/6) to the cou-
plings of the chambered blade (Fig. 103/5) and
the coating unit (Fig. 103/4).
Both ends are fitted with the same coupling.
9. Close the coating unit guard on the feeder side.
6
5
Fig. 103 Mounting the chambered blade
10.6 Coating operation
Preparing the coating operation
Note
Only start the coating operation once
you have set up the print job completely.
In this way you prevent the varnish from
hardening. The same applies to print in-
terruptions.
The following steps can only be performed while the
chambered blade is disengaged.
1. Make the following settings on the control sys-
tem:
● Preselect the screen roller
● Preselect the chambered blade or the pres-
surized chambered blade
SC.999.0020/01 B.11.63
Coating unit
● Preselect the level control if necessary. It
can also be activated with the chambered
blade engaged.
See the operating manual for the control
station.
The Varnish metering roller on/off button
(Fig. 104/1) on the feeder side control panel on
O.S. flashes.
2. Open the guards as required.
3. Insert the screen roller required for the relevant
varnish volume.
4. Insert the coating pan and then the chambered
blade into the coating unit.
5. Swing the chambered blade onto the screen
SC.B01.1367-001GRAUND_00
roller.
4 + 1
Press the Chambered blade on/off button
(Fig. 104/2) on the feeder side control panel on
3 2 O.S. twice in quick succession.
Note
The varnish can only be circulated when
Fig. 104 Control panel coating unit O.S., feeder side
the chambered blade is engaged with
the screen roller.
6. Close all guards.
The screen roller starts to rotate automatically.
7. Check the rotation of the screen roller.
Activating the coating unit
Requirement
Suction set 1 is in the varnish tank.
CoatingStar only: The suction set 2 must
be in the rinsing tank.
The chambered blade is prepared as de-
scribed in the "Preparing the chambered
blade" section.
1. Press the Varnish circulation (Fig. 104/4) on the
feeder side control panel on O.S.
The Circulate varnish button lights up.
2. Press the Varnish pump on/off (Fig. 104/3) on the
feeder side control panel on O.S.
The Varnish pump ON/OFF button lights up.
B.11.64 SC.999.0020/01
Coating unit
Setting the pressure of the pressurized cham-
FS.901.1032-000GRAUND_01
bered blade
If you run the chambered blade as closed pressurized
chambered blade in pressure control mode, you have
to preselect the desired pressure on the feeder-side
1 control panel or on the control station. Set the reducing
valve (Fig. 105/1) to your empirical value.
1. Set the pressure on the feeder-side control panel
on O.S. or on the control station.
● Press the button (Fig. 106/1) to increase the
pressure in increments of 10 mbar.
● Press the button (Fig. 106/2) to reduce the
pressure in increments of 10 mbar.
Result
The pressure indicator (Fig. 106/3) at the
control panel shows a two-digit value.
This value corresponds to 1/10 of the
Fig. 105 Reducing valve on pressurized chambered
actual pressure. In the example shown
blade
in Fig. 106, the value of 30 corresponds
SC.B01.1367-002GRAUND_00
to an actual pressure of 300 mbar.
3 1 At the control station, the pressure is
shown in the range of 50 ... 300 mbar.
2
Pressure indicator is flashing
The pressure indicator flashes if the reducing valve is
set inappropriately, if the machine is at standstill, if the
Fig. 106 Control panel coating unit O.S., feeder side varnish is circulated and the guards on the coating unit
are closed.
1. Set the reducing valve (Fig. 105/1) in such a way
that the display stops flashing.
Volume flow operation
You can operate the pressurized chambered blade in
volume flow mode. To do so you need to open the re-
ducing valve (Fig. 105/1) fully (position 9).
Please note: You can only switch from volume flow
operation to pressure control operation and vice versa
while the chamber is disengaged.
Note
If you wish to work with volume flow con-
trol all the time, use the standard cham-
bered blade without reducing valve.
Adjusting the delivery volume in volume control
SC.B01.1367-005GRAUND_00
3 1 Note
The delivery volume depends on the vis-
2 cosity of the varnish and varnish con-
sumption of the motif.
1. Adjust the delivery volume on the feeder-side
Fig. 107 Control panel coating unit O.S., feeder side control panel (Fig. 107).
Adjust the delivery volume such that a sufficient
quantity of vanish flows out of the overflow pipe
during the coating process.
SC.999.0020/01 B.11.65
Coating unit
● Press the button (Fig. 1071) to incremental-
ly increase the feed pump output by 10%.
● Press the button (Fig. 107/2) to incremen-
tally reduce the feed pump output by 10%.
Result
The indicator (Fig. 107/3) at the control
panel shows a two-digit value. This val-
ue corresponds to part of the maximum
feed capacity of the varnish pump. In the
example in Fig. 107, 08 corresponds to
exactly 80% of the maximum capacity of
the varnish pump.
10.7 Cleaning the chambered doctor blade and the coating unit
Caution - Risk of machine damage!
Do not allow the varnish to dry. In case of
a machine standstill, e. g. due to a power
failure, rinse and clean the screen roller
with water immediately.
Clean the coating unit with a suitable cleaning agent
and clean water.
Clean the coating unit thoroughly before performing
any work on the machine.
Note
Automatic cleaning functions depend on
the type of varnish supply unit connect-
ed.
Performing a cleaning procedure
SC.B01.1367-003GRAUND_00
1. Empty the chambered doctor blade and the coat-
1 + ing pan.
Press the Empty varnish supply system button
2 3 (Fig. 108/1).
The Empty varnish supply system button lights
up. The varnish is pumped out of the chambered
Fig. 108 Control panel coating unit O.S., feeder side blade and the coating pan and pumped into the
varnish tank.
Once the chambered blade and the coating pan are
empty:
2. Close the coating unit guards on the feeder and
delivery side before you start rinsing the cham-
bered blade/pressurized chambered blade.
Note
The screen roller only rotates with the
guards closed. This considerably im-
proves the tightness between the cham-
bered blade and screen roller.
3. Press the Rinse varnish supply system button
(Fig. 108/1).
The button Rinse varnish supply system lights
up.
B.11.66 SC.999.0020/01
Coating unit
Note
The rinsing solution tank must be full.
The "Rinse varnish supply system" pro-
cedure can only be started once the var-
nish supply system has been emptied for
at least 30 seconds.
The coating supply unit switches over to the rinsing
solution circuit. The chambered blade, the coating
pan, the varnish pump and the coating system are
flushed.
4. Rinse the varnish circuit while the screen roller is
turning until the chambered doctor blade, screen
roller and the coating pan are clean.
Once the system is clean:
5. Press the Empty varnish supply system button
(Fig. 108/1).
The rinsing solution is pumped off into the rinsing so-
lution tank.
Once the rinsing solution is pumped off:
6. Disengage the chambered doctor blade.
Press the Chambered blade on/off (Fig. 108/3)
on the feeder-side coating unit control panel on
O.S. twice in quick succession.
Note
The chambered blade can only be dis-
engaged after the varnish or rinsing so-
lution have been sucked off for at least
10 seconds, and the pump has been
switched off.
SC.999.0020/01 B.11.67
Coating unit
10.8 Removing the chambered blade
Note
SC.B01.1377-000GRAUND_00
A.S. The chambered blade must be disen-
D.S. gaged for removal.
C.E.
L.I. 1. Put on protective gloves.
L.V.
2. Open the coating unit guard on the feeder side.
Caution - Leaked varnish can damage
the machine!
Prior to removing the chambered doctor
blade, the chambered doctor blade,
coating pan, varnish pump and coating
system must be rinsed through and the
1 chambered doctor blade and the coating
pan emptied completely. Please refer to
2 the section "Cleaning the chambered
blade and the coating unit".
3 3. Disconnect the varnish feed hose (Fig. 109/6)
first from the coupling on the chambered blade
4 (Fig. 109/5) and then from the connection piece
in the coating unit (Fig. 109/4).
4. Swing up the latches on D.S. (Fig. 109/2) and
O.S.
5. Grasp the chambered blade by the profiles on
both sides (Fig. 109/3). Lift the chambered blade
from the mounting fixtures on D.S. (Fig. . 109/1)
and on O.S.
6. Place the chambered blade on a clean, flat sur-
face with the doctor blades facing upward.
7. Clean the chambered blade immediately.
6
5
Fig. 109 Removal of the chamber-type doctor blade
10.9 Cleaning the chambered blade
Note
Clean the chambered blade immediately
after each use. The varnish residue
hardens intensely and makes a later
change of the blades more difficult.
1. Put on protective gloves.
2. Remove the chambered blade from the coating
unit. Please refer to the section "Removing the
chambered blade".
3. Eliminate thoroughly all varnish residues.
B.11.68 SC.999.0020/01
Coating unit
Tip
When printing using dispersion varnish,
place the chambered blade in a trough
full of water immediately after use. How-
ever, the chambered blade may not re-
main in the trough overnight, but must be
taken out again after a while and dried.
4. Only put the chambered blade back in if it is com-
pletely dry.
10.10 Removing the coating pan
Caution - Risk of machine damage!
SC.B01.1389-000GRAUND_00
You must only remove the coating pan
when the machine is at standstill and
when the chambered blade is complete-
ly empty.
1
KR 1. Open the coating unit guard on the feeder side.
2. Disconnect the varnish return hose from the cou-
pling in the coating unit.
Fit the plug.
3. Lift the front part of the coating pan until the jour-
2
nal jumps out of the retaining springs (Fig. 110/3).
4. Pull the coating pan on the rails (Fig. 110/2) out of
the coating unit.
In the process, the short pins (Fig. 110/1) slide on
3 the rails.
5. Lay down the coating pan on a clean, flat surface.
6. Clean the coating pan immediately after remov-
ing with a suitable cleaning agent.
Fig. 110 Removing the coating pan
SC.999.0020/01 B.11.69
Coating unit
10.11 Outlet tube on the pressurized chambered blade
The parts set of the pressurized chambered blade in-
SC.B01.1390-000GRAUND_00
cludes an outlet tube. This outlet tube should be used
for foaming varnishes (e.g. UV varnishes) in particular.
1. Attach the outlet tube (Fig. 111/1) from below on-
to the connection piece on the pressurized cham-
bered blade.
Fig. 111 Outlet tube on pressurized chambered
blade
10.12 Adjusting the chambered blade to the screen roller
1 Working blade
FS.901.1039-000GRAUND_00
2 Closing blade
When do you need to adjust the chambered blade
1 to the screen roller?
The chambered blade must be adjusted at the factory
so that the working blade and the closing blade are
aligned parallel to the screen roller. This setting is also
retained when either the screen roller or the blades are
replaced.
If printing problems occur for no obvious reason or ex-
cessive or one-sided wear occurs on the blade you
must readjust the chambered blade.
Fig. 112 Chambered doctor blade and screen roller
B.11.70 SC.999.0020/01
Coating unit
Is the screen roller fitted correctly?
SC.B01.1371-000GRAUND_00
1 Check the screen roller before starting to adjust the
chambered blade.
The screen roller must sit properly in the journal boxes.
If you have newly inserted the screen roller:
● Shake the screen roller (Fig. 113/1) and check
that the screen roller is fitted correctly.
● Engage the screen roller with the coating blanket
cylinder and let the machine turn for one revolu-
tion.
Fig. 113 Screen roller installed
Before you start
Read the complete section below and familiarize your-
self with the functions of the adjusting elements. You
will need approximately half an hour to adjust the
chambered blade.
You can make gages using strips of onion skin paper
or plastic; the strips should have different widths and a
thickness of 0.1 ... 0.15 mm.
Step 1 - Prerequisites for the setting process
Make sure that the following prerequisites are fulfilled:
● The screen roller is fitted correctly.
● The coating pan has been removed.
● The coating unit, the chambered blade and the
screen roller are clean and dry.
Preparing chambered blades
● The lateral gaskets and retaining springs are re-
moved.
● Both working blade and closing blade are made
of steel.
● The blades are installed properly, new and not
damaged.
● The clamped blades are neither wavy nor are
they in any other way deformed.
● The chambered blade has been disengaged.
Display on the pressure regulator (Fig. 114):
6 bar
SC.999.0020/01 B.11.71
Coating unit
Pressure controller
SC.B01.1392-000GRAUND_00
The pressure regulator (Fig. 114/1) has no influence
on the contact pressure and no influence on the wear
of the blade.
For normal operation you need to set the pressure
regulator to 6 bar. Check the pressure reading on the
manometer (Fig. 114/2).
● The display on the manometer reads 6 bars : the
chambered blade is disengaged.
● The display on the manometer reads 0 bar: the
chambered blade is engaged.
2 1 In order to adjust the chambered blade you must
switch off the pressure on the pressure regulator.
Fig. 114 Pressure controller
Step 2 - Switching off the pressure on the pressure
regulator
Requirement
The chambered blade must be disen-
gaged. Display on the pressure regula-
tor: 6 bar
1. Check whether the chambered blade moves
freely.
2. Set the pressure on the pressure regulator
(Fig. 114/1) to 0 bar.
Adjusting screws for doctor blade pretension
SC.B01.1378-000GRAUND_00
Use the adjusting screws (Fig. 115/1) to adjust the
contact pressure of the chambered blades to the
screen roller.
The adjusting screws are captive.
Step 3 - screw in the adjusting screws for preten-
sioning the blade
To prevent the chambered blade from getting jammed
during the adjustment you must complete one step at
a time.
3. Unscrew the adjusting screw (Fig. 115/1) on D.S.
and O.S. counterclockwise up to the stop.
4. Evenly and alternately screw in the adjusting
screws on D.S. and O.S. 3 ... 4 turns in clockwise
direction.
1 Caution - Machine damage!
Do not activate the chambered blade via
the control button at this point.
Fig. 115 Adjusting screws for doctor blade preten-
sion
B.11.72 SC.999.0020/01
Coating unit
Step 4 - Adjusting the chambered blade with a
SC.B01.1391-000GRAUND_00
gage
1 Tip
You can make gages using strips of
onion skin paper or plastic; the strips
should have different widths and a thick-
ness of 0.05 mm to 0.1 mm. For better
handling you can bend the upper edges
of the gages (Fig. 116/1).
Note
Due to the surface texture of the screen
roller, the onion skin paper that is next to
the screen roller may not move easily. In
this case, place 2 strips on top of each
other. The wider strip is next to the
screen roller, the narrower strip next to
the blade.
5. On both D.S. and O.S., insert one gage (2 strips
of onion skin paper, Fig. 116/1) between the doc-
Fig. 116 Checking with the gage
tor blade and the screen roller. The wider strip is
next to the screen roller.
6. Insert the gages until you feel a resistance.
Ensure that you check just one blade knife.
7. Gently press the chambered blade against the
screen roller with your hand.
8. Check the settings of the working blade and the
closing blade using the gages. In doing so, pull
out only the onion skin paper strip that is next to
the doctor blade.
If the adjustment is correct, you should be able to pull
out the onion skin paper strips next to the doctor blade
on D.S. and O.S. with the same slight force.
9. If you need to make corrections to the adjust-
ment, open the locking screws (Fig. 118/1) on
D.S. and O.S.
SC.999.0020/01 B.11.73
Coating unit
Basic setting
SC.B01.1379-000GRAUND_00
The distance between the bearing block and the screw
head on D.S. and O.S. is the basis for the adjustment
of the chambered blade:
● approx. 3 mm on the visible thread
Should you have made greater changes to the setting
by mistake, you can change the setting to the old val-
ues again and start the adjusting process anew.
Fig. 117 Distance between screw head and bearing
block
10. Turn the Allen screws (Fig. 118/2)
SC.B01.1380-000GRAUND_00
In this way you align the working blade and the
1 closing blade from D.S. to O.S. axially parallel
and evenly to the screen roller.
Note
Please note the table 1 for the direction
of turning in the Allen screws.
Fig. Designation Adjustment, view
2
on the screw head
118/2 Allen screw Turning clockwise:
Turning counter-
Fig. 118 Adjusting the chambered blade, in this clockwise:
case on D.S.
Tab. 1 Alignment of the chambered blade
Step 5 - Tightening the locking screws
11. After the chambered blade has been correctly
aligned to the screen roller, tighten the locking
screws (Fig. 118/1) again on D.S. and O.S.
B.11.74 SC.999.0020/01
Coating unit
Step 6 - Unscrewing the adjusting screws for pre-
SC.B01.1378-000GRAUND_00
tensioning the blade
Caution - Machine damage!
It is absolutely necessary that you first
fully unscrew the two adjusting screws
before you engage the chambered
blade.
12. Fully unscrew the two adjusting screws
(Fig. 119/1) evenly on D.S. and O.S. in a coun-
terclockwise direction.
Evenly means you must unscrew the adjusting
screws on D.S. and O.S. alternately by one turn
at a time until they are unscrewed all the way.
The adjusting screws are captive.
Fig. 119 Adjusting screws for pretensioning the
blade, in this case on D.S.
Step 7 - Setting the pretension of the blade
SC.B01.1392-000GRAUND_00
13. Set the operating pressure on the pressure reg-
ulator to 6 bars (disengaged).
14. Engage the chambered blade by pressing the
corresponding button. The blades must not yet
be in contact with the screen roller.
2 1
Fig. 120 Pressure controller
SC.999.0020/01 B.11.75
Coating unit
15. Slowly and evenly screw in the two adjusting
SC.B01.1378-000GRAUND_00
screws on D.S. (Fig. 121/1) and on O.S. clock-
wise until the doctor blades just about touch the
screen roller.
Check the adjustment with onion skin strips.
16. Disengage the chambered doctor blade.
17. Then screw in the two adjusting screws on D.S.
and on O.S. by exactly 1 more revolution in a
clockwise direction.
Fig. 121 Adjusting screws for pretensioning the
blade, in this case on D.S.
Step 8 - Checking the adjustment
18. Press the button Chambered blade ON/OFF
twice in short succession.
19. Engage the chambered blade and then disen-
gage it again immediately after engaging it.
The engaging and disengaging motion of the cham-
bered blade must be even and gentle. When engag-
ing, the toggle lever must be pushed through fully by
the pneumatic cylinder.
B.11.76 SC.999.0020/01
Coating unit
Step 9 - Fitting the gaskets
SC.B01.1386-000GRAUND_00
B.S. 1. Disengage the chambered blade and remove it.
O.S. 2. Place the lateral gaskets (Fig. 122/2) together
C.S. with the retaining springs (Fig. 122/1) inside the
L.S. chambered blade as shown in the section
L.M. "Preparing the chambered blades, inserting the
gasket."
Ensure that the mounting position of the gaskets
is correct.
1
2
Fig. 122 Gasket and retaining spring
SC.999.0020/01 B.11.77
Coating unit
11 Screen rollers of spraying device (option)
SC.B01.3020-000UTKENU_00
11.1 Function/Task
Due to the use of quick-drying, water-based varnishes,
residual varnish may build up at the lateral gaskets of
the chambered blade and at the edge of the screen
roller. The need to remove the dried varnish increases
the cleaning effort.
Your machine is equipped with spray nozzles at the
chambered blade bearings on D.S. and O.S. that con-
tinuously wet the chambered blade gaskets with water
during the coating process. This reliably prevents dry-
ing of the varnish.
This device is optional and therefore not every ma-
chine is equipped with it. The spraying device can be
retrofitted. To do this, contact Heidelberg service.
11.2 Activating/deactivating the spraying device
The screen rollers of the spraying device can be
SF.901.7701-001GRAUND_00
switched on and off on the control station. You can also
change or reset the water volume per time at the con-
trol station.
Information on operating the screen rollers of the
spraying device is available on the control station in
the related operating manual.
Fig. 123 Control station
B.11.78 SC.999.0020/01
Coating unit
11.3 Cleaning
Once the chambered blade has been removed, the
SC.B01.3020-000GRAUND_00
spraying devices (Fig. 124/2) at the chambered blade
bearings (Fig. 124/1) are easily accessible.
1. Check the functioning of the spray nozzles on
D.S. and O.S.
2. Clean the spray nozzles, if necessary.
To do so, follow the instructions in the separate
operating manual "Maintenance and Cleaning,
Customer".
Fig. 124 Spraying device, here: O.S.
11.4 Installation location and function
Installation location
SC.B01.3021-000GRAUND_00
The water canister (Fig. 125/1) is located on the coat-
ing unit under the footboard on O.S.
Function
The processed water is fed to the spray nozzles in the
coating unit by an electropneumatic pump.
Information on operating the screen rollers of the
spraying device is available on the control station in
the related operating manual.
Fig. 125 Water canister
SC.999.0020/01 B.11.79
Coating unit
11.5 Components
The system mainly consists of:
SC.B01.3022-000GRAUND_00
● the 5-liter canister with processed water
2 (Fig. 126/1)
and
● the removable suction pipe (Fig. 126/2) with in-
tegrated screw cap.
Fig. 126 Canister and suction pipe
11.6 Requirements of the water
Observe the specifications for disinfecting water doc-
umented in the separate "Customer Maintenance and
Cleaning" manual.
11.7 Replacing canister
Preparing for the change
SC.B01.3023-000GRAUND_00
An empty canister can easily be replaced with a full
canister with processed water.
or
The empty canister can be filled with processed water.
The replacement of the canister is described in the
following.
Note
The suction pipe is fitted with a matching
screw cap. Use suction pipe with inte-
grated screw cap developed by Heidel-
berg only. The position of the screw cap
on the suction pipe is set to an exact lev-
el. To avoid any malfunctions, the posi-
Fig. 127 Canister with processed water tion of the screw cap on the suction pipe
must not be altered.
1. Remove the screen under the footboard.
2. Place a full canister with processed water
(Fig. 127) next to the coating unit on the O.S.
Ensure that the labeling is correct.
3. Unscrew the screw cap from the full canister.
B.11.80 SC.999.0020/01
Coating unit
Replacing canisters
SC.B01.3024-000GRAUND_00
1. Pull out the empty canister from below the foot-
2 board.
Ensure that neither the hose nor the electric ca-
1 ble is stretched too much. You do not need to
release the plug-in connection.
2. Firmly hold the suction pipe (Fig. 128/2) and un-
screw the screw cap (Fig. 128/1).
Note
When removing the suction pipe from
the canister, small amounts of water may
leak out of the suction pipe.
3. Pull the suction pipe (Fig. 128/2) upwards out of
the canister.
Hold the suction pipe as upright as possible with
the suction opening facing downwards.
Fig. 128 Canister and suction pipe 4. Collect any dripping water using a cloth.
On canister provided:
SC.B01.3025-000GRAUND_00
5. Insert the suction pipe (Fig. 129/1) carefully,
when upright, from above into the full canister.
Fig. 129 Inserting suction pipe
SC.999.0020/01 B.11.81
Coating unit
6. Hold the suction pipe (Fig. 130/2) firmly and
SC.B01.3024-000GRAUND_00
screw the screw cap (Fig. 130/1) onto the canis-
2 ter.
7. Check the suction pipe is correctly seated in the
1 canister.
8. Push the canister under the footboard on the
coating unit.
Note
Ensure that the suction hose does not
become bent or damaged.
9. Mop up any spilled water from the floor and care-
fully dry the cleaned area.
10. Hook in the screen under the footboard.
Fig. 130 Suction pipe in canister
11.8 Commissioning
If you are operating the roller protection system for the
SF.901.7701-001GRAUND_00
first time, you must fill the empty line system with wa-
ter. This requires a specific procedure to be followed.
Information about this is available on the control sta-
tion in the relevant operating manual.
Fig. 131 Control station
B.11.82 SC.999.0020/01
Coating unit
12 CoatingStar varnish supply unit
LS.901.6016-000UTKENU_11
12.1 Features
Features of the CoatingStar
Like conventional varnish supply units, the
CoatingStar varnish supply unit has one circuit for var-
nish and one for the washing fluid. Additional func-
tions:
● Cleaning the coating unit and pump circuit with
fresh water.
● Facility for heating up fresh water and washing
fluid.
● Programmable cleaning sequence: You can
record and call up complete cleaning programs.
A coating unit can also be equipped with 2 varnish
supply units. In this instance you must select the var-
nish supply unit to be controlled on the control station
of the press.
Note
Each varnish supply unit comes with a
separate operating manual which con-
tains information on operation and main-
tenance.
12.2 Varnish circulation
Chambered blade metering
LS.901.6081-001GRAUND_01
1 2 ● Control panel O.S. (Fig. 132/1)
3 4
● Hand-held control unit (Fig. 132/2)
5 ● Level sensor (Fig. 132/3)
● Chambered blade (Fig. 132/4)
● Collecting trough (Fig. 132/5)
6 ● Varnish return flow tube (Fig. 132/7), return flow
hose and varnish pipes (Fig. 132/6)
7 ● Flow sensor (Fig. 132/8)
14 15
8 ● Supply hose and varnish pipes (Fig. 132/9)
● CoatingStar (Fig. 132/10)
9 ● Fresh water supply (Fig. 132/11)
● Suction set 1 and varnish tank (Fig. 132/12)
10
● Suction set 2 and container for washing fluid
(Fig. 132/13)
● Connection on press control station (Fig. 132/14)
13 12 11 ● Distribution box (Fig. 132/15)
Fig. 132 Varnish circulation chambered blade me-
tering
SC.999.0020/01 B.11.83
Coating unit
12.3 Control panels
You operate the varnish supply unit via the O.S. con-
FS.901.4093-000GRAUND_00
1 2
trol panel (Fig. 133/1) on the feeder side of the coating
unit. There is also a hand-held control unit (Fig. 133/2)
offering the same functionality.
Fig. 133 Hand-held control unit for varnish supply
unit
12.4 Setting the pumping capacity (flow rate)
You can set the pumping capacity on the control panel
or on the hand-held control unit. The settings range
extends from 1 (lowest pumping capacity) to 10 (high-
est pumping capacity).
Note
The more viscous the varnish, the higher
the pumping capacity must be. If you use
the cleaning program, you can set the
pumping capacity for varnish, washing
fluid and fresh water separately.
12.5 Tips on optimum cleaning results
Liquid volumes and residual liquids in the supply
circuits
The varnish supply unit has 2 supply circuits (one var-
nish circuit and one washing fluid circuit). Depending
on the operating mode (circulating varnish or circulat-
ing washing fluid), one of the supply circuits is con-
nected to the coating unit circuit.
Circulated volume of liquid with chambered blade me-
tering:
● About 7 liters with CX 92, SM/CD/CX 102,
CX 104 and XL 106.
● About 5 liters with SX 74/XL 75.
Circulating liquid volume with water pan roller meter-
ing:
B.11.84 SC.999.0020/01
Coating unit
● About 14 liters with CX 92, SM/CD/CX 102,
CX 104 and XL 106.
● About 10 liters with SX 74/XL 75.
If you switch between "Circulate varnish" and "Circu-
late washing fluid", the system automatically goes into
the operating mode "Empty coating pan/chambered
doctor blade". In this operating mode, the liquid is
pumped out of the coating unit circuit and pumped
back into the supply circuit last active.
About 1 to 2 liters of liquid remain in the piping system.
When the supply circuit is changed, this residual liquid
is carried over into the other supply circuit.
Fresh water
The CoatingStar varnish supply unit has an additional
fresh water tap. After completing the cleaning cycle
with washing fluid, you can perform an additional
cleaning cycle with fresh water. After the cleaning pro-
cess, the dirty water is pumped into the container with
the washing fluid.
Note
Only use fresh water when working with
water based varnishes (e.g. dispersion
varnishes). Shut off the fresh water sup-
ply for non-water based varnishes (e.g.
UV varnishes). You need to block the
fresh water supply on the control panel
of the varnish supply unit (see separate
operating manual for the CoatingStar).
Tip
If you have no experience with this pro-
cess yet: Set the cleaning cycle with
washing fluid to a rinsing time of 5 min-
utes. Heat the washing fluid to a temper-
ature of about 35°C. Rinsing with fresh
water: Set the pumping capacity to level
4 and the rinsing time to 2 minutes. This
pumps about 10 liters of fresh water into
the circuit.
Varnish tank and washing fluid container
If you clean with fresh water, the container for the
washing fluid must be large enough to take up the ad-
ditional amount of liquid. Recommendation: use a 100
liter container with a drain cock at the bottom.
The size of the container depends on the varnish con-
sumption. The small 30 liter containers are only suit-
able for jobs with a low varnish consumption. With
larger container volumes, the liquid that is always car-
ried over during the cleaning process has less impact.
We recommend that you also use larger containers for
the varnish.
SC.999.0020/01 B.11.85
Coating unit
Changing the varnish type
About 1 to 2 liters of liquid remain in the coating unit
circuit. When changing over from pigmented varnishes
to colorless varnishes or from dispersion varnishes to
UV varnishes: Take care to empty the supply lines and
the coating pan completely. Rewash the coating unit
by hand.
Tip
Let a small amount of the new varnish
run into the coating unit and pump it out
again.
12.6 Manual cleaning with washing fluid only
Requirement
LS.901.6078-000GRAUND_00
Varnish is delivered: The Circulate var-
nish and Varnish pump ON/OFF buttons
are on.
Fig. 134 Circulate varnish and Varnish pump ON
1. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The varnish is pumped out. Wait until the coating
pan is empty (minimum waiting period is 30 sec-
onds).
Fig. 135 Emptying the coating pan
2. Press the Circulate washing fluid button.
SG.901.7351-000GRAUND_00
The washing fluid is pumped into the coating unit.
Wait until the coating unit is rinsed through.
Fig. 136 Circulate washing fluid
3. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The washing fluid is pumped out. Wait until the
coating pan is empty (minimum waiting period is
30 seconds).
Note
Fig. 137 Emptying the coating pan If the pump is switched off, no waiting
time is required.
4. Press the Circulate varnish button.
SG.901.5937-000GRAUND_00
Result
The lights in all buttons are off. The var-
nish supply unit is idle. With the buttons
Circulate varnish and Varnish pump ON/
OFF you can switch the varnish supply
Fig. 138 Circulate coating back on.
B.11.86 SC.999.0020/01
Coating unit
12.7 Manual cleaning with washing fluid and fresh water
Requirement
LS.901.6078-000GRAUND_00
Varnish is delivered: The Circulate var-
nish and Varnish pump ON/OFF buttons
are on.
Fig. 139 Circulate varnish and Varnish pump ON
1. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The varnish is pumped out. Wait until the coating
pan is empty (minimum waiting period is 30 sec-
onds).
Fig. 140 Emptying the coating pan
2. Press the Circulate washing fluid button.
SG.901.7351-000GRAUND_00
The washing fluid is pumped into the coating unit.
Wait until the coating unit is rinsed through.
Fig. 141 Circulate washing fluid
3. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The washing fluid is pumped out. Wait until the
coating pan is empty (minimum waiting period is
30 seconds).
Note
Fig. 142 Emptying the coating pan If the pump is switched off, no waiting
time is required.
4. Press the Circulate washing fluid button again.
SG.901.7351-000GRAUND_00
This switches on the supply of fresh water.
Fresh water is pumped into the coating unit. Wait
until the coating unit is rinsed through (with the
pumping capacity set to level 4 it takes about
2 minutes to deliver 10 liters of fresh water).
Fig. 143 Circulate washing fluid
5. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The water is pumped out. Wait until the coating
pan is empty (minimum waiting period is 30 sec-
onds).
Note
Fig. 144 Emptying the coating pan If the pump is switched off, no waiting
time is required.
6. Press the Circulate varnish button.
SG.901.5937-000GRAUND_00
Result
The lights in all buttons are off. The var-
nish supply unit is idle. With the buttons
Circulate varnish and Varnish pump ON/
OFF you can switch the varnish supply
Fig. 145 Circulate coating back on.
SC.999.0020/01 B.11.87
Coating unit
12.8 Automatic cleaning process with a cleaning program
You can preselect one of 8 cleaning programs. The
cleaning programs 1 to 4 have been preset in the fac-
tory. The cleaning programs 5 to 8 are user-pro-
grammable.
Requirement
LS.901.6078-000GRAUND_00
Varnish is delivered: The Circulate var-
nish and Varnish pump ON/OFF buttons
are on.
Fig. 146 Circulate varnish and Varnish pump ON
1. Press the Cleaning program ON button.
LS.901.6084-000GRAUND_00
The selected cleaning program is executed. The
remaining time for the cleaning program is dis-
played. At the end of the cleaning program, the
varnish supply unit is switched off automatically.
Fig. 147 Cleaning program ON
12.9 Interrupting/aborting the cleaning process
Interrupting the cleaning process
LS.901.6082-000GRAUND_00
You can interrupt the cleaning process at any time.
1. Press the Varnish pump ON/OFF button.
Result
The varnish supply unit stops. The but-
Fig. 148 Varnish pump ON ton for the operating mode last active is
on.
If a cleaning program is running, the re-
maining time of the interrupted cleaning
program is displayed.
If you press the Varnish pump ON/OFF button again,
the varnish supply unit continues to run with the oper-
ating mode last set.
If a cleaning program is in progress: The cleaning pro-
gram is continued. The last (not yet completed) pro-
gram step is repeated from the beginning.
Aborting the cleaning process
LS.901.6082-000GRAUND_00
You can abort the cleaning process at any time.
1. Press the Varnish pump ON/OFF button.
When a cleaning program is running: You can
cancel the cleaning program on the press control
station.
Fig. 149 Varnish pump ON
Result
LS.901.6083-000GRAUND_00
The varnish supply unit stops. The but-
ton for the operating mode last active is
on.
2. Press the buttons for the operating modes one
after the other: Empty coating pan, Circulate
Fig. 150 Button sequence for aborting the cleaning washing fluid, Empty coating pan, Circulate var-
process nish.
B.11.88 SC.999.0020/01
Coating unit
Result
The lights in all buttons are off. The var-
nish supply unit is idle. With the buttons
Circulate varnish and Varnish pump ON/
OFF you can switch the varnish supply
back on.
12.10 Recording a cleaning program using the recorder function
With the recorder function you can carry out a cleaning
program manually while recording it. You control the
recording sequence from the coating unit panel, so
that you can monitor the cleaning process visually.
Requirement
LS.901.6078-000GRAUND_00
Varnish is delivered: The Circulate var-
nish and Varnish pump ON/OFF buttons
are on.
Fig. 151 Circulate varnish and Varnish pump ON
1. On the control station of the press: Select the
LS.901.6084-000GRAUND_00
program location for the recording. Press the
Record button. Select the coating unit. Press the
Start recording button.
Result
The Cleaning program ON button on the
Fig. 152 Cleaning program ON coating unit control panel is flashing.
2. On the coating unit control panel: Execute a
cleaning cycle as with a manually controlled
cleaning process. On the press control station,
the selected functions, including the relevant
times can be recorded.
3. Once the cleaning cycle has ended (varnish
pump off): On the press control station, press the
Accept data button.
Result
The parameters for the cleaning cycle
are saved. You can reedit the data sub-
sequently.
SC.999.0020/01 B.11.89
Coating unit
13 CoatingStar Compact varnish supply unit
SC.901.5081-000UTKENU_04
13.1 Features
Features of CoatingStar Compact
The varnish supply unit has a common circuit for var-
nish and washing fluid.
A coating unit can also be equipped with 2 varnish
supply units. In this instance, you must select the var-
nish supply unit to be controlled on the control station
of the press. Notes on this can be found in the separate
operating manual for the control system.
Note
Each varnish supply unit comes with a
separate operating manual which con-
tains information on operation and main-
tenance.
13.2 Varnish circulation
Chambered blade
FS.901.6081-000GRAUND_00
1 2 3 4 5 ● Control panel O.S. (Fig. 153/1)
● Hand-held control unit (Fig. 153/2)
● Level sensor (Fig. 153/3)
● Chambered blade (Fig. 153/4)
● Screen roller (Fig. 153/5)
● Collecting trough (Fig. 153/6)
6
● Filter (Fig. 153/7)
7 ● Varnish return line, return flow hose and varnish
pipes (Fig. 153/8)
8
14 13 ● Flow sensor (Fig. 153/9)
9 ● Supply hose and varnish pipes (Fig. 153/10)
● CoatingStar Compact (Fig. 153/11)
● Suction set and varnish tank (Fig. 153/12)
10 ● Distribution box (Fig. 153/13)
● Connection to the press control station
(Fig. 153/14)
12 11
Fig. 153 Chambered blade scheme
B.11.90 SC.999.0020/01
Coating unit
Pressurized chambered blade
FS.901.6082-000GRAUND_00
1 2 3 4 5 ● Control panel O.S. (Fig. 154/1)
● Hand-held control unit (Fig. 154/2)
● Level sensor (Fig. 154/3)
● Reducing valve on the pressurized chambered
blade (Fig. 154/4)
● Pressurized chambered blade (Fig. 154/5)
6 ● Collecting trough (Fig. 154/6)
15
7 ● Filter (Fig. 154/7)
● Varnish return line, return flow hose and varnish
8 pipes (Fig. 154/8)
14 13
● Flow sensor (Fig. 154/9)
9
● Supply hose and varnish pipes (Fig. 154/10)
● CoatingStar Compact (Fig. 154/11)
10 ● Suction set and varnish tank (Fig. 154/12)
● Distribution box (Fig. 154/13)
● Connection to the press control station
12 11
(Fig. 154/14)
● Pressure sensor for pressure control
(Fig. 154/15)
Fig. 154 Pressurized chambered blade scheme
13.3 Control panels
You operate the varnish supply unit via the O.S. con-
FS.901.4093-000GRAUND_00
1 2
trol panel (Fig. 155/1) on the feeder side of the coating
unit. There is also a hand-held control unit (Fig. 155/2)
offering the same functionality.
Note
If two varnish supply units are connected
to the coating unit, you must select the
desired varnish supply unit on the con-
trol station.
Fig. 155 Varnish supply unit control panels
Dependencies
The individual parameters for the reducing valve, the
coating viscosity and the pressure in the pressurized
chamber blade depend on each other. A higher vis-
cosity of the coating, for example, requires a wider
opening of the reducing valve. You may also have to
increase the pressure in the pressurized chambered
SC.999.0020/01 B.11.91
Coating unit
blade. The ideal values for the individual parameters
for each print job must be determined on location.
You can change the pressure in the pressurized cham-
bered blade on the control station.
Standard values (example):
● 45 s-coating
● Reducing valve: 5 ... 6
● Pressurized chambered blade: 200 mbar
13.4 Setting the pumping capacity (flow rate)
Chamber-type doctor blade
You can set the pumping capacity on the control panel
or on the hand-held control unit. The display has two
digits. The adjustment range is from 1 (lowest pumping
capacity, corresponds to 10 %) to 10 (highest pumping
capacity, corresponds to 100 %).
Note
When using highly viscous (thick) var-
nish you must increase the pumping ca-
pacity. You must reduce the pumping
capacity for low-viscosity (thin) varnish.
When using the cleaning program, you
can set the pumping capacity for varnish
and washing fluid circulation separately.
Pressurized chambered blade
There are two control types for the pressurized cham-
bered blade:
● Pressure control: The nominal pressure is set
here.
The pumping capacity depends on whether the
pressure in the pressurized chambered blade is
too high or too low. The setting of the reducing
valve serves to set the default setting. The pump-
ing capacity must be between 15 and 30 % of the
maximum capacity In order to ensure this, the
valve is set during setup with the varnish so that
the pumping capacity is approx. 22 %. The pump-
ing capacity will still be inside the valid range
when the coating warms up, or other influences
change the pumping capacity. If the pumping ca-
pacity is outside the permitted range, the pump
will begin to cycle and there will be pulsation in
the pressurized chambered blade. Or the pump
will reach its capacity limit and will not be able to
generate the desired pressure.
● Volume flow control: Set the reducing valve to 9
(fully open).
You can set the pumping capacity on the control panel
or on the hand-held control unit. The display has two
digits. The adjustment range is from 1 (lowest pumping
B.11.92 SC.999.0020/01
Coating unit
capacity, corresponds to 10 %) to 10 (highest pumping
capacity, corresponds to 100 %).
Note
When setting the volumetric flow rate,
you must increase the pumping capacity
for a highly viscous (thick) varnish. You
must reduce the pumping capacity for
low-viscosity (thin) varnish.
When using the cleaning program, you
can set the pumping capacity for varnish
and washing fluid circulation separately.
13.5 Tips on optimum cleaning results
Fluid quantities and residual quantities in the sup-
ply circuit
The varnish supply unit has only one supply circuit. For
cleaning, you need to move the lances into a washing
fluid container.
Circulated volume of liquid with chambered blade me-
tering:
● approx. 6.5 l
When you switch from "Varnish circulation" to "Empty
coating pan", the fluid is pumped out of the coating unit
circuit and pumped back into the varnish tank.
About 1 liter of liquid remains in the line system. This
quantity of liquid is entrained during changes and can
dilute/contaminate the new media.
Changing the varnish type
About 1 liter of liquid remains in the coating unit circuit.
When changing over from pigmented varnishes to col-
orless varnishes or from dispersion varnishes to UV
varnishes: Take care to empty the supply lines and the
coating pan completely. Rewash the coating unit by
hand.
Tip
When emptying, you can loosen the cou-
pling on the suction lance and hold it low
over a collecting vessel. Collect residual
quantities in this way.
Tip
When pumping in varnish again, hold the
return lance in a separate vessel until
fresh varnish emerges. Stop the pump.
Move the return lance to the varnish tank
and switch the pump on again. In this
way you prevent the washing fluid from
mixing with the varnish.
SC.999.0020/01 B.11.93
Coating unit
13.6 Manual cleaning with washing fluid
Requirement
LS.901.6078-000GRAUND_00
Varnish is delivered: The Circulate var-
nish and Varnish pump ON/OFF buttons
are on.
Fig. 156 Circulate varnish and Varnish pump ON
1. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The varnish is pumped out. Wait until the coating
pan is empty (minimum waiting period is 30 sec-
onds).
Fig. 157 Emptying the coating pan
2. Press the Circulate washing fluid button.
SG.901.7351-000GRAUND_00
The pump stops. The Varnish pump on/off button
flashes.
3. Move the lance from the varnish tank to the wash-
ing fluid container.
4. Press the Varnish pump ON/OFF button.
Fig. 158 Circulating the washing fluid
The washing fluid is pumped into the coating unit.
Wait until the coating unit is rinsed through.
5. Press the Empty coating pan button.
SG.901.6124-000GRAUND_00
The washing fluid is pumped out. Wait until the
coating pan is empty (minimum waiting period is
30 seconds).
Note
Fig. 159 Emptying the coating pan If the pump is switched off, no waiting
time is required.
6. Press the Circulate varnish button.
SG.901.5937-000GRAUND_00
Result
The lights in all buttons are off. The var-
nish supply unit is idle. With the buttons
Circulate varnish and Varnish pump ON/
OFF you can switch the varnish supply
Fig. 160 Circulate coating back on.
13.7 Semi-automatic cleaning with cleaning program
Requirement
The varnish has been sucked out. The
lance is in the washing fluid container.
The Circulate washing fluid and Varnish
pump ON/OFF buttons are lit up.
You can preselect one of 2 cleaning programs.
● Standard short: 200 seconds
● Standard long: 320 seconds
You can increase the cleaning times if necessary.
Notes on this can be found in the separate operating
manual for the control station.
B.11.94 SC.999.0020/01
Coating unit
1. Press the Cleaning program ON button.
LS.901.6084-000GRAUND_00
The selected cleaning program is executed. The
remaining time for the cleaning program is dis-
played. At the end of the cleaning program, the
varnish supply unit is switched off automatically.
The chambered blade swings down.
Fig. 161 Cleaning program ON
13.8 Interrupting/aborting the cleaning process
Interrupting the cleaning process
LS.901.6082-000GRAUND_00
You can interrupt the cleaning process at any time.
1. Press the Varnish pump ON/OFF button.
Result
The varnish supply unit stops. The but-
Fig. 162 Varnish pump ON ton for the operating mode last active is
on.
If a cleaning program is running, the re-
maining time of the interrupted cleaning
program is displayed.
If you press the Varnish pump ON/OFF button again,
the varnish supply unit continues to run with the oper-
ating mode last set.
If a cleaning program is in progress: The cleaning pro-
gram is continued. The last (not yet completed) pro-
gram step is repeated from the beginning.
Aborting the cleaning process
LS.901.6082-000GRAUND_00
You can abort the cleaning process at any time.
1. Press the Varnish pump ON/OFF button.
When a cleaning program is running: You can
cancel the cleaning program on the press control
station.
Fig. 163 Varnish pump ON
Result
LS.901.6083-000GRAUND_00
The varnish supply unit stops. The but-
ton for the operating mode last active is
on.
2. Press the buttons for the operating modes in suc-
cession: Empty coating pan, Circulate washing
Fig. 164 Button sequence for aborting the cleaning fluid, Empty coating pan, Circulate varnish.
process Result
The lights in all buttons are off. The var-
nish supply unit is idle. With the buttons
Circulate varnish and Varnish pump ON/
OFF you can switch the varnish supply
back on.
SC.999.0020/01 B.11.95
Coating unit
14 Coating unit with 2 varnish circulation systems (optional)
SC.B01.0001-000UTKENU_00
14.1 Varnish separation
2 varnish circulation systems
SC.B01.0004-000GRAUND_00
● 2 separate varnish circulation systems can be or-
dered or retrofitted as an option.
● The piping of the two varnish circulation systems
is located on D.S.
● The piping of the additional varnish circulation
system is provided with a cable tie at several
points (Fig. 165/yellow). The cable ties serve as
an identifying feature for the 2nd varnish circula-
tion system.
1. Replace the coating pan and the chambered
blade when changing the varnish circulation sys-
tem.
For details on this topic, see the chapter "Chambered
blade and pressurized chambered blade".
Fig. 165 2 varnish circulation systems
B.11.96 SC.999.0020/01
Dryer
Dryer
Dryer
1 Dryer - Safety Instructions .................................................................................................... B.12.3
1.1 To be observed when performing work .......................................................................... B.12.3
2 Dryers in the units (optional) ............................................................................................... B.12.5
2.1 General notes ................................................................................................................ B.12.5
2.2 Overview (example) ...................................................................................................... B.12.6
2.3 Switching on the dryer .................................................................................................. B.12.6
2.4 Removing/fitting the interdeck dryer ............................................................................. B.12.7
2.5 Y dryer .......................................................................................................................... B.12.9
2.6 Cleaning the interdeck dryer and the Y dryer ............................................................... B.12.9
2.7 Adjusting the sheet guide straps ................................................................................... B.12.10
3 UV interdeck dryer (optional) ............................................................................................... B.12.11
3.1 General information about UV interdeck dryers ............................................................ B.12.11
3.2 Adjusting the sheet guide straps ................................................................................... B.12.11
4 Dryers in the delivery (optional) .......................................................................................... B.12.13
4.1 Delivery versions ............................................................................................................ B.12.13
4.2 Variants and drying principle ......................................................................................... B.12.13
4.3 Switching on the dryer .................................................................................................. B.12.14
4.4 Removing and cleaning the slide-in dryer ..................................................................... B.12.14
4.5 Fitting the slide-in dryer ................................................................................................. B.12.16
4.6 Operation without slide-in dryers .................................................................................. B.12.16
5 Print-related notes on the dryer ........................................................................................... B.12.17
5.1 Pile temperature ............................................................................................................. B.12.17
5.2 Temperature measurement in the pile ........................................................................... B.12.17
5.3 Dryer output ................................................................................................................... B.12.17
5.4 Recommended settings ................................................................................................. B.12.18
5.5 Air circulation in the press room ..................................................................................... B.12.19
SC.999.0020/01 B.12.1
Dryer
B.12.2 SC.999.0020/01
Dryer
1 Dryer - Safety Instructions
SF.901.8800-000UTKENU_00
1.1 To be observed when performing work
Warning - Explosion hazard due to
evaporating solvents!
When using dryers, only use inks and
varnishes that do not create any ex-
plosive atmosphere when heated in
the dryer. This is specified in the cor-
responding safety data sheets.
Ensure that no solvents can enter into
the dryer area when using cleaners on
the press. Never use and store sol-
vents in the vicinity of the dryer.
When using an automatic washup de-
vice, set the wash program so that the
blankets and impression cylinders are
dry before you continue with the pro-
duction. This ensures that no solvent
can enter into the dryer area.
Warning - Risk of burning from hot
surfaces!
After dryer use, wait until all accessible
parts have cooled down and are no
more than lukewarm (approximate-
ly 40 °C).
Warning - Explosion hazard and fire
hazard due to dust deposits!
Dust, such as powder or paper dust,
can result in fire hazard or explosion
hazard.
Therefore, clean the areas affected by
dust regularly, at least once a week,
using a vacuum cleaner.
Only use suitable and approved indus-
trial vacuum cleaners and avoid work-
ing with compressed air, as this could
swirl up the dust.
SC.999.0020/01 B.12.3
Dryer
Warning - Danger of death from
electrical voltage!
Dryers work with very high operating
voltages. Ensure that the machine and
the dryers cannot be switched on be-
fore starting any maintenance work on
the dryer:
Switch the main switch to 0/Off and
lock it in this position with a padlock.
Leave a sign with the name of the per-
son authorized to switch on the main
switches.
Never touch any plugs of the electrical
connections or disconnect them when
the dryer is in operation. Protect all
plugs of electrical connections against
moisture, contamination and damage.
Faulty cables, plugs and insulation
should be repaired by skilled person-
nel only, using original spare parts.
Caution - Fire hazard due to displaced
sheets and sheet fragments
If sheets or sheet fragments are lost in
the press, you need to search for them
and completely remove them from the
press. Otherwise, these sheets or sheet
fragments could be dragged into the dry-
er area and cause fires.
Caution - Damage to dryers when
dropping!
Strong shocks cause damage to the ra-
diators in the slide-in dryer. The slide-in
dryers are heavy. Have a second person
stand at the guide rail to assist you in re-
moval and transportation of the dryer.
Do not grab hold of the radiators.
B.12.4 SC.999.0020/01
Dryer
2 Dryers in the units (optional)
SC.B01.1402-000UTKENU_01
2.1 General notes
Your machine can be equipped ex factory with one or
SF.901.0408-000GRAUND_00
more Y units (optional).
The Y unit contains an interdeck dryer (Fig. 1) and an
additional dryer (Y dryer, Fig. 2/1).
The dryers work with infrared technology (IR) and/or
hot air (HA).
The interdeck dryer can be removed for cleaning, for
example. The Y-unit dryer can be swung upwards; it
cannot be removed.
This chapter gives you operating information about the
following topics:
● Overview
● Switching on the dryer
Fig. 1 Interdeck dryer ● Removing and installing the interdeck dryer
● Swinging the Y-unit dryer up and down
SF.901.6974-000GRAUND_00
● Adjusting the sheet guide straps
More information about installing and removing, clean-
ing and maintaining the interdeck dryer and the Y dryer
1
can be found in the operating manual of the manufac-
turer. This operating manual is provided with the
press.
Caution - Damage on dryer and print-
ing press!
The interdeck dryers used are designed
specifically for this machine model. Nev-
er replace the interdeck dryers with dry-
ers from a different manufacturer.
Fig. 2 Dryers in the intermediate unit
SC.999.0020/01 B.12.5
Dryer
2.2 Overview (example)
Interdeck dryer, Y-unit dryer
SF.901.6969-000GRAUND_00
1
5 4 3 2 1
. Interdeck dryer (IR and HA)
Dryer air 100 °C
2
. Y dryer (IR and HA)
Dryer air 100 °C
3
. Interdeck dryer (IR and HA)
Dryer air 100 °C
Fig. 3 Dryer diagram, example 4
. Y dryer (HA)
Dryer air 100 °C
5
. Interdeck dryer (HA)
Ambient air and suction
2.3 Switching on the dryer
Depending on the country of destination, the dryers
FS.901.6968-000GRAUND_00
(Fig. 4) may be ready for operation as soon as the
machine is switched on. Simply switch on the machine
at the main switch.
or
You must switch on the dryers separately at the control
cabinet (Fig. 5).
Fig. 4 Dryer control cabinet without main switch
B.12.6 SC.999.0020/01
Dryer
Requirement
JB.901.0428-000GRAUND_00
The press is switched on.
1. Activate the dryer with the main switch (Fig. 5/1)
on the dryer control cabinet.
The dryer is ready to run.
1
2. Select the dryers and functions on the control
station. Information on controlling the dryer op-
eration is available in the control system operat-
ing manual.
When production starts, the control system switches
on the dryers in the press.
When the Emergency Stop button is pressed during
production, all dryer units are switched off.
When switching off the dryers, the supply air and ex-
haust air blowers keep running for a period of time.
Fig. 5 Dryer cabinet (country-specific) with main
switch
2.4 Removing/fitting the interdeck dryer
Removing an interdeck dryer
SC.B01.1404-000GRAUND_01
Note
Dryers can become very hot. After the
interdeck dryer has been in operation,
1 wait until the interdeck dryer and the sur-
rounding areas have cooled down and
are only lukewarm.
1. First, open the automatic plate changer (Fig. 6/1),
if available, or the corresponding protection grid.
2. Open the guard above the connecting box of the
interdeck dryer (Fig. 6/2).
3. Open the transfer guard (Fig. 6/3) above the
transfer cylinder.
4. Disconnect the plug of the interdeck dryer on
3 D.S. from the press.
Unlatch the safety rail and disconnect the plug.
2
5. Grip the interdeck dryer by the handle on O.S.
6. Swing up the interdeck dryer.
The interdeck dryer remains in the swung-up position.
Fig. 6 Opening the guards
SC.999.0020/01 B.12.7
Dryer
Note
The plug and cable are permanently
connected to the interdeck dryer. When
removing the interdeck dryer, hold the
plug and the connecting cable away
from gripper systems and adjacent ma-
chine parts.
You can store the plug in the lateral
opening of the dryer on D.S.
7. Pull the interdeck dryer slightly toward O.S. until
you can lift it up.
8. Lift the interdeck dryer on O.S. out of the bearing
bracket. Pull the interdeck dryer upwards to de-
tach it.
Note
The interdeck dryer weighs approx.
25 kg. Enlist the help of a second person
to lift out the interdeck dryer.
You can pull the interdeck dryer across the entire width
of the press toward O.S. in the guide rail.
9. Pull out the interdeck dryer toward O.S. until it
hits the stop.
10. With the help of a second person:
Lift the interdeck dryer out of the guide rail.
11. Put down the interdeck dryer in a clean, safe
place.
12. Close all open guards.
Installing an interdeck dryer
JB.901.0422-000GRAUND_00
1. First, open the automatic plate changer (Fig. 6/1),
if available, or the corresponding protection grid.
2. Open the guard above the connecting box of the
interdeck dryer (Fig. 6/2).
1 3. Open the transfer guard (Fig. 6/3) above the
transfer cylinder.
4. With the help of a second person:
Place the interdeck dryer (Fig. 7/1) into the guide
rail on O.S.
Note
When inserting the interdeck dryer, hold
the plug and the connecting cable away
from gripper systems and adjacent ma-
chine parts.
Fig. 7 Interdeck dryer on guide rail 5. Slide the interdeck dryer toward D.S.
B.12.8 SC.999.0020/01
Dryer
6. On O.S., place the bearing bracket of the inter-
JB.901.0421-000GRAUND_00
1 deck dryer (Fig. 8/1) into the guide rail.
Note
Do not swing down the interdeck dryer
yet.
7. Push the interdeck dryer towards D.S. until it hits
the stop.
8. Take the plug out of the lateral opening of the
dryer on D.S.
9. Swing down the interdeck dryer.
10. Reconnect the interdeck dryer plug to the ma-
chine on D.S.
Press the plug into the plug-type coupling.
11. Swing up the safety rail.
Fig. 8 Bearing bracket O.S.
12. Close all open guards.
2.5 Y dryer
Swinging up the Y-unit dryer
SC.B01.1404-001GRAUND_00
Note
Dryers can become very hot. After using
the Y dryer, wait until it and the surround-
1 ing areas have cooled down and are only
lukewarm.
1. First, open the automatic plate changer (Fig. 9/1),
if available, or the corresponding protection grid.
2. Open the transfer guard (Fig. 9/2) above the
transfer cylinder.
3. Take the Y dryer by the handle on D.S. or O.S.
4. Swing up the dryer.
5. Lock the dryer in the upper position. Lift the safety
lever on O.S. and let it engage with the pin at the
2
side.
Fig. 9 Opening the guards
Swinging the Y dryer into work position
1. Unlock the Y dryer on O.S.
Pull up the safety lever.
2. Grip the dryer by the handle and swing it down.
3. Close all open guards.
2.6 Cleaning the interdeck dryer and the Y dryer
Observe the specifications in the operating manual
from the manufacturer.
SC.999.0020/01 B.12.9
Dryer
You can find notes on washing fluids in the "Mainte-
nance and cleaning, customer" manual.
2.7 Adjusting the sheet guide straps
Note
SF.901.6867-000GRAUND_00
1 2
After using the dryers, wait until the dry-
ers and the surrounding areas have
cooled down and are only lukewarm.
Interdeck dryer and intermediate dryer
can remain installed and in work position
when the sheet guide straps are adjust-
ed.
1. First, open the automatic plate changer, if avail-
able, or the corresponding protection grid.
2. Open the transfer guard above the transfer cylin-
der.
3. Adjust the sheet guide straps (Fig. 10/1) to the
current print job.
Using the pin wrench, press the clamping bolts
(Fig. 10/2) on the sheet guide straps, and shift the
sheet guide strap on the cross bar.
Position the sheet guide straps within the sheet
size to image-free areas, if possible.
Fig. 10 Adjusting the sheet guide straps
4. For small print formats: Position all unneeded
SF.901.6866-000GRAUND_00
sheet guide straps (Fig. 11/1) in the print-free
margin on D.S. or O.S.
5. Close all open guards.
Fig. 11 Sheet guide strap O.S.
B.12.10 SC.999.0020/01
Dryer
3 UV interdeck dryer (optional)
SC.B01.1404-000UTKENU_00
3.1 General information about UV interdeck dryers
Ex factory, the printing press can optionally be
equipped with one or more "Heidelberg DryStar UV"
interdeck dryer(s).
This chapter gives you operating information about the
following topics:
● General information about the handling of UV in-
terdeck dryers
● Operating information about adjusting the sheet
guide straps
You can find more information on how this is done in
the operating manual of the manufacturer:
● Cleaning or changing the filtering mat
● Maintenance and cleaning of the interdeck dryer
Caution - An incorrect dryer type can
damage the printing press!
The employed "Heidelberg DryStar UV"
interdeck dryer has been designed
specifically for this press model. It may
not be replaced with a dryer from a dif-
ferent manufacturer. Use only "Heidel-
berg DryStar UV" interdeck dryers.
3.2 Adjusting the sheet guide straps
Note
FS.901.6864-000GRAUND_00
For larger formats and when the inter-
deck dryer is installed, you should insert
all sheet guide straps if possible. For
smaller sheet sizes use at least 3 sheet
1
2 guide straps.
The printing material can hit the inter-
deck dryer when not enough sheet guide
straps are installed.
When an interdeck dryer is installed, the temperature
of the sheet guide straps can be over 200 °C.
1. After utilization of the interdeck dryer, wait until
the interdeck dryer and the neighboring areas
have cooled down and are only warm to the
Fig. 12 Sheet guide straps touch.
2. Open the transfer guard above the transfer cylin-
der.
3. Adjust the sheet guide straps (Fig. 12/1) to the
current print job.
Using the pin wrench, press the clamping bolts
(Fig. 12/2) on the sheet guide straps, and shift the
sheet guide strap on the cross bar.
Position the sheet guide straps within the sheet
size to image-free areas, if possible.
SC.999.0020/01 B.12.11
Dryer
4. With smaller print formats, position all sheet
guide straps that are not required to the image-
free area on D.S. or O.S.
5. Close all open guards.
B.12.12 SC.999.0020/01
Dryer
4 Dryers in the delivery (optional)
SC.B01.1403-000UTKENU_00
4.1 Delivery versions
Depending on model and design, your press can be
equipped with various different slide-in dryers.
Note
For more specific operating and mainte-
nance information, please refer to the
separate operating manual for the dryer
of your press.
4.2 Variants and drying principle
Standard Delivery
FS.901.9862-000GRAUND_00
The press can be equipped with a slide-in dryer
(Fig. 13/1) in the sheet ascent ramp.
1 The slide-in dryer can be a UV dryer (without cold air)
or a combined infrared hot-air dryer.
Extended delivery
Depending on the configuration, the press can be
equipped with up to three slide-in dryers
(Fig. 14/1 ... 3).
The slide-in dryers can be UV dryers (with cold air) or
combined infrared hot-air dryers.
Heidelberg offers the option of combining various dry-
er variants in the extended delivery, see Tab. 1.
Drying principle
the sheets are dried with a combination of hot air and
Fig. 13 Standard delivery with one slide-in dryer infrared radiation. A sensor in the delivery continually
measures the temperature of the incoming sheets and
FS.901.9863-000GRAUND_00
the pile surface.
3 2 1
On presses with UV equipment, the sheets are dried
with UV radiation.
Before they are delivered, the sheets are cooled with
ambient air.
Operation and Adjustment
You can set all dryer functions at the control station.
Information on this is available on the control station in
the corresponding operating manual.
The hot air temperature and the output of the infrared
Fig. 14 Double extended delivery with three slide-in
radiators and cold/hot air blowers can be adjusted
dryers
manually. With the selectable automatic function, the
dryer automatically adjusts the hot air temperature and
the IR output to the preselected temperature of the pile
surface.
SC.999.0020/01 B.12.13
Dryer
Possible slide-in unit variants are listed in the following
FS.901.9873-000GRAUND_00
X3 X2 X1
table. The order of the individual dryer variants is vari-
able in the process. Depending on the press configu-
X0 ration, a UV dryer, an infrared dryer or a cold air/hot air
slide-in unit can be used in each slide-in unit.
Module in Delivery Possible Slide-In
Dryer/Air Unit
Sheet ascent ramp X0 UV
IR + HL
X1 extension module UL/KL or
Fig. 15 Diagram of the triple extended delivery HL or UV
X2 extension module UL/KL or
HL or UV
X3 extension module UL/KL
Tab. 1
Legend
UV = UV dryer
IR = Infrared dryer
HL = Hot-air slide-in unit
UL/KL = Plug-in unit for circulating air/cold air
4.3 Switching on the dryer
1. Switch on the dryer on the dryer control cabinet
SG.901.9864-003GRAUND_00
(Fig. 16/1).
The dryer is ready to run.
2. Switch on the dryer mode on the control station.
For information on how to activate the dryer
mode, see the related operating manual on the
control station.
At the beginning of production, the control system
switches on all selected dryer units.
When the Emergency Stop button is pressed during
1 production, all dryer units are switched off.
On presses with UV equipment, the UV dryers in the
delivery only go off if the Emergency Stop button on
the last PU/AU or delivery is pressed during produc-
tion. If the Emergency Stop button on a different PU or
on the feeder is pressed, the UV dryer switches into
"Standby".
When switching off the dryers, the fresh air and ex-
haust air blowers continue running for approx. one
minute.
Fig. 16 Dryer control cabinet
4.4 Removing and cleaning the slide-in dryer
Powder, paper dust and grease residue can burn into
the radiation lamps of the dryer slide-in units and short-
en their service life. You can find notes on cleaning the
B.12.14 SC.999.0020/01
Dryer
slide-in dryers and the dryer section in the manufac-
turer's operating manual. Repairs to the dryer system
may only be performed by authorized service staff.
Pulling Out Slide-In Dryer into Cleaning Position
SG.901.9865-001GRAUND_00
The slide-in dryers can be accessed after opening the
doors on the operator's side of the delivery.
You can:
1 2 ● pull out the slide-in dryers for cleaning,
● remove the slide-in dryers for service work.
The slide-in dryers are equipped with safety switches.
When you pull out a slide-in dryer, the emergency stop
function is activated.
On presses with a perfector, the emergency stop func-
tion only becomes active when the slide-in dryer is re-
moved. Only the inching mode is possible with the
dryer pulled out.
Fig. 17 Dryer slide-in unit in the delivery 1. Move the handle (Fig. 17/2) on the slide-in dryer
upwards.
SG.901.9866-001GRAUND_00
2. Pull the slide-in dryer by the recessed grip
1 (Fig. 18/1) all the way out to the stop.
You do not have to remove the dryer to clean it!
Cleaning the slide-in dryer
Caution - Damage to the radiators
caused by improper handling!
Radiators are very fragile. Do not touch
the radiators with bare hands. Avoid fin-
gerprints. Protect the slide-in dryer
against vibrations. Do not use any scour-
ing or acidic cleaners. Radiators with a
damaged gold layer are no longer us-
able.
Fig. 18 Slide-in dryer removed (cleaning position)
Be sure to observe the notes in the operating manual
from the manufacturer.
1. Clean the slide-in dryer with a dry, soft cloth. Use
an authorized industrial vacuum cleaner to vac-
uum the metal surfaces of the slide-in dryer.
Removing Slide-In Dryer
SG.901.9865-001GRAUND_00
Caution - Damaging the dryers by
dropping them!
Heavy impacts damage the radiators in
1 2 the slide-in dryer.
The slide-in dryers are heavy. Ask a sec-
ond person to assist you in removing and
transporting the dryers. Do not grab hold
of the radiators.
1. Move the slide-in dryer into the cleaning position.
2. Have a second person hold the slide-in dryer.
3. Press the release button (Fig. 19/1) and pull out
the slide-in dryer until just before the guide end.
Fig. 19 Dryer slide-in unit in the delivery
SC.999.0020/01 B.12.15
Dryer
Note
There are several recessed grips on the
front and the sides of the slide-in dryer
for pulling out and transporting the unit.
4. With the help of the second person, remove the
slide-in dryer and place it in a protected location
on its back.
4.5 Fitting the slide-in dryer
1. Fit the slide-in dryers in the opposite order to
which you removed them.
You do not have to press the release button to
slide-in the slide-in dryers.
4.6 Operation without slide-in dryers
If you wish to operate the press without slide-in dryers,
guard covers must be fitted in front of the slide-in dryer
openings. The guard covers are part of the press de-
livery.
On presses that are supplied without slide-in dryers,
the slide-in openings in the delivery are covered with
glass plates.
B.12.16 SC.999.0020/01
Dryer
5 Print-related notes on the dryer
FS.901.9110-000UTKENU_00
5.1 Pile temperature
The pile temperature required depends on the:
● type of printing material,
● type of ink,
● press speed,
● area coverage.
You have to determine the correct pile temperature for
each print job. The following pile temperature guide
values will help you to find the optimal setting.
● Protective varnish: 30 ... 34 °C
● Ink drying: 36 °C
● Glossy varnish: 36 °C
● High gloss varnish: 36 ... 38 °C
If no experimental values are available yet, proceed as
follows:
● Ink drying
Reduce the pile temperature to 30 °C. If the pile
temperature is too high, the ink might become
soft. See that the printing sheets are delivered
smoothly to avoid scratches on the sheets.
● Varnish drying
Change the delivery pile more frequently. The
risk of blocking is reduced by having a lower pile
height.
If the pile temperature is too high, the printing ink
can become sticky and block the pile. If the pile
temperature is too low, the coating does not dry
properly. Gloss and scuff resistance are insuffi-
cient.
Reduce the pile temperature in case of:
● multiple passes,
● when using inks on vegetable oil base.
Increase the pile temperature in case of:
● higher press speeds,
● a higher grammage of the printing material,
● glossy surfaces.
5.2 Temperature measurement in the pile
Oxidation processes during drying can warm up the
paper pile even further. Therefore Heidelberg recom-
mends measuring the temperature using a sword-
shaped thermometer (pile sword). Note that darker ar-
eas heat up more than bright areas.
5.3 Dryer output
Reduce the dryer output for lightweight substrates.
SC.999.0020/01 B.12.17
Dryer
Increase the dryer output for printing material with
heavy grammage.
If you wish to increase the overall dryer output:
● First increase the output of the IR dryer.
● First increase the dryer output in the sheet ascent
ramp.
If you wish to reduce the overall dryer output:
● First reduce the output of the hot-air dryer.
● First reduce the drying output of the dryer closest
to the delivery pile.
Reduce the IR dryer output when the job to be printed
has a highly varied color combination and extremely
dark sections.
5.4 Recommended settings
The recommendations specified below are only in-
tended as reference values and need to be adapted to
the prevailing conditions of your print job.
Slide-in Slide-in Slide-in Slide-in Volume Pile tem- Note
unit 1 unit 1 unit 2 unit 4 perature
sheet as- sheet as- module module X3
cent ramp cent ramp X11) Hot air 4
IR Hot air 1 Slide-in
unit 3
mod-
ule X21)
Hot air 2/3
Cardboard High-gloss 70...100 % 100 ºC 70 ºC 20 ºC 100 % 36 ... 38 ºC IR at
varnish 12000 ... 1
8000 iph
See note
below
Protective 50 ... 70 % 100 ºC 50 ºC 20 ºC 30 ... 34 ºC
varnish
Paper High-gloss 70 % 100 ºC 50 ºC 20 ºC 36 ... 38 ºC See note
coated on varnish below
one side
Protective 30 ... 50 % 70 ºC 30 ºC 20 ºC 30 ... 34 ºC
varnish
Paper Glossy var- 70 % 100 ºC 30 ºC 20 ºC 32 ºC
coated on nish 34 ºC
both sides
Protective 30 ... 50 % 70 ºC 30 ºC 20 ºC 30 ºC
varnish 33 ºC
Labels Glossy var- 20 ... 50 % 70 ºC 30 ºC 20 ºC 36 ºC See note
nish below
Protective 20 ... 50 % 70 ºC 20 ºC 20 ºC 34 ºC
varnish
Tab. 2 Presses in operation without perfector
B.12.18 SC.999.0020/01
Dryer
1)
Depending on the configuration of your press.
Note
Many high gloss varnishes produce bet-
ter results at pile temperatures lower
than 32 ºC.
Slide-in Slide-in Slide-in Slide-in Volume Pile tem- Note
unit 1 unit 1 unit 2 unit 4 perature
sheet as- sheet as- module module X3
cent ramp cent ramp X11) Hot air 4
IR Hot air 1 Slide-in
unit 3
mod-
ule X21)
Hot air 2/3
Cardboard High-gloss 70...100 % 100 ºC 70 ºC 20 ºC More than 34 ... 36 ºC IR at
varnish 250 g/m2 : 12000 ... 1
50 % 8000 iph
200 g/m2: See note
38 % below
Protective 50 ... 70 % 100 ºC 50 ºC 20 ºC 170 g/m2 : 30 ... 34 ºC
varnish 30 %
Paper High-gloss 55 ... 100 % 80 ºC 40 ºC 20 ºC 15 % 33 ... 35 ºC See note
coated on varnish Cold air below
one side with
Protective 30 ... 50 % 80 ºC 40 ºC 20 ºC 30 ... 34 ºC
varnish 135 g/m2:
20 %
Tab. 3 Presses in perfecting mode
1)
Depending on the configuration of your press.
Note
Many high gloss varnishes produce bet-
ter results at pile temperatures lower
than 32 ºC.
5.5 Air circulation in the press room
During the drying process of inks and dispersion var-
nishes, the warmed-up air absorbs water. The air can
only take a limited quantity of water. Therefore you
should provide a sufficient supply of fresh air.
SC.999.0020/01 B.12.19
Dryer
B.12.20 SC.999.0020/01
Index
Index
A Brake module
– Adjusting the air individually B.10.57
Adjustment information for special printing material
B.5.122
Air in the pile area B.10.41 C
Air settings
Central oil lubrication
– Control panel B.10.36
– Emptying the residual-oil reservoir B.6.104
– Format bridging device B.10.49
Chambered blade B.11.53
– Sheet ascent ramp B.10.36
– Metering B.11.9, B.11.10, B.11.83, B.11.90
Air-supported sheet guiding B.6.102
Chambered blade and pressurized chambered blade
Automatic non-stop pile change B.5.14, B.5.33
– Adjustment to the screen roller B.11.70
– Determining the actual sheet size B.5.34
– Cleaning B.11.68
– Interruption B.5.23, B.5.43
– Coating operation B.11.63
– Maintenance work B.5.25, B.5.45
– Cutting the blade to size B.11.59
– Malfunctions B.5.20, B.5.40
– Design B.11.56
– Performing a pile change B.5.15, B.5.34
– Fitting B.11.63
Automatic non-stop system B.10.132, B.10.140
– Function B.11.54
– Troubleshooting B.10.138, B.10.140
– Inserting the doctor blade B.11.60
– With belt table B.10.132
– Inserting the gaskets B.11.60
– With delivery belt table B.10.140
– Preparation B.11.57
Automatic pile alignment B.5.30
– Removal B.11.68
Automatic plate changer B.7.15, B.7.17, B.7.20
Chambered doctor blade and coating unit
– Malfunctions in data transmission B.7.29
– Cleaning B.11.66
– Malfunctions when removing the plate B.7.22
Changing bearings
– Plate loading faults B.7.30
– Screen rollers and metering rollers B.11.51
AutoPlate B.6.46
Changing plates B.6.46
– Required size for the edge-bent printing plate
Changing screen roller
B.6.42
– Tool B.11.41
– Technical printing plate requirements B.6.43
Cleaner
AutoPlate Pro B.7.4
– Requirements B.6.53
– Blade trough B.7.4
Cleaning
– Electronic flag B.7.5
– Format bridging B.10.49
– Manually removing the plate B.7.12
Cleaning tape inserter B.10.108
– Manual plate change B.7.12
Cleaning the dampening system B.9.24
– Mounting the plate manually B.7.13
Cleaning the tape inserter B.10.114
– Overview B.7.4
CleanStar B.10.99
– Plate change B.7.10
Coating blanket
– Usable printing plates B.7.4
– Installation B.11.20
Autoprotect B.8.47
– Removing B.11.18
Coating blanket cylinder B.11.13
B – Clamping device B.11.14
– Packing sheet B.11.15
Bearer B.6.9
Coating blanket cylinder with combination clamping
Blanket cylinder B.6.53
rails B.11.31
– Mounting the blanket B.6.57
Coating pan
– Packing B.6.12
– Installation B.11.61
– Preparing blanket B.6.53
– Removal B.11.69
– Preparing packing sheet B.6.57
Coating plate
– Removing the blanket B.6.55
– Installation B.11.27
Blanket washup device B.6.65
– Removal B.11.24
– Fitting the washup unit B.6.75, B.6.76
Coating plate change
– Mounting a washup cloth B.6.71
– Tools B.11.14
– Preparing the cloth supply roll B.6.69
CoatingStar B.11.83
– Removing the washup cloth B.6.69
– Aborting the cleaning process B.11.88
Blower bar B.9.23
– Cleaning program B.11.88
SC.999.0020/01 Ind.1
Index
– Cleaning with fresh water B.11.87 Cover plates on the delivery B.10.27
– Cleaning with washing fluid B.11.86 – in the horizontal area B.10.30
– Pumping capacity B.11.84 – on the sheet ascent ramp B.10.27
– Recording a cleaning program B.11.89 Crash bar
– Tips on cleaning B.11.84 – Adjusting B.5.121
CoatingStar Compact B.11.90 – Function B.5.121
– Aborting the cleaning process B.11.95 CutStar B.5.124
– Cleaning program B.11.94 CutStar Preset Plus
– Cleaning with washing fluid B.11.94 – Operation with B.5.124
– Control panels B.11.91 – Operation without B.5.127
– Pumping capacity B.11.92 Cylinder rolling B.6.9–B.6.11
– Tips on cleaning B.11.93 Cylinder undercut B.6.9
– Varnish circulation B.11.90
Coating unit B.11.9
D
– Chambered blade and pressurized chambered
blade B.11.53 Dampening distributor
– Coating blanket cylinder with combination clamping – Cleaning B.9.24
rails B.11.13 Dampening solution B.9.6
– CoatingStar B.11.83 Dampening solution amount B.9.4
– CoatingStar Compact B.11.90 Dampening solution pan
– Mounting/demounting the coating blanket – Cleaning B.9.10
B.11.18 Dampening system B.9.9
– Mounting/demounting the coating plate B.11.24 – Adjusting the rollers B.9.13
– Print-related notes B.11.11 – Dampening solution pan B.9.10
– Screen roller B.11.40 – Installing the rollers B.9.13
– Spraying device of screen roller B.11.78 – Manual washup B.9.5
Combination clamping rails B.11.13 – Overview B.9.9
Compressed-air control unit A.1.58 – Print-related notes B.9.4
Contact B.9.4 – Removing rollers B.9.11
Control panel Delivery
– Air control B.2.12 – Control panel B.4.3
– Air settings B.10.36 – Cover plates behind CleanStar B.10.31
– CoatingStar B.11.84 – Cover plates in the horizontal area B.10.30
– CoatingStar Compact B.11.91 – Cover plates on the sheet ascent ramp B.10.27
– Dampening system O.S. B.3.8 – Guide pulleys B.10.19
– Feeder start control B.2.8 Detection of whole body access A.1.51
– First printing unit B.3.5 Determining the actual sheet size B.5.8, B.5.28,
– Non-Stop and Autopile pile control B.2.6 B.10.133
– Pile control B.2.4 Distribution, lateral B.8.5
– Printing unit D.S. B.3.8 Double sheet detector
– Printing unit O.S. B.3.6 – Clearing the feeder B.5.95
– Suction head B.2.13 – Double sheet detector in the pull lay (option)
Control panels B.5.88
– Coating unit B.3.9 – Multiple sheet detector B.5.88
– Feeder B.2.3 – Sheet monitoring B.5.85
– Intermediate unit B.3.17 – Sheet stream / multiple-sheet detector B.5.91
Controls A.1.25 – Switching the feeder back on B.5.93
– Control panel selection A.1.30 – Ultrasonic double sheet detector B.5.86
– Emergency stop palm button A.1.26 Dryer
– Main switch A.1.25 – Dryers in the delivery B.12.13
– Reset A.1.29 – Print-related notes B.12.17
– Zone stop palm button A.1.28 Dryers in the delivery B.12.13
Control station – Cleaning the slide-in dryer B.12.15
– Checking protective devices A.1.54 – Fitting the slide-in dryer B.12.16
Cover plates behind CleanStar B.10.31 – Operation B.12.14
– Operation without slide-in dryers B.12.16
Ind.2 SC.999.0020/01
Index
– Removing the slide-in dryer B.12.14 Forwarding sucker
– Variants B.12.13 – Adjusting the height B.5.52
Dryers in the units B.12.5 Forwarding suckers B.5.52, B.5.54
– Cleaning B.12.9 Front lays B.5.118
– Installing an interdeck dryer B.12.8 – Adjusting the blowing/suction nozzles B.5.120
– Overview B.12.6 – Adjusting the gripper bite B.5.119
– Removing/fitting the interdeck dryer B.12.7 – Cleaning B.5.119
– Removing an interdeck dryer B.12.7 – Throwing on/off B.5.118
– Switching on B.12.6 Function
– Y dryer B.12.9 – CleanStar B.10.99
DWBA – Format bridging device B.10.49
– Operator protection through the protective device – Non-stop pile change B.10.120
for the detection of whole body access B.10.10 – Overrun sheet control B.10.90
– Pile change B.10.117
– Rear edge stop B.10.96
E
– Rear edge suction B.10.98
Emergency stop A.1.26 – Removal of sample sheet B.10.103
Extractor B.11.51 – Sheet joggers B.10.92
F G
Fans Gluing on the polyester underlay foil B.6.28
– Adjusting B.10.42 Gripper opening cam
– ON/OFF B.10.41 – Setting B.10.87
– Positioning B.10.43 Gripper pads
Feeder – Height adjustment B.6.13
– Safety instructions B.5.7 Guards
Feeder emergency measures B.5.134 – Fixed guards A.1.33
– Manually setting air volume controller B.5.141 Guide plate B.5.80
– Manually setting cover guide height B.5.138 – Adjusting B.5.80
– Manually setting pull lays to sheet width B.5.142 Guide pulleys B.10.19
– Manually setting side stops to sheet size B.5.137 – Engaging/disengaging sheet supports B.10.25
– Manually setting suction head to sheet size – Fitting B.10.22
B.5.135 – Positioning B.10.24
– Manually throwing off the separator rolls B.5.140 – Releasing the locking device B.10.21
– Manual suction head height adjustment B.5.136 – Removing B.10.26
– Overview B.5.134 – Table of variants B.10.20
Feeder touch screen – Variants B.10.19
– Feeder menu B.2.26 Guide rolls on the suction tape B.5.104
– Production menu B.2.23
Fitting/removing rolling bearings B.11.51
H
Flexokit B.11.10
Foil printing B.5.70 Hand-held scanner with base station B.6.30
– Forwarding suckers B.5.72 Hickey catcher B.6.29
– Ionizing unit B.5.70
– Lifting suckers B.5.72
I
– Rear edge blowing unit B.5.73
– Special air-blast nozzles for the suction head Impression cylinder washup device B.6.80
B.5.70 – Function and design B.6.80
Format bridging – Installing B.6.88
– Cleaning B.10.49 – Mounting a washup cloth B.6.86
Format bridging device – Operation B.6.80
– Function B.10.49 – Preparing the cloth supply roll B.6.83
– Setting B.10.49 – Removing B.6.81
Forwarding flap B.5.55 – Removing the used-up washup cloth B.6.82
Forwarding rollers – Roll specifications B.6.84
– Adjusting to sheet format B.5.103 Ink fountain B.8.41, B.8.52
SC.999.0020/01 Ind.3
Index
Ink fountain liner Lifting sucker
– Replacing B.8.41 – Adjusting the height B.5.51
– Retightening B.8.41 – Replacing the foam ring/foam strip B.5.51
Ink fountain roller Lifting suckers B.5.50, B.5.54
– condensation of water B.8.9 – Replacing B.5.50
Inking form rollers Longitudinal blast tubes
– Lateral clearance B.8.8 – Setting B.10.43
Inking roller Lost sheets B.6.16
– Concise instructions B.8.12
Inking rollers
M
– Installing B.8.22
– Preparations for removal B.8.16 Main switch A.1.25
– Removing B.8.18 Malfunctions B.6.104
– removing and installing B.8.11 Metering roller
– Width of contact area B.8.13, B.9.9 – Changing bearings B.11.51
Inking roller washup device B.6.95 – Cleaning B.9.24
Inking unit Modular sheet brake system
– Lateral distribution B.8.5 – Handling the sheet brake modules B.10.59
– Safety instructions B.8.3 – Overview B.10.52
– Template for roller adjustment B.8.33 Mounting the blanket
Inking unit temperature control B.8.9 – Metal-backed blanket B.6.57
Ink vibrator B.8.36 Multiple sheet detector
– Adjusting B.8.36 – Switching the feeder back on B.5.94
– Installing B.8.36
– Removing B.8.36 N
Inner carrier air blowers
– Adjusting the blast air B.5.60 Non-gripped sheets
Inserting/changing a tape roll B.10.107 – In straight printing units B.6.16
Inserting/changing the tape rolls B.10.110 – In the perfector B.6.18
Installing blanket – In the printing unit/coating unit B.6.16
– Conventional blanket B.6.60 – In the sheet reversing area B.6.19
Intelliline – Units after the perfector B.6.17
– LED bar B.3.3 Non-stop feeder
Intermediate roller B.9.4 – Pile heights B.5.26, B.5.46
Intermediate unit Non-stop pile change
– Adjusting the sheet guide straps B.12.10 – Function B.10.120
Ionizing blowers at the suction head B.5.67 – Manual B.10.124
– Activation/deactivation B.5.67 – Non-stop operation with non-stop rake B.10.126
– Positioning B.5.68 – Non-stop operation with rack board B.10.127
Ionizing unit B.5.63 – Performing B.10.125
– Preparing B.10.124
– Recommended adjustments B.10.123
L – Sheet catcher B.10.122
Lateral distribution B.8.5
– Changing the distribution travel B.8.5 O
– Changing the start of distribution B.8.6
Lateral sheet separation blowers B.5.78 Operating mode
– Automatic adjustment B.5.78 – Crawl speed mode A.1.32
– Manual adjustment B.5.78 – Inching mode A.1.31
– Setting the blast air volume B.5.79 – Positioning A.1.32
Lateral tape inserter B.10.109 Operator protection through the protective device for
Lateral tape inserter, design B.10.109 the detection of whole body access, DWBA B.10.10
LED bar on printing unit guard B.3.3 Outer carrier air blowers
– Cleaning the LED bar and LED element B.3.4 – Adjusting the blast air B.5.60
Lifting/lowering the tape inserter B.10.112 – Adjusting the direction of blast air B.5.60
– Adjusting the height B.5.60
Overdampening B.9.5
Ind.4 SC.999.0020/01
Index
Overrun sheet control – Plate detection error B.7.30
– Comb B.10.91 – Positions B.7.6
– Function B.10.90 Plate cylinder B.6.28
– Ultrasonic sensor B.10.90 Pneumatic system A.1.58
Overview - suction head settings B.5.54 – Aerating A.1.60
– Bleeding A.1.59
– Securing against start-up A.1.59
P
Positioning correction B.6.50
Packing B.6.10 – At the tail edge B.6.50
Packing sheet Positioning correction for coating blanket cylinder
– Preparing B.11.15 – Correcting the coating plate in the circumferential
Packing thickness direction B.11.33
– Blanket cylinder B.6.12 – Shifting the print start in the circumferential
– Plate cylinder, measurement B.6.11 direction B.11.34
Pile alignment Positioning corrections B.11.31
– Automatic B.5.30 – Coating blanket cylinder with combination clamping
– Determining the actual sheet size B.5.30 rails B.11.31
Pile area Positioning corrections for coating blanket cylinder
– Adjusting the air B.10.41 – Tensioning/buckling the rear edge of the coating
– Longitudinal blast tubes B.10.43 plate B.11.32
Pile change Powdering B.10.44, B.10.46, B.10.47
– Determining the actual sheet size B.5.8, – Checking the powder application B.10.47
B.10.133 – Disadvantages B.10.45
– Function B.10.117 – Powder application / powder selection B.10.45
– Malfunctions B.10.129 – Powder grain size B.10.45
– Non-stop pile change B.5.10 – Powder quality B.10.45
– Normal pile change B.5.8 – Powder volume B.10.46
– Performing B.10.118 – Print-related notes B.10.45
– Pile control panel B.10.118 – Production B.10.46
– Preloading device B.5.28 Powder spray device B.10.44
Pile heights Preloading B.5.28
– for a printing press raised 525 mm B.5.46 Preparing blanket
– for a printing press raised 875 mm B.5.46 – Conventional blanket B.6.54
– on printing press raised 500 mm B.5.26 – Metal-backed blanket B.6.53
– on printing press raised 900 mm B.5.27 Pre-separation air
Pile stops on the suction head B.5.62 – Adjusting B.5.61
– Adapting the pile weight to the printing material Pressing roller B.11.36
B.5.62 – Cleaning B.11.38
Plate – Installation B.11.37
– Pulling B.6.52 – Removal B.11.37
– Removal B.6.47 Pressurized chambered blade B.11.53
– Stretching B.6.51 – Fitting the outlet tube B.11.70
Plate changer – Metering B.11.91
– Error message: "General malfunction: automatic Printing plate
plate change" or "Finger protecting bar / protective – Requirements B.6.42
device" B.7.17 – Specified dimensions B.6.42
– Error message: "Malfunction: Plate rear edge Printing pressure B.6.10
sensor PU x" B.7.22 Printing-related notes
– Error message "Malfunction: Printing plate ejection, – Cylinder rolling B.6.9
printing plate end position" B.7.23 Printing unit
– Error message "Malfunction: Printing plate ejection – Air settings B.6.102
in PU x" B.7.24 – Blanket cylinder B.6.53
– Errors before the start of the plate change B.7.20 – Control panels B.3.5
– Fault on data transmission sensor B.7.29 Print-related notes
– Method of functioning B.7.8 – Dryer B.12.17
– Opening B.7.7
SC.999.0020/01 Ind.5
Index
Protective devices A.1.33 – Commissioning B.8.51
– Automatic non-stop A.1.49 – Preselecting the operating mode B.8.51
– Automatic non-stop device A.1.34 Roller protective agent B.8.47
– Checking A.1.54 – Automatically applying B.8.47
– Coating unit A.1.43, A.1.45 Rollers
– Delivery A.1.47, A.1.48 – Detaching, mounting bearings B.8.40
– Feeder A.1.34 – Servicing B.8.38
– First printing unit A.1.36 – Storage B.8.38
– Intermediate unit A.1.41, A.1.42 Rope guide B.5.80
– Printing unit A.1.37, A.1.38 – Replacing the rope B.5.81
Pulling device
– Adjusting the pull distance B.5.112
S
– Adjusting the pull stop to the stock B.5.108
– Adjusting the retainers B.5.113 Safety devices A.1.33
– Adjusting the suction air B.5.107 – Coating unit A.1.46
– Functioning B.5.106 – Plate changer A.1.39
– Removing/installing the retainers B.5.113 – Printing unit A.1.40
– Retainer B.5.112 Safety instructions A.1.1
– Setting the format B.5.106 – Coating unit B.11.5
Pull lay – Code of practice A.1.6
– Cleaning B.5.114 – Explosion protection A.1.10
Pull lay monitor B.5.109 – Handling volatile substances A.1.6
– Adjusting B.5.109 – Hints for the user A.1.1
– Adjustment principle B.5.110 – Personal protection equipment A.1.5
– Preselecting B.5.109 – Plate changer B.7.3
– Preset Plus delivery B.10.7
– Structure A.1.2
R
– Use A.1.3
Rear edge blowers Screen roller B.11.40
– Adjusting the blast air B.5.61 – Bearing B.11.39
– Adjusting the direction of blast air B.5.61 – Changing bearings B.11.51
Rear edge stop B.10.96 – Cleaning B.11.39, B.11.40
– Setting automatically B.10.96 – Cleaning and maintenance B.11.39
– Setting manually B.10.97 – Installing B.11.46
Rear edge suction B.10.98 – Removing B.11.41
Recommended adjustments – Spraying device B.11.78
– Non-stop pile change B.10.123 – Transport B.11.39
Recommended setting Sensing roller B.5.92
– Air, extension area B.10.39 Separator rolls
– Air, sheet ascent ramp B.10.39 – Cleaning B.5.116
– Air, sprocket wheel shaft area B.10.38 – Cleaning the sheet guide plate B.5.117
Removal of sample sheet – Function B.5.115
– Function B.10.103 – Height adjustment B.5.115
– With CleanStar B.10.104 – Position adjustment B.5.116
– Without pile lowering B.10.104 – Throwing off B.5.116
– With pile lowering B.10.103 Setting
Removing blanket – Air, format bridging device B.10.49
– Conventional blanket B.6.55 – Air, sheet ascent ramp B.10.36
– Metal-backed blanket B.6.55 – Gripper opening cam B.10.87
Removing the tape module – Longitudinal blast tubes on the delivery B.10.43
– Removing the tape feeder B.10.113 – Sheet decurler B.10.40
Roller diagram B.8.11 Sheet alignment monitor B.5.96
Roller Protection Liquid B.8.47 – Early sheet or overrunning sheet B.5.96
– Advantages B.8.47 – Late sheet or missing sheet B.5.98
– Changing canister B.8.49 – Sheet infeed/Pull distance B.5.99
– Cleaning the inking rollers B.8.51 Sheet alignment monitor
– Misaligned sheet B.5.98
Ind.6 SC.999.0020/01
Index
Sheet ascent ramp Suction head
– Air settings B.10.36 – Adjusting blast air B.5.59
Sheet brake – Adjusting the blast air B.5.59
– Suction tapes B.10.85 – Adjusting the sheet size B.5.49
Sheet brake system B.10.51 – Inner carrier air blowers B.5.60
– Presses with automatic non-stop system B.10.75 – Lifting suckers and forwarding suckers B.5.54
– Presses with perfector B.10.78 – Manual height adjustment B.5.50
– Remedies in the event of problems B.10.84 – Manual operation B.5.50
– Removing/fitting a starwheel module B.10.68 – Outer carrier air blowers B.5.60
– Straight printing B.10.75 – Overview B.5.48
Sheet catcher B.10.122 – Pre-separation air B.5.61
Sheet decurler – Rear edge blowers B.5.60
– Setting B.10.40 – Reducing the air of the lifting suckers and
Sheeter B.5.124 forwarding suckers B.5.53
Sheet guide – Setting the height B.5.50
– Air-supported B.6.102 – Sheet separation blower B.5.59
Sheet guide plate under CleanStar – Sheet separation blowers B.5.55
– Cleaning B.10.35 – Sheet separator fingers B.5.54
Sheet joggers B.10.92 – Sheet stops and forwarding flap B.5.55
– Activating/deactivating the alignment movement Suction tapes B.10.85
B.10.95
– Automatic adjustment B.10.92
T
– Function B.10.92
– Manual adjustment B.10.92 Tandem washup concept B.6.96
– Setting to sheet length B.10.94 Tape inserter B.10.105
Sheet loss Tape inserter design B.10.106
– Sheet ascent B.6.20 Tape inserter malfunctions
Sheet monitoring B.5.85 – Malfunctions at the tape inserter B.10.114
Sheet separation blower Tape inserter on face side B.10.106
– Adjusting the blast air B.5.59 tape inserter operation B.10.106
Sheet separation blowers B.5.55 Tape inserter operation B.10.109
– Adjusting the height B.5.60 Tape inserter overview B.10.105
Sheet separator fingers B.5.54 Tape inserter reset B.10.112
– Adjusting the distance to the pile B.5.57 Template for roller adjustment B.8.33
– Adjusting the height B.5.57 Touch screen
– Fitting the supports B.5.57 – Control elements B.1.3
– Function B.5.57 – Footer B.1.6
Sheet stop fingers – Header B.1.4, B.1.5
– Raising the sheet stop fingers B.5.120 – Main field B.1.6
Sheet stops B.5.55 – Overview B.2.14
Sheet-transferring cylinders and drums B.6.97 – Status display B.1.7
Sized packing sheet Touch screen, 1st PU
– Installing the clamping bar B.11.16 – Consumables display menu B.2.32
– Tools B.11.15 – Job menu B.2.17
Specifications A.1.20 – Washup menu B.2.30
– Cleaners A.1.21 Touch screen 1st PU
– Electrical fusing A.1.23 – Feeder pile menu B.2.28
– Ink/Varnish A.1.20 Touch screen feeder
– Noise emission values A.1.21 – Feeder pile menu B.2.28
– Printing material A.1.20 Touch screen PU1
– Weight of the pile A.1.20 – Feeder menu B.2.26
Spraying device for screen roller – Job change tab B.2.18
– Commissioning B.11.82 – Job tab B.2.17
– Replacing canister B.11.80 – Malfunction information menu B.2.36
Start-up warning signal A.1.52 – Malfunction menu B.2.35
StaticStar B.5.63 – Overview B.2.15
SC.999.0020/01 Ind.7
Index
– Paper run menu B.2.38 W
– Service menu B.2.37
Washing fluid B.6.90
Transfer drum
– Water B.6.90
– Feed cylinder B.6.13
Washing fluid container B.6.90, B.6.95
Troubleshooting B.5.129
– Bleeding B.6.90
– Delivery B.10.142
– Filling B.6.91
Turning the press manually A.1.61
– Pressure regulator B.6.91
– Relief valve B.6.91
U Washup devices B.6.94
– Blanket washup device with washup cloth B.6.96
Ultrasonic double sheet detector B.5.86
– Inking roller washup device B.6.95
Ultrasonic sensor B.10.90
– Tandem washup concept B.6.96
Ultrasonic sheet drag monitor B.5.102
– Washing fluid container B.6.95
UV equipment B.12.11
Water
– Adjusting the sheet guide straps B.12.11
– Requirements B.6.90
– General information B.12.11
Water pan roller
UV interdeck dryer B.12.11
– Cleaning B.9.24
Workplaces at the press A.1.24
V
Varnish circulation B.11.9, B.11.83, B.11.96 Y
Varnish supply unit
Y dryer
– Control panel B.11.84
– Swinging up B.12.9
– Control panels B.11.91
– Work position B.12.9
– Design B.11.83, B.11.90
– Function B.11.83, B.11.90
– Operation B.11.84 Z
Zone stop A.1.28
Ind.8 SC.999.0020/01
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