Professional Documents
Culture Documents
Flexoprint MIRAFLEX AM OP
Eq.59468 Training manual OP
Windmller & Hlscher KG | Postfach 1660 | 49516 Lengerich | Deutschland | Tel.: +49 5481 14-0 | Fax: +49 5481 14-2649
info@wuh-lengerich.de | www.wuh-lengerich.de
Copyright Windmller & Hlscher KG
Z WINDMLLER & HLSCHER Overall table of contents
1 Training instructions
1.1 Information on the training manual
1.2 Instructions for training
2 Safety
2.1 Machine data
2.1.1 Manufacturer's address and name plate
2.1.2 Technical specifications
2.2 Workplaces
2.2.1 Overview of the workstations
2.3 Safety devices: Description
2.3.1 Emergency-Stop
2.3.2 Eltainer
2.3.3 Winder
2.3.4 Printing unit
2.3.5 Drying system
2.3.6 Central warning device
3 Machine description
3.1 Machine overview
3.1.1 Overview of the entire machine
5 Operation
5.1 Unwind
5.1.1 Design and function
5.1.2 Compressed-air supply line
5.1.3 Establishing the ready-for-operation status
5.1.4 Swiveling the turret manually
5.1.5 Loading a roll and operating the chucks
5.1.6 Switching the drive of the winding shaft on or off
5.1.7 Roll change
5.1.8 Web tension increase at the unwind
5.1.9 Lifting gear
5.2 Static removal
5.2.1 Static charge removal
5.3 Printing unit
5.3.1 Layout and function
5.3.2 Programs for deck in/deck out operations
5.3.3 Register adjustment
5.3.4 Nip roll in sleeve technology
5.3.5 Ink supply
5.3.6 Hinged cap bearing
5.3.7 Anilox roll sleeve change
6 Maintenance
6.1 ATEX-relevant greasing points
6.1.1 Important information on 'ATEX-relevant greasing points'
6.1.2 ATEX-relevant greasing points on the printing unit
6.2 Cleaning
6.2.1 Rewind
6.2.2 Unwind
6.2.3 Unwinder
6.2.4 Rewind
6.2.5 Rewind
6.2.6 Printing unit
6.2.7 Printing unit
6.2.8 Printing unit
6.2.9 Printing unit
6.2.10 Printing unit
6.2.11 Overhead structure
6.2.12 Drying system
6.2.13 Drying
6.2.14 Rear frame
6.2.15 Film slitter
6.2.16 Film slitter
6.2.17 Procontrol
6.2.18 Eltainer
6.2.19 Easy-Col
6.2.20 Easy-Set
6.2.21 Easy-Reg
1 Training instructions
1 Training instructions
1.1 Information on the training manual....................................................................................2
X000059714
All rights reserved. The training material, files / storage media and films / video cassettes are protected
by copyright law. Every utilization and/or distribution to third parties requires the prior written approval
of WINDMLLER & HLSCHER. This applies in particular to reproductions, modifications, micro-
filming, storage and processing in electronic systems as well as unlawful transfer and commercial
usage (e.g. through rental, presentation, etc.).
Disclaimer
The material included, files / data storage media and films / video cassettes have been created to the
best of our knowledge solely for training purposes. Their contents can differ, in particular with regard
to commissioned or equipment-related machine designs / documentation. As such, we cannot as-
sume any guarantee / liability that the training material and the associated training (including the
information conveyed verbally) is correct and free of errors. This applies, in particular, to technical
documentation for a specific machine type and/or for a machine with specific equipment. Damages
that occur as a result are always excluded.
The machinery and shift manager trainees must fulfill the physical and mental requirements for work-
ing with the machine. The maintenance trainees must possess qualified knowledge in the necessary
electronic and mechanical fields. The training assumes familiarity with the internationally applicable
standards, guidelines, regulations, etc. along with the national standards of the country in which the
equipment is operated. As such, these are not included in the scope of the training.
Safety instructions
The safety and accident prevention regulations applicable for the machine and the warnings included
in the instruction manual delivered with the machine must be read and complied with at all times.
Safety regulations
If the training takes place on the premises of WINDMLLER & HLSCHER then the training partic-
ipants must comply with the company's internal safety and accident prevention regulations, security
regulations and access rules. Photographs and video recordings are prohibited in the buildings.
2 Safety
Name plate
NOTE
The details given on the name plate are important for ordering spare parts. Windmller & Hlscher
can only supply the correct spare part if the machine model and equipment number are known.
Masch.-Bez.
Masch.-Typ. 2
Equip.-Nr. 3
Baujahr 4
X000323556
Space required
Length See installation drawing
Width See installation drawing
Height See installation drawing
Power supply
Connected load KVA 190
Compressed air
Pressure kPa 600
(overpressure)
Turboclean, approx. m3/h 120
(with ink mixer integrated in the cover)
Solvent analyzers, approx. m3/h 12
during sleeve change, approx. m3/min 2.5
(for each sleeve change normally lasting less than one minute)
2.2 Workplaces
2.2.1 Overview of the workstations............................................................................................2
CAUTION
Missing lighting
Potential hazards at the unwind and rewind workstations and the upper color decks due to poor
lighting.
Lamps should be provided at the superstructure to illuminate the printing section in the upper area
and the unwind and rewind workstations.
2.3.2 Eltainer..............................................................................................................................3
Main switch....................................................................................................................3
Emergency trip wire.......................................................................................................4
2.3.3 Winder...............................................................................................................................5
Double light barrier with chain.......................................................................................5
Fixed guards locked in place on the winder...................................................................6
Fixed guards on the winder...........................................................................................6
2.3.1 Emergency-Stop
When hitting the EMERGENCY-STOP button the machine stops and all of the machine movements
are slowed in a controlled manner.
DANGER
Risk of injury from the machine when starting
There is a risk for persons to get hurt if the machine is restarted before the potentially dangerous
situation has been cleared.
Eliminate all danger sources and make sure that no persons are present in the machine's protected
area before unlatching the button. Do not restart the machine unless the potentially dangerous sit-
uation has been cleared.
NOTE
There is a risk of damage when misusing the EMERGENCY-STOP button.
The machine will be exposed to great stress when actuating the Emergency-Stop pushbutton. Dam-
age to the machine may occur if the machine is usually switched off by use of the EMERGENCY-
STOP pushbutton although there is no threat of personal danger.
The EMERGENCY-STOP pushbutton must only be actuated if there is a threat of personal danger.
(-) EMERGENCY-STOP
X000192430
2.3.2 Eltainer
Main switch
The main switch serves to switch the entire electrical power to the machine on or off. Components
still live after the main switch has been switched off are covered and provided with warning signs.
Power supply to the temperature control unit is switched off.
The main switch comprises an operating element attached outside the Eltainer and a power pack
mounted inside the Eltainer. The operating element is used to switch the electrically driven power
pack on or off.
Pulling the emergency trip wire causes the main switch to be switched off immediately.
DANGER
Risk of fatal injury from electrical current.
Persons may get hurt when switching the main
switch back on before the dangerous situation
has been eliminated. Do not switch the main
switch back on unless the dangerous situation
has been eliminated.
X000192432
2.3.3 Winder
Double light barrier with chain
The winder is secured by a double light barrier with safety chain to prevent injuries caused by rotating
parts and circular knives from occurring. During production, the safety chain may only be opened to
permit operation of the roll loading and unloading systems at the winding station.
The plugged in chain is monitored by a limit switch. When the chain is unplugged, the lighted SAFETY
LIGHT GRID BLOCKED pushbutton in the operator panel of the winder flashes. All movement of the
cut-off assembly or the turret is blocked. The blocking of the rotary and traversing movements is
cleared by pushing the safety chain back in and by pressing the pushbutton.
(1) Chain 1
(2) Double light barrier
The chain (1) and the double light barrier (2) are
located on the front side of the winder.
When removing the chain while the turret is rotat-
ing or while the cut-off assembly is traversing, all
rotary and traversing movements are stopped im- 21
mediately. In production mode, the machine is
stopped in a minimum of time.
The double light barrier serves as crawl-under pro- Wic_0339
tection. When the safety chain is plugged in and
the turret and the cut-off assembly are moving, all
movement is stopped if the monitored range of the
double light barrier is entered. In production mode,
the machine is stopped in a minimum of time.
Guard doors
X000288509
The guard doors/optional roll up doors and sliding glass doors can only be opened when the color
decks on the respective side (color decks 1-4/1-5 or 5-8/6-10) are in their zero position or when the
anilox roll drives are switched off.
The doctor bars can only be moved when the guard doors/optional sliding glass doors on the re-
spective side (color decks 1-4/1-5 or 5-8/6-10) are closed.
Changes in the doctor blade pressure have an effect only when the guard doors/optional sliding glass
doors on the respective side (color decks 1-4/1-5 or 5-8/6-10) are closed
The doctor bar can only be swung on and off automatically during inking or purging when the guard
doors/optional roll up doors and sliding glass doors on the respective side (color decks 1-4/1-5 or
5-8/6-10) are closed.
Guard doors
The guard doors/optional roll up doors and sliding glass doors can only be opened when the color
decks on the respective side (color decks 1-4/1-5 or 5-8/6-10) are in their zero position or when the
anilox roll drives are switched off.
The doctor bars can only be moved when the guard doors/optional sliding glass doors on the re-
spective side (color decks 1-4/1-5 or 5-8/6-10) are closed.
Changes in the doctor blade pressure have an effect only when the guard doors/optional sliding glass
doors on the respective side (color decks 1-4/1-5 or 5-8/6-10) are closed
The doctor bar can only be swung oi and out automatically during inking or purging when the guard
doors/optional roll up doors and sliding glass doors on the respective side (color decks 1-4/1-5 or
5-8/6-10) are closed.
The guard doors/optional roll up doors and sliding glass doors can only be opened when the color
decks on the respective side (color decks 1-4/1-5 or 5-8/6-10) are in their zero position or when the
anilox roll drives are switched off.
The doctor bars can only be moved when the guard doors/optional sliding glass doors on the re-
spective side (color decks 1-4/1-5 or 5-8/6-10) are closed.
Changes in the doctor blade pressure have an effect only when the guard doors/optional sliding glass
doors on the respective side (color decks 1-4/1-5 or 5-8/6-10) are closed
The doctor bar can only be swung on and off automatically during inking or purging when the guard
doors/optional roll up doors and sliding glass doors on the respective side (color decks 1-4/1-5 or
5-8/6-10) are closed.
X000288509
Safety chain
Arrangement
(1) Emergency-Stop
(1) Emergency-Stop
X000258290
X000258290
Definitions
Term Definition
GWD Gas warning device
LEL Lower explosive limit
Specifications accord- The gas-heated drying system is laid out for a solvent vapor concentra-
ing to AS1375 (Annex tion of max.25% LEL.
F6) This threshold limit value must not be exceeded. Danger of explosion!
Specifications accord- The gas-heated drying system is laid out for a solvent vapor concentra-
ing to NFPA86 tion of max.45% LEL.
This threshold limit value must not be exceeded. Danger of explosion!
DIN EN 1539 The flow-type heaters are suited for using gases and vapors in compli-
ance with explosion hazard subgroup IIB, ex temperature class T3 (flexo-
graphic printing) and explosion hazard subgroup IIB, ex temperature
class T2 (gravure printing).
The maximum permitted concentration level in flammable substances for
dryers limited to a defined solvent vapor concentration is subdivided in
operating zones according to DIN EN 1539.
Specifications accord- The drying system in operating zone 1 is laid out for a solvent concen-
ing to EN 1539 tration of max.40% LEL.
The drying system in operating zone 1 is laid out for a solvent concen-
tration of max.40% LEL.
The LEL depends on the solvents used and the maximum drying tem-
perature. This threshold limit value must not be exceeded. Danger of
explosion!
Operating zone 1 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, exceed the threshold.
Operating zone 2 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, are below the threshold.
Tro_0266
For the mounting location of the gas warning device please refer to the electrical component ID or
the electrical circuit diagrams.
X000258290
Temperature sensors
Pressure transmitter
NOTE
For the mounting location please refer to the electrical component ID or the electrical circuit diagrams.
X000258290
Safety functions
The safety functions are constantly active and running in the background. Should a safety limit be
violated, measures will be taken immediately and the relevant error messages will be activated.
A solvent vapor analyzer continuously measures the solvent concentration in the drying air for every
drying circuit. Evaluation of the measurement and the introduction of any measures take place in the
W&H computer.
Three functions are constantly monitored:
The warning alarm
The main alarm
Checking the sensor for proper functioning
NOTE
The machine speed slows down. All color decks involved return to the ' Print Off ' printing position.
NOTE
The machine speed slows down. All color decks involved return to the ' Print Off ' printing position.
NOTE
The central warning device should be checked for proper functioning at regular intervals.
(1) Horn
3 Machine description
The module overview shows the configuration of a MIRAFLEX flexographic printing press without
inline unit. The module overview may show modules which do not form part of the customer's ma-
chine.
EASY-SET S and EASY-REG D are pure software modules and not listed in the overview. The sen-
sors on the EASY-REG S module are attached to the individual color decks.
X000103362
Item Modules
1 Main operator column PROCONTROL
2 Unwind
3 Printing unit
4 TURBOCLEAN
Item Modules
5 Cleaning agent container
6 Drying system and superstructure
7 ELTAINER
8 Rewind
9 Web tension sensing system
10 Slitter
11 EASY-SET HD
12 Rear frame
(1) Control console +R52 (2) Control elements for operating the roll up
door
(3) Control elements provided for a sleeve (4) Control console +R10 with operator ter-
change on color decks 1-4 (1-5) and for minal as an option
operating the roll up door
(5) Main control console +P59 (6) Control console +R93
X000125890
(1) Control elements provided for a sleeve (2) Control console +R51
change on color decks 5-8 (6-10) and for
operating the roll up door
(3) Pneumatic control elements for setting (4) Control console +R90 with operator ter-
up the nip rolls minal as an option
4.2.3 EMERGENCY-STOP........................................................................................................5
4.2.4 Pre-alarm/Jog....................................................................................................................5
Status of the LED in the Pre-alarm/Job pushbutton......................................................5
Pushbutton - Pre-alarm/Jog...........................................................................................6
4.2.5 Stop...................................................................................................................................6
LED status in the Stop pushbutton................................................................................6
Pushbutton Stop.........................................................................................................6
4.2.6 Slow...................................................................................................................................7
Status of the LED in the Slow pushbutton.....................................................................7
Pushbutton Slow.........................................................................................................7
4.2.7 Fast...................................................................................................................................7
Status of the LED in the Fast pushbutton......................................................................7
Pushbutton Fast..........................................................................................................8
Certain pushbuttons provide status LEDs. The meaning of the status LEDs is described in the indi-
vidual operating steps.
Blinking green:
Flashing orange:
Blinking orange:
Flashing red:
Blinking red:
X000036834
The mains switch is used to switch the entire electrical energy to the machine on or off. Parts of the
machine which are still live after the mains switch has been switched off are covered and provided
with warning signs.
The voltage supply to the temperature control unit will not be switched off.
DANGER
Risk of injury or even death caused by electric shock
When switching off the mains switch for service or repair work, it must be secured with a padlock to
prevent unauthorized persons switching it back on. The name of the person who switched off the
machine, the time and the approximate period that it will be switched off must be documented on a
sign that is clearly visible to everyone.
Only authorized persons are allowed to switch the mains switch back on.
Main switch:
The main switch comprises an operating element attached outside the Eltainer and a power pack
mounted inside the Eltainer. The operating element is used to switch the electrically driven power
pack on or off.
Operating element
Turn the switch in the operating element (1) to
ON to switch on power. Turn the switch back to
OFF to switch off power.
Power pack
Use the operating element attached outside the
Eltainer to switch the power pack (1) inside the El-
tainer on or off.
Warning light
The flashing warning light (1) attached to the op-
erating element indicates the following states:
The switch-on requirements have not been met.
The emergency trip wire switch in the Eltainer
has tripped.
The uninterruptible power supply is not ready.
The power supply shut-off time has not yet ex-
pired.
X000242750
4.2.3 EMERGENCY-STOP
4.2.4 Pre-alarm/Jog
Status of the LED in the Pre-alarm/Job pushbutton
Flashing orange: The LED flashes orange when the pre-alarm mode has ended.
Flashing green: Jog mode is started when pressing the PRE-ALARM/JOG push-
button once more. The LED in the PRE-ALARM/JOG pushbutton
and the LED in the MACHINE ON pushbutton flash green while
holding down the PRE-ALARM/JOG Pushbutton.
Pushbutton - Pre-alarm/Jog
4.2.5 Stop
LED status in the Stop pushbutton
Pushbutton Stop
Dw__1149
X000259306
4.2.6 Slow
Status of the LED in the Slow pushbutton
Pushbutton Slow
Dw__1151
4.2.7 Fast
Status of the LED in the Fast pushbutton
Pushbutton Fast
Dw__1152
4.3 Unwind
4.3.1 Operator panel +R10.........................................................................................................2
1 2
3 4 5
6 7 8
9 10 11 12
13 14 15
16 17 18 19 20
21 22 23 24 25
Z AUTOMATION TECHNOLOGY
Wic_0413
X000261658
1 2 3 4 5
Z AUTOMATION TECHNOLOGY
6 7 8 9 10 11 12
Dw__1128
X000259303
4.4.2 Machine On
Status of the LED in the Machine On pushbutton
Pushbutton Machine On
Dw__1219
Dw__1220
Depending on the machine layout, color decks 1-4 or 1-5 are operated by use of operator panel +R51.
1 2
Dw__1155
X000250316
1 2 3
Z AUTOMATION TECHNOLOGY
Dw__1129
1 2
Dw__1130
X000250316
Dw__1160
Depending on the machine layout, color decks 5-8 or 6-10 are operated by use of operator panel
+R52.
1 2
X000242695
1 2 3
Z AUTOMATION TECHNOLOGY
Dw__1158
1 2
Dw__1157
X000242695
Dw__1161
1 2
Dw__1254
X000293646
1 2
Dw__1253
Dw__0400
X000103089
Control elements
As the operator pendants can be used on the web infeed and on the web outfeed side, the correct
side must be selected by pressing the PU1 or PU2 pushbutton. It is ensured that the operating modes
are carried out according to their correct use.
(2) PU2
PU1 TC
Press the PU1 pushbutton (1) if the operator
pendant is connected on the web infeed side.
Hold the pushbutton for at least three seconds. PU2 2 MENU
PU1 = Color deck side 1-4 (1-5)
Press the PU2 pushbutton (1) if the operator
pendant is connected on the web outfeed side. F1 F2 F3 F4
Display-dependent pushbuttons
F1 F2 F3 F4
ESC
Dw__0402
(1) ESC
(2) ENTER PU1 TC
ESC
Dw__0801
(1) BACK
(2) FORWARD PU1 TC
(3) MENU
PU2 MENU
Press the BACK (1) button to get to the previos
display in the display field. 2
Press the FORWARD (2) button to get to the F1 F2 F3 F4
3
next display in the display field.
Press the BACK (1) and the MENU (3) button ESC
simultaneously in order to get a brighter display
field. Dw__0802
Dw__0404
X000103089
(1) STOP
(2) SLOW
(3) FAST 1 2 3 4 5
Register adjustment
X000103089
Dw__0409
Dw__0410
ESC
Dw__0804
X000103089
Dw__0805
(1) F2 KEY
(2) F3 KEY
(3) PARALLEL / MACRO display
(4) CORRECTION VALUES display
(5) PLATE CYLINDER FORWARD / BACK
(6) ANILOX ROLL FORWARD / BACK
X000103089
(2) F4 5
CD 1 PRINT OFF P M
(3) F2 PU1 TC
--> DECK OUT
(4) F4 PC SLEEVE
AR SLEEVE
(5) SELECTED COLOR DECK display 6
PU2 MENU
+ Start Stop -
(6) DECK TRAVEL display
X000103089
2 3
4 5
Hg_0211
16 16
1 2 3 4
15 A
5 6
B
7 8
9 10 11 12 13
14 14
Ls_0304
X000301261
4.8 Rewind
4.8.1 Operator panel +R90.........................................................................................................2
1 2
3 4 5
6 7 8
9 10 11 12 13
14 15 16 17 18
19 20 21 22 23
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Wic_0414
X000261667
4.9 Procontrol
4.9.1 Procontrol..........................................................................................................................3
Operator panel...............................................................................................................3
Layout of a screen page................................................................................................4
Layout of the top line.....................................................................................................5
Color codes of the flexographic color decks..................................................................7
Color codes of the gravure color decks.........................................................................9
4.9.3 Alarms.............................................................................................................................18
Alarm overview............................................................................................................18
Alarms with acknowledgement....................................................................................19
Alarms with acknowledgement and password entry....................................................20
X000298585
4.9.1 Procontrol
Operator panel
The illustration of the operator panel is to be regarded as an example only. The display screens and
control panels may also be integrated in other operator panels.
The representation of graphical elements may not necessarily come up to reality on your machine.
All necessary parameters for operating the production process are entered and monitored via the
visual display unit. Entries are made by directly touching the touch-sensitive screen surface with your
finger.
(1) Screen page number, customer name, (2) Top line with key panels
date and time
(3) Touch-sensitive machine module selec- (4) Touch-sensitive fields for process oper-
tion fields ation
(5) Display field showing the latest alarm
message
X000298585
The display shows the set and actual values for the current job.
X000298585
Different colors in the visual display unit indicate the different functional statuses of the plate cylinders
and anilox rolls.
X000298585
Different colors in the visual display unit indicate the different functional statuses of the gravure cyl-
inder and the impression roller.
1. Press the COMPANY LOGO (1) button in the top line. A virtual numeric keypad (2) pops up.
2. Enter the desired screen page number and confirm with OK.
X000298662
1. Press the START SCREEN button (1) in the top line. The Display shows the start screen.
1. Strike the touch-sensitive surface of the desired machine module. The surface of the machine
module is highlighted in yellow.The display shows all relevant process control panels for the
desired module.
X000298662
Some of the screen pages can be accessed only by entering the customer password or by W&H
service technicians.
1. Press the PAGE OVERVIEW (1) button in the top line. The display shows the page overview
(2).
2. Touch the desired button in the page overview (2).
For calling up the help menu, an input field must be selected first. The input field turns yellow when
selected.
1. Press the HELP button (1) in the top line. The help menu is displayed.
2. Press the OK button to close the help menu (2).
X000298662
Entering values
1. Press the touch-sensitive surface of the input field (1). A virtual numeric keypad (2) pops up.
2. The desired value can be entered via the numeric keypad 2. Confirm the entry with OK.
1. Actuate the touch-sensitive area of the desired input field (1).The display shows buttons with
selection fields (2).
2. Press the desired button. Your selection is applied and displayed in the selection field (1).
X000298662
Entering a text
1. Actuate the touch-sensitive area of the desired input field (1).The display shows a virtual key-
board with an input field (2).
2. Enter the desired text and confirm with OK.
4.9.3 Alarms
Alarm overview
If an alarm has occurred, the ALARME button (2) blinks red and shows the number of alarms.
X000300680
X000299192
X000299192
Unwind
X000299192
Winder
X000299192
Rewind
X000299192
Abbreviations Significance
AR-DS Anilox roll Drive side
AR-OS Anilox roll Operator side
PC-DS Plate cylinder Drive side
PC-OS Plate cylinder Operator side
SR Sidelay register
LR Longitudinal register
RW Anilox roll
FZ Plate cylinder
FW Color deck
HDW Main printing unit
ZDW Inline printing unit
GDZ Impression cylinder
X000299192
X000299192
X000299192
Drying system
X000299192
Peventive Maintenance
Trending
X000299192
Job processing
X000299192
Downtimes
X000299192
X000300687
Recipe management
X000300687
Next level
X000300687
Recipe management
X000300687
PreMakeReady is used to transfer data to the color decks not involved in the current job while the
machine is running.
A job change can only be performed if the following conditions are fulfilled:
The machine must be at a standstill.
The color decks must be in their zero position.
X000300687
Printouts
X000301199
1. Press the PAGE OVERVIEW button.The display shows the page overview.
2. Press the CLEAN SCREEN button.The screen is locked and can be cleaned.
X000301672
Lock screen
1. When the lock screen (1) is displayed. Clean the screen. The remaining cleaning time (2) is
displayed.
The entire data system to control the machine is made up of several self-sufficient computers, indi-
vidual controllers and intelligent components. These devices are generally equipped with random
access memory (RAM) as well as remanent FLASH memory for storage purposes. The PROCON-
TROL computer is merely used as main database, visual display unit and operating tool.
Certain parameters have to be set to operate the separate controllers. These values are fixed INI-
files and depend on the configuration of the respective machine.
Additionally, the system utilizes adjustable system constants (SYSKON files), which can be used to
configure and optimize the behavior of single components. These adjustments can be made by using
the specific service pages for the separate controllers.
Apart from the controllers, the parameters of several electronic components (i.e. absolute value en-
coders, converters) can also be changed using the respective service pages. The procedure descri-
bed here has to be read in conjunction with the information on the service screens.
Basically, the parameter values required by a controller are permanently stored in the internal FLASH
memory. From this remanent (permanent) memory, the data is transferred automatically into the RAM
of the controller during the controller booting sequence, hence the data is again available.
All parameter values required for controller operation are generally stored in the internal memory,
therefore, i.e. these controllers can operate self-sufficiently.
X000298570
The operator can gain access to and read all of the services pages. For safety reasons, the service
pages have been assigned so-called user classes. These user classes serve to regulate who is
allowed to make changes on which service pages.
User class: Operator - Level 2
Various input and display screens are available to the operator for operating the machine. These
displays are available in the language of the customer's choice and in German. The language can
be changed by accessing the page overview display and pressing the language button.
Apc_0232
Load Syskon
Apc_0233
X000298570
Save Syskon
All set values are saved to the PROCONTROL computer. If not all of the Set fields are assigned
values, zero values are saved as well. Carry out ACT -> SET before changing the set values.
Apc_0234
-> Flash
All set values are saved to the PROCONTROL computer. If not all of the Set fields are assigned
values, zero values are saved as well. Carry out ACT -> SET before changing the set values.
Flash ->
Apc_0236
Send Syskon
All set values are saved to the PROCONTROL computer. If not all of the Set fields are assigned
values, zero values are saved as well. Carry out ACT -> SET before changing the set values.
Apc_0237
X000298570
User data
DANGER
Non-explosion proof equipment
Risk of explosion from non-explosion proof equipment.
Never use the service notebook within the machine's explosion-risk area.
DANGER
Remote-controlled machinery
Using remote-controlled machinery can cause serious injuries and may even lead to death. Using
remote-controlled machinery may cause damages to the machine.
The operator must permanently observe the machine while remote controlled. The machine must be
shut off immediately whenever a dangerous situation arises.
CAUTION
Danger from remote-controlled machinery.
The operator must permanently observe the machine while remote controlled. The machine must be
shut off immediately whenever a dangerous situation arises.
The INTERNET REMOTE SERVICE mode serves as a service mode only and cannot be regarded
as the normal production mode. It is imperative for the employer to fulfill his safety aud supervisory
obligations.
The employer must fulfill his supervisory obligations.
The employer must ensure that specially qualified personnel take care of the machine.
Before activating INTERNET REMOTE SERVICE mode, make sure that all safety devices are in
an orderly and proper condition and that they are in the state for which they were designed.
It is forbidden for persons to stay in the machine's danger zone while INTERNET REMOTE SERV-
ICE mode is running.
Any actions carried out in connection with the INTERNET REMOTE SERVICE generally require
the momentary individual approval of the employer.
No other than reading activities are allowed when the machine is running (production run, main-
tenance run or similar). Generally, any altering access to the machine's control system is forbidden.
It must be possible to shut down all machine/line activities by means of the EMERGENCY-STOP
mode.
Alterations to the control software or process interferences are allowed only under the supervision
of the employer and when the machine is at a standstill.
X000298597
The INTERNET REMOTE SERVICE mode serves as a service mode only and cannot be regarded
as the normal production mode. It is imperative for the employer to fulfill his safety aud supervisory
obligations.
The ports for Internet Remote Service require the following settings:
DNS okay
1533 (opened)
443 (opened)
8081 (opened)
8084 (closed)
Port 8084 is locked by Windmller und Hlscher. It will be opened only if a video inquiry is submitted
via the service notebook.
X000298597
Before starting the INTERNET REMOTE SERVICE mode, screen page 110 must be activated by
entering the customer password.
When Windmller & Hlscher is connected to the machine, the 'W&H Service' window pops up. When
pressing the STOP and ALLOW CONTROL button, access to the machine can be interrupted at any
time.
X000298597
Software update
Chat mode
Chat mode
The 'Chat' mode allows communication with the service staff member who has gained connection
to the machine.
DANGER
Non-explosion proof equipment
Explosions cause severe injuries.
Do not use the service notebook in the machine's explosion-risk area.
NOTE
Make sure to connect the headset and the webcam only to the interfaces marked for this purpose.
The service notebook, the webcam and the headset allow for direct communication with a staff mem-
ber of W&H's Information and Diagnosis Center (IDC).
More detailed information on how to connect and operate the equipment can be taken from the PDF
file on the service notebook.
The data for the winders, the draws and the web
guide controls can be entered and monitored via
the input fields (1) in the visual display unit.
When touching the input fields with your finger the
color turns yellow and a numeric keypad appears.
Use this keypad to enter numerical values into the
input fields. If the entered values are valid they will
be imported into the respective field when actuat-
ing the 'OK' button. Only one field can be selected.
X000054321
5 Operation
5.1 Unwind
5.1.1 Design and function
5.1.2 Compressed-air supply line
5.1.3 Establishing the ready-for-operation status
5.1.4 Swiveling the turret manually
5.1.5 Loading a roll and operating the chucks
5.1.6 Switching the drive of the winding shaft on or off
5.1.7 Roll change
5.1.8 Web tension increase at the unwind
5.1.9 Lifting gear
5.2 Static removal
5.2.1 Static charge removal
5.3 Printing unit
5.3.1 Layout and function
5.3.2 Programs for deck in/deck out operations
5.3.3 Register adjustment
5.3.4 Nip roll in sleeve technology
5.3.5 Ink supply
5.3.6 Hinged cap bearing
5.3.7 Anilox roll sleeve change
5.3.8 Plate cylinder sleeve change
5.3.9 Sleeve change - Hybrid mandrel
5.3.10 Safety guards on the printing unit
5.3.11 Operating the roll up doors
5.4 Web guide control unit
5.4.1 Web guide control
5.5 Nip rolls
5.5.1 Operating the nip rolls
5.6 Easy-Set
5.6.1 Safety instructions
5.6.2 Layout and function
5.6.3 Automatic functional steps and messages
5.6.4 Material requirements and technical specifications
5.6.5 Requirements and operation
5.6.6 EASY-TOPO
5.6.7 EASY-SET S
5.6.8 Quick reference guide
5.7 Easy-Reg
5.7.1 How to operate EASY-REG S
5.7.2 Quick reference guide
5.8 Easy-View
5.8.1 Easy-View
5.9 Easy-Col
5.9.1 EASY-COL - Overview
5.9.2 Notes
5.9.3 Assignment screen page
5.9.4 Manual color correction
5.9.5 Color correction with leftover ink
5.9.6 Color corrections using the Lab/LCh color values
5.9.7 Color correction using a recipe
5.9.8 Color correction using the color chart
5.9.9 Color settings
5.9.10 Measuring the substrate to be printed
5.9.11 Defining the target color location
5.9.12 Measuring the actual color location
5.9.13 Making corrections
5.9.14 Metering by use of a platform weigher
5.9.15 Anilox roll calibration
5.9.16 Consumption screen page
5.9.17 Control elements on the ink weighing system
5.9.18 Attaching the ink weighing system to the pump and valve unit
5.9.19 Operating the ink weighing system
5.9.20 Checking and calibrating the ink weighing system
5.10 Drying system
5.10.1 Safety instructions for use of the drying system
5.10.2 Layout and function
5.10.3 Operating the drying system
5.10.4 Measuring stations
5.10.5 Calculation examples
5.10.6 Dryer rating plate
5.10.7 Flow diagram with solvent vapor concentration controller
5.11 Solvent analyzer
5.11.1 Solvent analyzer Setup
5.12 Slitting assembly
5.12.1 Safety information
5.12.2 Design and function
5.12.3 Positioning of the cutting assembly
5.12.4 Setting the spreader roller
5.12.5 Changing the blades
5.12.6 Setting up the edge trim removal
5.12.7 Draw prior to the rewind
5.13 Rewind
5.13.1 Special function, bypassing the safety light grid
5.13.2 Design and function
5.13.3 Compressed-air supply line
5.13.4 Establishing the ready-for-operation status
5.13.5 Swiveling the turret manually
5.13.6 Inserting the core
5.13.7 Switching the drive of the winding shaft on or off
5.13.8 Roll change
5.13.9 Nip roll and lay-on roller
5.13.10 Taper tension on the rewind
5.13.11 Lifting gear
5.13.12 Automatic chucks (option)
5.14 Inking system
5.14.1 Safety instructions for using the inking unit
5.14.2 Design and function
5.14.3 Permitted solvents in the washing systems
5.14.4 Conductivity of fluids
5.14.5 Control elements on the pump and valve unit
5.14.6 Supply system for cleaning agents
5.14.7 Changeover when non-mixable inks are to be used
5.14.8 Control elements on the hand-held panel
5.14.9 Inking, wash-up and viscosity screen page
5.14.10 Starting inking, wash-up, preconditioning or pump out programs
5.14.11 Inking programs
5.14.12 Pump-out programs
5.14.13 Wash-up programs
5.14.14 Pre-conditioning programs
5.14.15 Error display on the hand-held panel
5.14.16 Cleaning the connectors
5.14.17 Pivoting and removing the doctor blade chamber
5.14.18 Layout and assignment of the drain boxes
5.14.19 Layout and arrangement of the doctor blade chambers
5.14.20 Profiled element on doctor blade chamber - Blade change
5.14.21 Doctor blade chamber profile - Changing the seal in the machine
5.14.22 Profiled element on the doctor blade chamber - Cleaning
5.14.23 Additional doctor blades
5.14.24 Fitting the additional doctor blade
5.14.25 Fitting/removing the clamping rail
5.14.26 Determining the doctor blade length
5.15 Viscosity control system
5.15.1 Viscosity controller and solvent pump
5.15.2 Viscosity control
5.15.3 Conversion
5.1 Unwind
5.1.1 Design and function...........................................................................................................2
Design............................................................................................................................2
Function.........................................................................................................................3
Chucks...........................................................................................................................4
X000260912
Function
Two motorized winding stations (4) are provided on the turret (1) which can be swiveled at will. De-
pending on the selected operating mode, the web can be unwound either in underwind or overwind
mode The turret renders possible to swivel the ready made roll from the loading position into the
winding position or the unwinding core from the winding position into the loading position. The new
roll can be brought into the loading position by use of a roll lifting platform (8) which is available as
an option. During production, the expiring roll should be in the winding position.
When the expiring roll swivels back from the winding position, idler rollers (3) are provided to ensure
proper web travel.
The light barrier and the safety chain (2) secure the interior of the winder against any unauthorized
access.
Automatic roll change without stopping the machine. The roll ready made with glue swivels from the
loading position into the winding position. The separating assemblies (6) move to their front limit
position. Depending on the selected winding direction, the unwinding web is pressed against the new
roll either by the upper or the lower nip roll (5). The associated cut-off knife is triggered either auto-
matically or manually to cut off the unwinding web. The empty core in the loading position is slowed
and the drive switched off so that the core can be removed.
Chucks
DANGER
Damages to winding shaft adaptors
Damages to the winding shaft adaptors may cause the winding shaft adaptors to break and result in
uncontrolled movements of the winding shaft. Risk of injury to persons and damage to the machine.
Check the winding shaft adaptors for damages every day. Make sure that the toothing of every
winding shaft support is completely embedded in the winding shaft adaptor before loading the winding
shaft. Make sure every time you remove the winding shaft that the toothing of the winding shaft is
completely outside the winding shaft adaptor.
The winding shaft adaptors must be handled in a proper way to prevent damages. Examples for
improper handling:
dropping of the winding shaft adaptor
running when the center shafts are not fully moved out (tilting of the winding shaft or improper entry
of the winding shaft data).
excessive loading of the winding shaft adaptor due to one-sided support when inserting the winding
shaft.
excessive loading of the winding shaft adaptor due to improper roll removal when using the lift table
(the winding shaft was not free to move at the time the lift table was lowered).
X000255291
WARNING
Pneumatically operated separating assemblies
Risk of severe injuries.
Always switch off the compressed air supply at the compressed air conditioner and withdraw the key
before starting any works inside the winder. There is in increased risk of injury from the pneumatically
operated separating assemblies.
NOTE
Never change the maximum or minimum working pressures! The manufacturer's warranty liability
does not include damages in the pneumatic system of the machine caused by impermissible air
pressure settings.
The compressed air provided on site must meet the quality requirements agreed upon. The manu-
facturer's warranty liability does not included damages due to an inappropriate composition of the air.
The working pressure is factory-set and must not be changed. The start-up time at the start-up valve
are factory-set and must not be changed.
1
3
Wic_0376
X000239883
Wic_0335
Wic_0336
X000263361
2 1
Wic_0416 4
CAUTION
Circulating chains, belts and rotating wheels
Parts of your body, clothes, hair and objects may be caught and crushed.
Care must be taken when inserting a roll while the machine is running.
In production mode, the blocking chain may only be opened to permit operation of the roll loading
and unloading systems at the winding station.
NOTE
The center shafts are laid out for certain roll diameters and roll weights. The maximum permissible
limits must not be exceeded. There is a risk of severe damage to the winder when exceeding the
limits.
If a roll is present in the unwind, the new roll must be loaded only when the diameter of the old roll
has run down to a sufficient size. There is a risk that both rolls will collide.
To prevent the chucks or the roll from major damage, the maximum adjustment force of the chucks
is limited by safety clutches.The maximum torque of the safety clutch is factory-set and must not be
changed by the customer. The manufacturer's warranty does not include damages caused by im-
permissible torque adjustments.
The permitted core diameter must not be exceeded. There is a risk that the core is not properly fixed
in place on the core chuck and the web tension required for proper web feed cannot be reached. Fire
hazard caused by strong friction in the winding core.
The manufacturer's specifications and safety instructions for use of the winding shafts must be heed-
ed at all times. Make sure not to expose the winding shafts to excessive loads.
The core chucks of the chucks must be completely retracted into the core of the roll.
The maximum and minimum roll width that can be handled is specified in the "Technical specifica-
tions"
X000260919
Both unwind stations are each designed as a pair of chucks. They allow shaftless support of the rolls.
A winding shaft is not required.
Chuck adapter
The core chucks are designed by default for a certain core inner diameter. Greater core diameters
require the use of appropriate core chuck adapters.
Appropriate chuck adapters to adapt to larger diameters are fitted over and fixed on the core chuck.
In addition to shaftless winding special chuck adapters can also be used.
X000260919
Before using the rolls in winding mode, the rolls must be fixed on the core chucks. Inflate the core
chucks in order to do this. The core chucks must be deflated before the roll can be taken out of the
winder. The core chucks are deflated.
This mode can only be used for chucks of the winding station which is in the unloading or loading
position.
Actuate the switch until the chuck wedges are audibly inflated or deflated.
In order for a new roll to be loaded into the winding station in the loading position the two chucks are
individually moved into the core. For this purpose, pushbuttons are provided on the drive and operator
side inside the winder frame. Deflate the chuck wedges to allow for the chucks to be moved. The core
for the roll to be supported has been raised to the height of the chucks by use of the hoisting gear.
The core chucks of the two chucks must be moved into the core completely to make sure that the roll
is supported over its entire length.
X000260919
If a roll is loaded into one of the two winding stations and inflated it can be moved laterally irrespective
of the turret's position. It is possible to change the position of the web in the winder prior to and during
production mode.
Wic_0422
To be able to take a roll from the unloading position out of the winding station, both chucks are
retracted from the core of the roll and moved into their outer limit position by pressing the MOVE
CHUCKS APART button.
Requirements:
The roll is in its unloading position.
The roll has been transferred onto the lift table (the contact bars are pressed).
The chuck wedges in the chucks are deflated.
Wic_0424
X000260919
A special mode allows for the cores or rolls having a diameter less than 180 millimeters to be taken
out of the winding station from the unloading position without using the lifting gear. This mode is only
feasible when the button flashes.
Requirements:
The roll is in its unloading position.
The roll diameter is less than 180 millimeters.
The chuck wedges in the chucks are deflated.
Hold the roll by hand.
Activation requirements:
The system is powered up ready for operation.
The winder is ready for operation.
A roll is in its winding position and the web is threaded into the machine.
1. Enter job data into the winder screen pages or the winder operator terminal.
X000302020
Flashing orange: The cut-off assemblies of the unwind and rewind move towards the
roll and ascertain the roll diameter.
NOTE
During the switch-on procedure, the cut-off assemblies move up against the roll to ascertain the
diameter. The cut-off assembly at the unwind returns to its limit position. The cut-off assembly on the
rewind stops at the roll.
Wic_0341
Before switching off the winding motor, the machine must be brought to a standstill. The main drive
must be switched off.
Wic_0341
NOTE
The new roll must be positioned only when the diameter of the old roll has run down to a sufficient
size. There is a risk that both rolls will collide.
The new roll should exceed a minimum diameter of 300 millimeters. Automatic roll changes cannot
be performed when using rolls with smaller diameters.
The roll change must be initiated within due time before the residual roll has expired.
The area of the safety light grid must not be accessed once the roll change has been initiated. If the
requested area of the safety light grid is violated, all rotary movements of the turret and all traversing
movements of the cut-off assemblies are stopped. The machine stops as quickly as possible.
X000302094
The groove in the chuck serves as a marking for the correct splice position during a roll change.
For center shafts providing two grooves, the groove which is not marked by a marking screw must
be used.
Splice make-ready
If the web is intended to pass high-temperature drying zones (120 - 140 degrees Celsius) it is abso-
lutely necessary to use heat-resistant adhesive tapes.
X000302094
The length of the cut off web still being fed through the machine after the splice is designated as the
web tail. This length is fixed and must not be changed.
Short tail
The blocking chain must be connected and the safety light grid activated.
X000302094
Long tail
The blocking chain must be connected and the safety light grid activated.
Manual
The blocking chain must be connected and the safety light grid activated.
X000302094
Roll change
The blocking chain must be connected and the safety light grid activated.
A fully automatic roll change is carried out by the machine controller and not by the operator. An
acoustic signal makes the operator aware of the roll change.
1. Enter the roll change data.Once the given diameter of the expiring roll has been reached, roll
change is carried out automatically at the set speed.
X000302094
Wic_0342
1. Enter the desired setpoints into the input fields for the draw downstream of the unwind unit (1)
in the winder operator terminal (optional) or into Procontrol.
X000302078
CAUTION
Inappropriate or defective lifting devices
Risk of severe injuries to persons and/or damage to machinery.
Be aware that unsuitable or defective chain hoists may lose their load and thus cause injury to persons
or damage to the machine. Chain hoists and load handling attachment must be in technically perfect
condition when used. Check the hoisting equipment for adequate carrying capacity. Check the hoist-
ing equipment and the load handling attachment for wear at regular intervals and replace whenever
necessary. Never stay or work beneath a suspended load!
CAUTION
The specified load rating and capacities must be heeded.
There is a risk of severe injury to persons and/or damage to machinery.
When using the lifting gear, the manufacturer's instructions and safety regulations must be heeded.
The lifting gear is laid out for certain roll diameters and roll weights. The given limits must not be
exceeded. Staying beneath the lift table is forbidden. The lift table must be secured against inadver-
tent mechanical lowering before starting any repair or maintenance works.
NOTE
The lifting gear is intended to load or unload a roll into or from the winder.
All use in excess thereof is forbidden.
X000260961
Lift table Up
Wic_0420
WARNING
Defective static charge removal device
Risk of fire and explosion from a static charge removal device when defective
Proper functioning of the static charge removal device must be ensured. Observe the maintenance
intervals.
Static charge removal mode is always used if materials are liable to static charging during a process
and thus may cause production failures or inconveniences to the personnel through unwanted dis-
charge of static electricity.
Unwanted discharge of static electricity means: Discharge of static electricity when touched or dis-
charge of static electricity in partial areas of the line. Both are unwanted discharges of static electricity.
Electrostatic systems reduce the risk of fire and explosion:
The anti-static bar serves to convert the high voltage from positive into negative supply. The high
voltage creates an electrical field at the anti-static bar emitters causing the air molecules around the
emitters to split into positive and negative ions. When material charged with static electricity passes
the electrodes, ions are exchanged between the anti-static bar and the charged material until the
material is neutralized.
X000271856
DANGER
Improperly mounted guards or covers
Explosions cause life-threatening injuries.
Improperly mounted guards or covers rub against the anilox roll causing fires or explosions. Be sure
to attach the guard or covers properly.
Only ever use brass screws to attach the anilox roll wipers.
NOTE
Because of the small working width of the machine, it must be ensured that ink hoses and lines are
prevented from getting bent or pinched in the sliding glass doors.
X000240032
(1) Sliding glass door Web outfeed side (2) Roll up doors Operator side
(3) Sliding glass door Web infeed side (4) Locked guard doors Drive side
Access to the printing unit on the operator side (2) is protected by roll up doors.
Access to the printing unit on the drive side is protected by guard doors (4).
Access at front to the color decks on the web infeed side (3) and the web outfeed side (1) is protected
by a sliding glass door.
Layout
A steel impression cylinder is supported in the side frame assembly (2). The impression cylinder is
motor-driven. Depending on the outfit, several color decks (3) are arranged in a ring-shaped manner
around the impression cylinder.
A nip roll (5) is mounted above the impression cylinder. It serves for the web to make contact with
the impression cylinder in a wrinkle-free manner.
The web is fed into the printing unit at the pivotable nip roll. The web travel follows the circumference
of the impression roller to the last color deck. Here, the web leaves the printing unit in the direction
of the drying system.
Slot blowers are arranged between the color decks for between-color drying (see dryer module).
The central operating modes for this module are carried out from the control panel and the control
elements (1) in the guard doors.
X000240032
(1) Stepping motor for plate cylinder adjust- (2) Hinged cap bearing Plate cylinder man-
ment drel
(3) Plate cylinder mandrel (4) Doctor blade unit
(5) Anilox roll mandrel (6) Hinged cap bearing Anilox roll mandrel
(7) Stepping motor for anilox roll adjustment
Stepping motor driven color decks are attached to the impression cylinder circumference. The des-
ignation of the color decks is defined with one (top right) to eight or ten (top left).
Each color deck consists of a plate cylinder mandrel (3), an anilox roll mandrel (5) and a doctor blade
unit (4). Stepping motors at the anilox roll (7) and at the plate cylinder are provided for axial adjustment
of the color decks (1). For the anilox roll and the plate cylinder, one stepping motor each is provided
on the drive and operator side.
Sleeve-technology is used for the plate cylinders and the anilox rolls. Compressed air is used to mount
the sleeves onto the mandrels. Compressed air flows out of the nozzles in the plate cylinder and
anilox roll mandrels and creates an air cushion that stretches the sleeve outwards. It is possible to
push on or extract the sleeves very quickly. The hinged cap bearings (2) and (6) support the journals
of the plate cylinder mandrels and the anilox roll mandrels and can be hinged away for removing the
sleeves from the respective mandrel.
The plate cylinder and anilox roll positions are individually adjustable (drive and operator side). The
longitudinal and sidelay register adjustments are motorized. The anilox roll mandrels and the plate
cylinder mandrels are driven separately.
(1) Pneumatic cylinder for swinging in the (2) Doctor blade chamber
doctor blade chamber
(3) Attachment of the doctor blade chamber (4) Handles
to the doctor bar
(5) Doctor bar (6) Ink duct
Screwed handles (3) which can easily be slackened are provided to attach the doctor blade chamber
(2) to the pneumatic (1) swing-type doctor bar (5).
The enclosed doctor blade chamber is used for inking the anilox roll. An ink tank contains the ink
which is pumped to the doctor blade chamber. The ink supply and return hose connections are located
at the rear of the doctor blade chamber.
Handles (4) are provided for safe transport of the removed doctor blade chamber.
For further information on the doctor blade chamber and inking please refer to the chapter under the
heading 'Inking'.
X000240054
Programs for deck in/deck out operations are provided to position the anilox roll and the plate cylinder
relative to the impression cylinder. Programs for deck in/deck out operations are started either from
Procontrol or the hand-held panel.
WARNING
Moving machine parts
Risk of crushing or shearing parts of your body.
Do not reach in between moving machine parts. Keep a safe distance.
Deck-in operation
Deck-in operation means the positioning of all
plate cylinders (1) and anilox rolls (2) involved in
the print job from the zero position to the pre-print
(print off) position.
The print off position depends on the format. This
position at the impression cylinder determines the
approach of the plate cylinder without touching the
web to be printed. The anilox roll is made to follow
up the plate cylinder however, without touching it.
Print On operation
During the Print On operation, the anilox rolls (2)
approach the plate cylinders (1) for inking. The
plate cylinder and the anilox roll conjointly ap-
proach the impression cylinder (3) for inking the
web to be printed.
Deck-out operation
Deck-out operation means the positioning of all
plate cylinders (1) and anilox rolls (2) involved in
the print job from the Print Off position to the zero
position.
The zero position is the most remote point of the
anilox roll and the plate cylinder from the impres-
sion cylinder (3).
Dw__1218
X000240057
In the printing machine, the web is fed through several individual color decks which are arranged
around the impression cylinder. A color separation is applied to the web in every color deck. The
trapping and separation method is used to generate the final printed image on the web. When printing
multi-color printed images on the web, different color separations must thus be made to coincide.
The printing machine is provided with so-called register adjustments to be able to precisely apply the
color separations to be printed in the different color decks to the web. The color separation offset in
the peripheral direction can be evened out by use of the longitudinal register adjustment. The color
separation offset in the axis direction of the plate cylinders can be evened out by use of the sidelay
register adjustment.
Longitudinal register
Use the color deck select button at the hand-held panel to select the desired color deck.
Sidelay register
Use the color deck select button at the hand-held panel to select the desired color deck.
X000240063
DANGER
Danger of explosion from electrostatic charging
Explosions cause life-threatening injuries.
Always push the new sleeve onto the nip roll mandrel until it hits the limit stop.
CAUTION
Improper use of compressed air
Improper use of compressed air may cause injuries
Wear safety goggles when working with compressed air.
NOTE
Do not perform a sleeve change unless all drives as well as the anilox roll drives have been switched
off.
Change sleeves only when the nip roll is swung away. Take suitable actions to prevent damage to
the impression roller during a sleeve change from occurring.
If the machine is provided with an optional Easy-Reg system, the sleeve can only be changed if the
Easy-Reg sensor of the first color deck has been brought into the measuring position by hand.
The thickness of the printing plate to be used must not exceed 4 mm.
Sleeve change
X000240063
(1) Bolt
(1) Holder
CAUTION
Improper use of compressed air
Improper use of compressed air may cause injuries
Wear safety goggles when working with compressed air.Do not aim compressed air at persons.
DANGER
Danger of explosion from electrostatic charging
Explosions cause extremely serious injuries
Always push the new sleeve onto the nip roll mandrel until it hits the limit stop.
(1) Sleeve
After changing the sleeve, all working steps must be carried out in reverse order to render the machine
operable.
NOTE
Ensure that all screws are properly tightened to prevent damage to the machine from occurring.
X000240075
DANGER
Potentially explosive atmosphere
Explosions cause life-threatening injuries.
Conditions to comply with in order to reduce the fire and explosion hazard to a minimum:
The following conditions apply for ink containers used on the machine:
All equipotential bonding cables must be connected.
Keep contact surfaces clean.
Disconnect the ground terminal last when removing the ink container and establish the connection
to the ground terminal first when refitting the ink container.
Only ever use suitable, conductive ink containers made of low-sparking material. Do not use con-
tainers made of aluminimum, titanium or magnesium.
Ink containers provided by the customer must be furnished with connectors for the equipotential
bonding cables to be connected to the machine.
Always keep the covers of the ink containers closed. Only ever open the ink containers for ink
replenishment.
Wear static dissipative shoes.
The following conditions apply for solvent containers used on the machine:
Only ever use suitable, conductive solvent containers made of low-sparking material. Do not use
containers made of aluminimum, titanium or magnesium.
The individual solvent containers on the color decks providing solvents to control the ink viscosity
should only be topped up with the amount of solvent required for one shift.
The solvent containers should be topped up outside the machine.
Solvent containers on color decks not involved in production must not contain any solvents.
Put the solvent pumps out of service.
Keep the lids of the solvent containers closed to prevent volatilizing and thus interference effects
of the ambient air from occurring.
The equipotential bonding cables for the solvent containers provided on the machine must be
connected.
Check equipotential bonding for effectiveness. Reestablish the functionality of equipotential bond-
ing whenever necessary.
To make filling safe, the container to be emptied and the one to be filled must be connected to the
equipotential bonding cable.
The pump and valve unit is connected to the ink hoses in the machine and ready for operation.
The plate cylinder mandrel and the anilox roll mandrel are fitted with the associated sleeves.
The doctor blade unit is completely mounted and installed.
Preparatory work
Ink duct
DANGER
Improperly mounted ink ducts
Explosions cause life-threatening injuries.
Improperly mounted ink ducts may rub against the anilox roll and cause fires or explosions. Be sure
to mount the ink ducts properly.
NOTE
When working on the upper color decks, make sure that both ladders at front are properly attached
to the mechanism provided for this purpose. Only ever use the ladders provided for this purpose. Two
persons are needed for working on the upper color decks.
X000240075
Ink hoses
NOTE
Ink hoses which are not connected to a doctor blade chamber must be engaged to their parking
position and locked in place against slipping off.
(1) Holder
Connect the ink supply hose (2) and the ink re-
turn hose (1) to the doctor blade chamber.
Inking
Continuous rotation
Dw__1193
Dw__1194
X000240075
NOTE
Before opening the hinged cap bearings on the plate cylinder or the anilox roll, the respective color
deck must be moved into its zero position.
Dw__1167
X000293750
There is no need to remove the lateral splash guard when changing the sleeve.
(1) Handle
WARNING
Cutting blades, knives or sharp-edged machine parts
Risk of severe gashes from cutting blades, knives or sharp-edged machine parts.
Safety devices must never be bypassed. Wear cut-proof gloves.
CAUTION
Hot surfaces
Risk of burning your skin when getting in contact with hot surfaces.
Wear safety gloves, safety shoes and long-sleeved clothing. Keep a safe distance. Keep away sub-
stances with low ignition temperatures.
CAUTION
Improper use of compressed air
Improper use of compressed air may cause injuries
Wear safety goggles when working with compressed air.Do not aim compressed air at persons.
CAUTION
Rotating rollers
Parts of your body, clothes, hair and objects may be caught and crushed.
Pay attention to the instruction plate.Be sure to position your hands correctly.
NOTE
Pushers must be used only when in their zero position. This mode must never be used during running
production.
The pusher should be used only when the respective mandrel is pressurized.
NOTE
The anilox roll sleeve and the anilox roll mandrel are provided with a rotation direction arrow. Push
on the anilox roll sleeve so that the rotational direction arrows of the anilox roll sleeve and the anilox
roll mandrel point in the same rotational direction.
The rotational direction of the anilox roll mandrel and the impression roller is the same.
X000293750
X000293730
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
The combination of a non conductive adaptor and a conductive sleeve is forbidden.
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
The bleeder resistance of the sleeve - carrier cylinder combination or the sleeve - adaptor - carrier
cylinder combination measured from the sleeve surface to the grounded conductive carrier cylinder
should be less than 106 Ohm.
(1) Handle
The plate cylinder sleeve must be arranged in a specified position on its mandrel. It is provided with
a locking groove for this purpose. A locking pin is found on the mandrel as a mounting aid. The plate
cylinder sleeve is properly mounted if the locking pin of the mandrel is located in the locking groove.
X000293730
WARNING
Cutting blades, knives or sharp-edged machine parts
Risk of severe gashes from cutting blades, knives or sharp-edged machine parts.
Safety devices must never be bypassed. Wear cut-proof gloves.
CAUTION
Hot surfaces
Risk of burning your skin when getting in contact with hot surfaces.
Wear safety gloves, safety shoes and long-sleeved clothing. Keep a safe distance. Keep away sub-
stances with low ignition temperatures.
CAUTION
Improper use of compressed air
Improper use of compressed air may cause injuries
Wear safety goggles when working with compressed air.Do not aim compressed air at persons.
CAUTION
Rotating rollers
Parts of your body, clothes, hair and objects may be caught and crushed.
Pay attention to the instruction plate.Be sure to position your hands correctly.
NOTE
Pushers must be used only when in their zero position. This mode must never be used during running
production.
The pusher should be used only when the respective mandrel is pressurized.
Dw__1257
X000293730
Sleeve change onto the plate cylinder adaptor (color decks 1-4)
A print repeat length greater than 500 millimeters requires an adaptor and a sleeve. The adaptor is
mounted just like a plate cylinder sleeve is.
The sleeve must be arranged in a specified position on its adaptor. It is provided with a locking groove
for this purpose. A locking pin is found on the adaptor as a mounting aid. The sleeve is then correctly
mounted if the locking pin of the adaptor is located in the locking groove.
Sleeve change onto the plate cylinder adaptor (color decks 5-8)
A print repeat length greater than 500 millimeters requires an adaptor and a sleeve. The adaptor is
mounted just like a plate cylinder sleeve is.
The sleeve must be arranged in a specified position on its adaptor. It is provided with a locking groove
for this purpose. A locking pin is found on the adaptor as a mounting aid. The sleeve is then correctly
mounted if the locking pin of the adaptor is located in the locking groove.
NOTE
When a damage to the CRP adaptors may have occurred due to inadmissible stress conditions within
or outside the printing press (web wound around the printing cylinder after a web break or similar
stresses), the former parts must individually be taken out of the machine one by one.
In the event of a fault as described above, the operating company is obliged to check the CRP adaptor
for possible deformations and cracks in the first place and to adhere to the adaptor manufacturer's
instruction manual. Additionally, the remaining adjacent machine components must be checked for
possible damages or mistadjustments.
X000293739
Hydraulics - Adaptor
Settings at Procontrol
For safety reasons, a sleeve change within the machine must only be carried out with confined hy-
draulic pressure between the hybrid shaft and the adaptors.
When the hydraulic clamping device is released, the air supply to the adaptor sleeves must be
switched off.
X000293739
For safety reasons, a sleeve change within the machine must only be carried out with confined hy-
draulic pressure between the hybrid shaft and the adaptors.
The following sequence:
1. Remove the sleeve
2. Switch off the compressed air supply to the adaptor sleeve
3. Remove the adaptor
must be strictly observed.
For safety reasons, a sleeve change within the machine must only be carried out with confined hy-
draulic pressure between the hybrid shaft and the adaptors.
The following sequence:
1. Remove the sleeve
2. Switch off the compressed air supply to the adaptor sleeve
3. Remove the adaptor
must be strictly observed.
X000132184
Pneumatic button
Safety guard
After approx. ten seconds the safety guard will be depressurized and lowers down.
X000113225
Overview
Safety devices
WARNING.
Rotating rollers
Parts of your body, clothes, hair and objects will be pulled in and crushed.
Keep a safe distance. It is forbidden to remain behind the closed roll up door.
X000113225
Operation
NOTE
Never attach other than the service carts supplied by W&H to the lift table. Overloading may occur if
the load protrudes too far.
The total load on all service cart mandrels must not exceed 264 kg.
Only materials required for a sleeve change must be transported or deposited on the lift table. Clear
the lift table after finishing the works.
Prevent projection of the sleeve after a sleeve change. Always push the sleeves onto the mandrel
until it hits the limit stop or push it off the mandrel completely.
Load the service cart for the upper color decks as follows:
3 anilox roll sleeves
3 adaptors
3 plate sleeves
(1) Adapter
(2) Adapter opening on the roll up door drive
The figure serves as a schematic of the web guide control components. The web guide controls on
the machines may not be the same as shown in the figure.
One or several sensor heads detect the position of the web and transfer the respective data to the
control unit. The control unit checks the measured position against the given value. If there is a
difference the control unit sends a corresponding correction signal to the servo drive. The servo drive
moves the pivoting frame and the web is repositioned properly.
X000287997
Control elements
The buttons and the display are integrated in the operator panels for the rewind and unwind.
The figure only serves as a schematic diagram of the nip rolls in the machine.The representation may
not come up to reality on your machine.
1 2
3 4
All_0134
(1) Nip roll Impression cylinder (2) Nip roll Draw Unwind
(3) Nip roll Draw Cooling roller (4) Lay-on roller Rewind
X000309509
1 2 3
7 6 5 4
Wic_0328
5.6 Easy-Set
5.6.1 Safety instructions.............................................................................................................2
5.6.6 EASY-TOPO.....................................................................................................................8
Function.........................................................................................................................8
EASY-TOPO display screen..........................................................................................9
Changeover to EASY-TOPO.........................................................................................9
Buttons in the top line..................................................................................................10
Selecting the cylinders.................................................................................................10
Setting up the viewport and the type of view...............................................................11
WARNING
Camera box
Parts of your body, clothes, hair and objects may be caught and crushed.
Open the box only when the machine is at a standstill.
CAUTION
Bright light source
Bright light sources cause impaired vision.
Never look directly into the light source. Open the box only when the machine is at a standstill.
X000196985
CAUTION
Risk of injury from rotating rollers.
The EASY-SET HD unit may only be swiveled away when the machine is at a standstill.
Function
EASY-SET HD defines an optimal printing pressure for the color deck. The process takes place in
two steps.
When EASY-SET HD is selected, the gap between the inked-up plate cylinder and the substrate is
set first. To do this, the printing gap is modified continually until a stable ink transfer between the plate
cylinder and the web to be printed is ensured. Set the inking gap between the anilox roll and the plate
cylinder so that an ink transfer between the plate cylinder and the web to be printed barely exists.
Both steps in the process are carried automatically without any action of the operator. During proof
printing, settings are disabled for the drying systen, the web guide control, the machine speed as well
as the printing pressure for the color decks and register settings.
The progress of proof printing is displayed under "Status" on screen page 35 on Procontrol. After
proof printing has ended, the determined impression pressures are saved and the machine moves
into its printing position.
Automatic proof printing for all of the pre-selected color decks may be canceled at any time by stop-
ping the machine. For aborting proof printing shall for one single color deck, select the 'Print Off' mode
at the hand-held panel for the respective color deck.
X000196988
Proof printing using the EASY-SET HD system is subdivided in several functional steps (phases)
which are being displayed for every selected color deck on screen page 34 on Procontrol.
Phases
Phase 1: Initialization Material requirements check for successful proof printing with EASY-
SET HD.
Phase 2: Measuring run 1 Determination of the precise impression pressure point for the printing
(Plate cylinder impression gap.
pressure)
Phase 3: Measuring run 2 Determination of the precise impression pressure point for the inking
(Anilox roll impression gap.
pressure)
Phase 4: EASY-REG D When EASY-REG D is selected, the system automatically goes to
option screen page 32, EASY-REG D. The operator is requested to select
the EASY-REG halftone dots in the printed images displayed.
The dots should be selected as quickly as possible to prevent unnec-
essary waste.
For further information on the EASY-REG D system please refer to
the relevant operating instructions.
Phase 5: Completion An acoustic signal indicates the completion of the proof printing proc-
ess.
Messages
If EASY-SET HD has finished or canceled the proof printing process, a corresponding message is
displayed in Procontrol and in most cases an acoustic signal is sounded in addition.
After successful proof printing the choice boxes for the color decks are displayed in green. If a fault
has occurred the choice boxes for the color decks are displayed in red.
The reason for canceling will be displayed in Procontrol if EASY-SET HD has canceled the proof
printing process. Help texts associated with the message give additional information.
Supported materials
Opaque (non-transparent) substrate yes
Transparent substrate yes
Metallized substrate to be agreed upon with W&H
Further substrates to be agreed upon with W&H
Tubular materials no
Material properties
The substrate must be visually unique (no ink changes in the material).
The substrate must be unprinted on both sides.
The substrate must be free of holes, dents and kinks.
The substrate must lie wrinkle-free against the impression cylinder.
The substrate must pass the cameras wrinkle-free.
Motif
For proof printing all image elements greater than 5 x 5 mm 2 will be considered.
Fine screens, especially those of low-contrasty inks will not be supported.
X000196991
Technical specifications
5.6.6 EASY-TOPO
Function
EASY-TOPO serves to check the proof print results of EASY-SET D and the printing plates in use.
The measurement results recorded during proof printing with EASY-SET HD are diagramed by EASY-
TOPO on the EASY-VIEW monitor.
The topology of the printing plate is either displayed as the top view, a stationary 3D view or a rotating
3D view.
X000158669
(1) Top line (2) Scale for depicting the contact pressure
(3) Depiction of the printing plate topology (4) Overview of printed image
(5) Control panels for viewport
A false color representation is provided for the operator depicting the proof printing behavior on the
selected color deck, red sections presumably indicate that printing pressure may be too high.
Changeover to EASY-TOPO
X000158669
(1) Scale
(2) Topology card as per the view selected
(3) Overview of printed image
(4) Buttons for selecting the view
5.6.7 EASY-SET S
Function and requirements for use
By reducing the printing gap between the plate cylinder and the impression cylinder incrementally,
EASY-SET S determines the point at which the plate cylinder and the impression cylinder make
contact. EASY-SET S recognizes the resistance at this point and the plate cylinder movement is
stopped immediately. This procedure prevents damage to the printing plate from occurring, even if
the machine is at a standstill. The anilox roll is moved parallel to the plate cylinder. An additional
printing impression value (preset value) determined and preset by the operator beforehand is added
to these position values. The proof printing result decisively depends on the printing plate used.
For proper functioning of the Easy-Reg S system, the following conditions must be fulfilled:
The machine must be ready for production.
The color decks that will be needed must have been set up.
The correct plate size must have been entered.
The printing plate must correspond to the default values.
The measurement run must be started from the pre-print position.
Operation
The displayed screen pages show the maximum enhancement to EASY-SET S. The screen pages
on the machine may differ from this.
X000165600
During the measurement cycle, the plate cylinder is moved until it touches the rotating impression
cylinder. This guarantees that the printing plates are not damaged during the measurement cycle.
The preset values are rule-of-thumb values and must be determined by the operator.
X000142494
The machine is at a standstill and the color decks are in their zero or pre-print position.
The process takes place sequentially, i.e. the register position is defined first and the proof printing
position is to be determined afterwards.
5.7 Easy-Reg
5.7.1 How to operate EASY-REG S...........................................................................................2
Switching on requirements............................................................................................2
Operation.......................................................................................................................2
Register label.................................................................................................................4
For proper functioning of the Easy-Reg S system, the following conditions must be fulfilled:
The color decks that will be needed must have been set up.
The correct plate size must have been entered.
The register labels must have been correctly pasted on relative to the printing plate.
We recommend to start register setting from the color decks' zero position.
Operation
The color deck moves into the measuring position, the plate cylinder rotates and the longitudinal and
sidelay register positions are determined.
X000142222
For cleaning, it must be possible to swing the sensor in its measuring position manually.
Register label
For proper use of the Easy-Reg system the pressure-sensitive register labels must be exactly posi-
tioned on the sleeve by using a plate mounter.
In order to facilitate register label pasting the protective film across the pasting surface is split in three.
X000142222
When beginning to peel off the register label (1) from the side, the two outer protective films remain
on the label. The central part (2) of the protective film is removed. The register label can now be
positioned above the sleeve without sticking on the plate mounter. Once the correct position has been
reached the central pressure-sensitive part is being pressed on the sleeve. The register label is fixed,
the remaining two protective films can be peeled off and the register label be finally attached.
The register label is being applied parallel to the outer sleeve edge by using the center line cross.
The cross line (1) of the plate mounter as shown in the image should be aligned to the label's center
line cross. The midpoint of the register label's reference point is found on the reference line (D). The
distance (A) for each printing width is determined once again. The distance is the result of the related
sleeve length minus 5 millimeters
The plate to be mounted should be aligned taking the microdots relative to the register label as a
reference. The distances (B) and (C) to the microdot can be selected to choice andshould be within
a tolerance range of +/- 0.01 millimeters for each sleeve to be used for the relevant job.
The machine is at a standstill and the color decks are in their zero or pre-print position.
The process takes place sequentially, i.e. the register position is defined first and the proof printing
position is to be determined afterwards.
5.8 Easy-View
5.8.1 Easy-View.........................................................................................................................2
Introduction....................................................................................................................2
Monitor...........................................................................................................................3
Image display in the main viewport................................................................................6
Camera setting..............................................................................................................8
Lighting settings...........................................................................................................10
Switching on image enhancement...............................................................................12
Switching on the splitscreen function...........................................................................14
5.8.1 Easy-View
Introduction
Easy-View is used to monitor the printed web on a large-scale monitor. The entire print width is shown.
Easy-View is an enhancement to Easy-Set-D, uses the installed cameras of the Easy-Set D system
for displaying the images and is operated on the main control panel using a computer mouse.
The camera system consists of 2 to 3 linear cameras depending on the width of the machine. Each
linear camera covers a web width of 680 millimeters. Easy-View compiles the individual images of
the cameras to a complete image.
The camera resolution is 0.3 millimeter per pixel element. This is equivalent to about 33 pixels per
centimeter or 85 pixels per inch. The camera supplies about one image per second. The image
repetition rate can vary with the web speed, the print repeat length and the selected enlargement
stage.
At the transition points of the cameras visible image faults can occur which can be cleared by the
image enhancement function (shading correction.
Whereas other modules (for example, Easy-Set D) control the cameras, the camera control functions
of Easy-View are deactivated and a signal field is displayed in the overview bar. Once the access of
the modules to the cameras is finished (for example, after completing the automatic print by Easy-
Set D), the camera functions for Easy-View are reactivated once again.
Detailed information on the respectrive control panels are displayed in the country language using
the control panel ONLINE HELP (question mark) in the top line of the monitor.
X000075640
Monitor
If selection fields are activated, the color of the selection fields turns from light gray to dark gray.
In the main viewport (2) the image of the web is displayed as desired (fitted in, zoomed or at original
size). The complete print repeat length of the web is shown in the overview window.
Top line
Toolbar
X000075640
(1) Main viewport (2) Selection fields for image display in the
main viewport
(3) Field of view in the overview window
X000075640
Camera setting
If selection field (1) is activated, additional selection fields (2) are faded in for image capture. By
reactivating the selection field (1) or by clicking in the main viewport outside the originated new field
the additional selection fields are faded out again.
X000075640
Lighting settings
If selection field (1) is activated, additional selection fields (2) are faded in for lighting. By reactivating
the selection field (1) or by clicking on the main viewport outside the originated new field the additional
selection fields are faded out again.
X000075640
At the transition points of the cameras visible image faults can occur which can be cleared by the
image enhancement function (shading correction.
If selection field (1) is activated, additional selection fields (2) are faded in for image enhancement.
By reactivating the selection field (1) or clicking on the main viewport outside the originated new field
the additional selection fields are faded out again.
X000075640
The splitscreen function serves to compare the reference image with the current print. As a rule, the
complete print repeat length is recorded in case of a single frame shooting. All changes like zooming
or moving the field of view have an effect on both windows.
If selection field (1) is activated, additional selection fields (2) are faded in for the splitscreen function.
By reactivating the selection field (1) or by clicking in the main viewport outside the originated new
field the additional selection fields are faded out again.
X000075640
5.9 Easy-Col
5.9.1 EASY-COL - Overview......................................................................................................3
Input units and measuring station..................................................................................3
Spectrodensitometers available.....................................................................................4
Ink weighing system......................................................................................................5
Platform weigher............................................................................................................6
5.9.2 Notes.................................................................................................................................7
Safety instructions.........................................................................................................7
Colorimetry instructions when using EASY-COL...........................................................7
Scrolling through comprehensive menus.......................................................................8
5.9.18 Attaching the ink weighing system to the pump and valve unit.......................................55
Notes...........................................................................................................................55
Mounting the ink weigher system................................................................................55
X000200246
(1) Operator column (2) Operator column when retrofits are de-
livered
(3) Measuring support plate and spectro-
densitometer
Spectrodensitometers available
NOTE
Be sure to only use the spectrodensitometer delivered together with EASY-COL or one which is
identical in construction.
Standard equipment
X000200246
Platform weigher
X000178317
5.9.2 Notes
Safety instructions
DANGER
Fire and explosion hazard caused by static charging
Fire or explosion may hurt persons and cause damage to the machine. Only electrically non-con-
ductive ink containers must be used for solvent-based inks. Connect the ink containers to the equi-
potential bonding lines at the weigher.
Risk of injury from inks, solvents and cleaning agents
Inks, solvents and cleaning agents may harm skin and eyes. Wear suitable protective clothing, gloves
and safety goggles. Always ensure adequate ventilation air. Wear an appropriate breathing mask, if
necessary. Always observe the safety data sheets and safety instructions applicable to the product
when handling inks, solvents and cleaning agents. The safety data sheets include details regarding
health, accidents and environmental protection and can be requested from the suppliers.
NOTE
If the platform weigher is used for metering, a maximum weigher load of 60 kilograms must not be
exceeded. Higher loads may result in weigher defects.
To achieve unique colorimetric data we recommend to print measurement points for each color. The
measurement points should have a diameter of at least six millimeters and be printed together with
the motif.
It is important for accurate colorimetry to always use the same backing since the backing is also
included in the colorimetry.
If color charts or color targets are used as the color original, then the validity must be observed. The
colors are subject to an aging process and the color perception changes. Therefore, the color chart
or the color target must always correspond to the same state.
During color matching with EASY-COL the viscosity in the relative color deck must not be changed.
After color correction, check and reset the viscosity, if necessary.
Menus for recipes, color charts or anilox rolls may be quite comprehensive. To make it easier for the
operator to scroll through long lists, EASY-COL automatically lists the names in alphabetical order.
The structrure is exemplified by use of a color chart.
Menu buttons
X000176660
Option
X000176660
Option
If EASY-COL shall not be used for color correction, select MANUAL for the relative color decks. All
entries made in the screen pages serve as an overview and have no effect on the calculations of
EASY-COL.
X000176684
Select LEFTOVER INK, if the components of an ink to be used are not definitely known. LEFTOVER
INK must also be selected if the ink recipe is known however, the recipe cannot be found in the recipe
database. A reliable color sample must be available at the machine as a reference. If a digital refer-
ence color location is given, select the optional COLOR CHART mode.
Recipe selection
The RECIPE button will pop up only if the optional module 'Connection to ink room' is enabled.
The COLOR CHART button will pop up only, if the optional module 'Digital color charge' is enabled.
X000176692
Completion
If only color values (tristimulus values) of a color are available, select Lab/LCh tristimulus values. For
selecting the Lab/LCh tristimulus values no reference samples are required. Use the LEFTOVER
INK list box if reference samples are available.
Recipe selection
X000176705
Completion
RECIPE can be selected, if for the desired color deck freshly matched ink is supplied from the ink
preparation system to the machine and the recipe has been stored to the recipe database. For this
optional mode, the module 'Connection to ink room' must be enabled. When using a recipe, this recipe
determines the reference color location.
X000176711
Recipe selection
Recipe selection
Completion
X000176815
The list box COLOR CHART must be selected if a digitally stored reference color location is to be
used for correction purposes and the color recipe is unknown. This optional function can be used only
if the module 'Digital color chart' is enabled.
Different color charts can be used for the relative color decks.
List box
X000176815
Completion
The color-difference formula currently used will be displayed under EASY-COL. The color-differ-
ence formula, the observer or the illuminant can be changed on a separate screen page.
X000177474
Illuminant
Observer
Color-difference formula
Metamerism illuminant
Ink mixing
X000177474
X000177779
If the substrate color differs from all other colors in the color decks, an individual substrate meas-
urement becomes necessary. This occurs for example, if reverse printing is carried out with a white
background and this is not the case in one of the color decks.
When using leftover inks the target color location must be measured. To do this, the target color
location is measured on the reliable reference sample using the spectrophotometer. The reference
sample may be a sample signed by the customer, a color chart or similar. If an ink is used on a
color deck for which a valid recipe exists, the display field in the column "Target" will automatically
be assigned the correct color shade. The same applies for the entry via the Lab/L Ch tristimulus
values and using the option 'Digital color chart'.
X000177787
When entering Lab or LCh tristimulus values, such values must have been determined under the
same measurement conditions (observer and illuminant) as set on the machine. If the measure-
ment conditions do not match, color deviations between the desired and the entered color value
will occur. Color matching by use of Lab/LCh tristimulus values must be set on screen page 1052
(operator column) or on screen page 33 (Procontrol).
X000177977
After measuring the target color locations, the actual color locations must be measured. To do so,
take a first proof of the sample to be matched out of the machine.
If actual color locations cannot be correlated automatically after the measurement, the individual
measurements must be correlated with the relative color decks manually.
New setpoint
X000177977
A fault message will be generated, if a measured value from the colorimeter cannot be correlated
uniquely with a color deck.
Press OK (2).
The fault message "Unable to correlate meas-
ured color with color deck" (1) will be deleted.
A fault message will be generated, if a measured value cannot be correlated with an actual average
value measured.
After all necessary entires for each individual color deck have been made, the correction values
can be calculated (see status display 'Calculate correction value'). The 'Correction' button gets you
to the screen page 'Calculate correction value'. This button is available only after all necessary
entries have been made. If corrections cannot be made, attention must be paid to the instructions
in the status display.
X000177991
The color diference value Delta E between the set and the actual value is displayed in color in the
display field. If no threshold value is available, the displayed numerical value is black. A green
numerical value indicates that the deviation lies below the warning limit. A yellow numerical value
indicates that the deviation lies between the warning and alarm limit. Deviations exceeding the
alarm limit are displayed in red.
When selecting the list box Recipe on screen page 1052 (operator column) or screen page 33
(Procontrol), two correction values are calculated for those color decks the formulas of which are
known. When using Recipe color correction mode, the calculated correction value is made up
exclusively of the base colors used in the formula. When using Color range correction mode, also
other base colors which did not form part of the formula as yet, can additionally be used. In both
cases, the expected color difference Delta E after the correction is displayed.
When selecting LAB/LCh tristimulus values, Leftover ink or Color chart on screen page 1052 (op-
erator column) or on screen page 33 (Procontrol), only the Color range correction will be calcu-
lated for the relevant color decks.
The greater the expected color difference Delta E displayed after the correction, the more likely is the
formula near its color space limit.
As a rule of thumb:
The expected color difference should be less than 5 for the first correction.
For the second correction, the value should be less than 2.
X000177991
After the anilox roll has been changed, the expected color difference compared to the ink available
in the color deck can be displayed. Use the PROPOSAL button to calculate the optimal anilox roll
which is supposed to have the least color difference Delta E relative to the reference color location.
The expected Delta E after changing an anilox roll is displayed in the field DELTA E OLD ANILOX
ROLL.
Before changing the anilox roll, the operator has to decide on whether the proposed anilox roll is
suitable for printing the motif.
An alternative anilox roll can only be calculated during the first correction process after having cal-
culated the correction value.
The anilox roll currently used is shown in the ' Display field ' (5).
When pressing the 'Change' button, the selected anilox roll will be displayed at the respective color
deck on screen page 1052 (operator column) and on screen page 33 (Procontrol).
A color correction using "Recipe color correction" or "Color range correction" mode can only be
made after the next actual color location has been measured.
Making a correction
After a correction recipe has been sent to the platform weigher, the screen display returns to the
screen page EASY-COL. The status display "Make correction" informs you that the calculated
correction for this color deck has not yet been made.
Always press the SAVE CORRECTION button after the correction has been made. On pressing the
button, the correction of the basic recipe with the added corrections will be generated.
Without saving, a second correction value cannot be calculated.
Completion
X000177991
If there is not enough ink left to do the job, use the SECONDARY COLOR CORRECTION mode to
mix the additionally required ink. Original ink must be left to do this and all correction values must
have been saved before.
In the display field Original ink quantity 1, the available original ink for this color deck must be entered
(minimum quantity: 1kg).
Then, the names of the base inks and the associated quantities which must be added to the original
ink appear in the column (2).
The display field TOTAL QUANTITY (3) shows the quantity of original ink and the added ink quantity.
The display field REQUIRED QUANTITY (4) shows ink quantity required to finish the job. By changing
the original ink quantity you can thus match the exact ink quantity required to finish the job.
When pressing the DO button, the secondary correction value for this color deck will be sent to the
platform weigher.
Example:
50kgs of original ink will be required for color deck 3 on the machine. 20kgs will be filled into the
machine first. During color matching with EASY-COL, 2kgs of yellow and 1kg of waste will be added.
If this ink quantity is insufficient to finish the print job, original ink must be replenished. As the original
ink is however, not matched, replenishment would result in a color drift. By use of the SECONDARY
CORRECTION mode, EASY-COL can now calculate the correction quantities to be added (e.g.: 1kg
yellow and 0.5kg waste per 10kgs of original ink) so that the ink replenished is identical to that avail-
able in the color deck.
For secondary correction, the ink viscosity must be checked. The viscosity of the re-corrected ink
must be the same as that of the ink available in the color deck.
Main menu
If no metering jobs exist, the buttons to the left of the diagrammed color decks are grayed out (inac-
tive). If metering jobs exist, the button to the right of the respective color deck indicates the ink quantity
to be metered (active).
X000040594
DANGER
Static charging.
Fire or explosion may hurt persons and cause damage to the machine.
For solvent-based ink, only use an electrically conductive ink container. Connect the ink containers
to the equipotential bonding lines located on the weigher.
DANGER
Inks, solvents and cleaning agents
Inks, solvents and cleaning agents may cause skin and eye irritation.
Wear suitable protective clothing, gloves and safety goggles. Always ensure adequate ventilation air.
Wear an appropriate breathing mask, if necessary. Always abide by the safety data sheets and safety
instructions that apply to the respective product when handling inks, solvents and cleaning agents.
The safety data sheets include details regarding health, accidents and environmental protection and
can be requested from the suppliers.
NOTE
The maximum admissible total weight for loading the platform weigher is 60 kg. Higher loads may
result in weigher defects.
Adding components
The various components (2) listed in the respective column are filled into the ink container on the
weigher.
Progress bar
The progress bar indicates the current filling quantity in percent. The color of the progress bar changes
from red to green the moment the filling quantity reaches the tolerance range which is depicted by
dashes below and above the 100 percent mark.
X000040594
Overdosing
If overdosing has occurred a warning appears recommending you to cancel the metering.
(1) Continue
(2) Cancel
X000200279
The calibration speed should correspond with the standard production speed. Use the average
speed value for calibration, if production speeds are different.
In case of significant differences in production speed, the anilox rolls can also be calibrated for
different speeds.
When using transparent films printed with opaque white, measuring must take place on the opaque
white area.
Anilox rolls can only be allocated to those color decks which have been activated on screen page
1052 (operator column) or on screen page 33 (Procontrol).
X000200279
Requirements:
A proof has been made using the entered speed, the entered anilox roll and the entered ink formula.
X000200329
X000200337
The ink weighing system serves to ascertain and display the ink consumption in the individual color
decks.
X000029517
5.9.18 Attaching the ink weighing system to the pump and valve unit
Notes
DANGER
There is a risk due to electrostatic charging.
All potential equalization cables must be connected. It is forbidden to operate the system without the
potential equalizing cables being correctly connected.
The contact surfaces must be kept clean.
The potential equalization cable must be clamped in place first when mounting the ink weigher system
and you must ensure that the potential equalization cable is taken off last when removing the ink
weigher system.
Mechanical connection
(1) Extensions
CAUTION
Risk of injuries from moving machine parts
Your hands may be crushed or sheared. Do not reach in between moving machine parts. Keep a
safe distance.
Do not reach under the ink container when raised.
X000165418
General information
Keep the ink weighing system clean. Remove spilled ink immediately, however, after changing the
ink container at the latest.
Do not put any objects on the ink containers.
If the remaining operating time calculated for a color deck is 10 minutes or less, the display turns from
green to red numbers.
An increase in printing speed results in an immediate reduction of the remaining operating time.
The job length must have been correctly entered in the Job operating page.
For a correct display of the ink quantity consumed in the current job, the job counter must be
reset.
When using solvent-based inks the hobbock must be made of electrically conductive material and
integrated in the equipotential bonding system.
X000165418
CAUTION
Risk of injuries from moving machine parts
Your hands may be crushed or sheared. Do not reach in between moving machine parts. Keep a
safe distance.
Do not reach under the ink container when raised.
Proper functioning of the ink weighing system requires regular checking of the system and the as-
sociated calibration unit. To do so, fit the calibrating unit into the ink weighing system instead of the
ink container. The calibration unit contains three removable individual weights weighing about fifteen
kilograms each. The exact weight is stamped on the individual weights.
If deviations are detected during the checking, the ink weighing system needs recalibration. Only
specially trained personnel are allowed to do the calibration work.
X000140836
Display in Procontrol
(1) CONSUMPTION
After successful calibration the ink weighing system must be checked once again as described
before.
DANGER
Gas warning device not maintained
Fire or explosion may hurt persons and cause damage to the machine.
The employer is responsible for the correct working state, the checking and the adjustment of the gas
warning device. The employer is liable to ensure that the gas warning device is set to the correct
solvent/solvent mixture before starting a new print job. The gas warning device must be checked at
regular intervals for proper functioning.
DANGER
Drying system not tested
Fire or explosion may hurt persons and cause damage to the machine.
The dryer and all the other safety devices must be tested by an expert at least once a year. The
machine must not be operated unless the dryer is in a proper working condition.
DANGER
Dampers improperly set
Fire or explosion may hurt persons and cause damage to the machine.
The dryer provides various dampers which are set during commissioning. These factory-set dampers
must not be readjusted by the customer. Improper adjustments might result in an impermissibly high
solvent vapor concentration. An increased danger of explosion will exist if the permitted threshold
limit values (LEL) are exceeded.
DANGER
Measuring error with the gas warning device
Fire or explosion may hurt persons and cause damage to the machine.
Any parts that were opened or removed for cleaning and/or maintenance work must be closed or
refitted. Otherwise, faulty solvent concentration measurements might be recorded. The doors or cov-
ers at the dryer must remain closed during operation. All measuring points on the measuring stations
must be closed with appropriate blind plugs.
DANGER
Improperly connected equipotential bonding cables
Fire or explosion may hurt persons and cause damage to the machine.
Cables are secured to the dryer at different places (green/yellow). These cables are used for creating
equipotential bonding between the specific components. These cables must never be removed or
loosened. A very high voltage level with severe potential differences might result if the connector is
broken or becomes loose. Check the equipotential bonding connectors at regular intervals.
X000192273
DANGER
Wrong color deck selection
Fire or explosion may hurt persons and cause damage to the machine. Electrostatic discharges may
also occur when using inks that contain metal, e.g. gold ink.
Therefore, inks containing metal should only be used in the last color deck.
DANGER
Wrong solvent
Fire or explosion may hurt persons and cause damage to the machine.
Dryers to be used in operating zone 2 in compliance with DIN EN 1539 are laid out for solvents
according to class T2 (explosions sub-group IIB, temperature class T2, gravure printing) and T3
(explosion sub-group IIB, temperature class T3, flexo printing). Solvents containing phenol and ep-
oxide require a special upgrade to be made to the gas warning device! Only the quantity of solvent
that is listed on the dryer rating plate attached to the machine is to be supplied. Only ever use the
data specified on the rating plate for the dryer attached to the machine to calculate the maximum
permitted amount of solvent. For calculation purposes please refer to the chapter "Drying system"
under the heading "Calculation examples" in the instruction manual.
DANGER
Wrong flow temperature when using drying systems which are operating in operating zone 2
in compliance with DIN EN 1539
Fire or explosion may hurt persons and cause damage to the machine.
The flow temperature to the dryer (e.g. heat exchanger) in flexographic printing presses must not
exceed: 160 degrees Celsius / 320 degrees Fahrenheit (80%, T3). The T3 approval is voided with
flow temperatures greater than 160 degrees Celsius / 320 degrees Fahrenheit. The flow temperature
to the dryer (e.g. heat exchanger) in gravure printing presses must not exceed: 240 degrees Celsius /
464 degrees Fahrenheit (80%, T2). The T2 approval is voided with flow temperatures greater than
240 degrees Celsius / 464 degrees Fahrenheit.
CAUTION
Hot surfaces
Risk of burning your skin when getting in contact with hot surfaces.
Wear safety gloves, safety shoes and long-sleeved clothing. Keep a safe distance. Keep away sub-
stances with low ignition temperatures.
CAUTION
Webs running onto rolls or rollers (infeed nips)
Parts of your body, clothes, hair and objects may be caught and crushed.
Wear tight-fitting clothes and a hairnet. Work without gloves. Keep hands clear of the running ma-
chine. Keep a safe distance. Only ever use the threading chain for web thread-up.
1 2 3 4
5
All_0101
X000258314
Function
NOTE
The drying system is a passive module and has no main switch. The drying system is operational
only after the energy supply has been switched on as described in the POWER SUPPLY documen-
tation module.
One slot blower (2) each is arranged in the web running direction around the impression cylinder
behind the color decks. They are provided to dry the just applied ink and to extract the solvent-laden
air. An exhauster downstream of the last color deck is optional.
The superstructure on the printing press is made up of a drying box equipped with slot blowers. They
serve to dry the ink which has just been applied in the last color deck and to finally dry the ink applied
in the other color decks.In addition to that, the solvent-laden air in the drying box is extracted.
Heating up and distributing the make-up air for the slot nozzles in the drying box and the slot blowers
on the between-color drying system is carried out separately. As an option, the make-up air can be
heated up by means of heat exchangers, electrical heaters or gas burners. The respective slot blow-
ers are provided with the heated-up make-up air by means of the recirculating air blower. The make-
up air flow towards the slot blowers is accomplished via distributor pipes.
The solvents absorbed in the make-up air are transferred to the exhaust air distributor together with
the fresh air (leakage air). Part of the exhaust air quantity is recirculated as make-up air. The re-
maining part of the exhaust air quantity is extracted from the press (exit air).
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
The operator is responsible for the correct working state, the checking and the adjustment of the gas
warning device. The employer is liable to ensure that the gas warning device is set to the correct
solvent/solvent mixture before starting a new print job. The gas warning device must be checked for
proper functioning at regular intervals.
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
The dryer and all the other safety devices must be tested by an expert at least once a year. The
machine must not be operated unless the dryer is in a proper working condition.
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
The dryer provides various dampers which are set during commissioning. These factory-set dampers
must not be readjusted by the customer. Improper adjustments might result in an impermissibly high
solvent vapor concentration. An increased danger of explosion will exist if the permitted threshold
limit values (LEL) are exceeded.
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
Any parts that were opened or removed for cleaning and/or maintenance work must be closed or
refitted. Otherwise, faulty solvent concentration measurements might be recorded. The doors or cov-
ers at the dryer must remain closed during operation. All measuring points on the measuring stations
must be closed with appropriate blind plugs.
WARNING
Opening explosion pressure relief dampers
Risk of severe injuries.
Overpressure in the drying system causes the explosion pressure relief dampers to open automati-
cally. Risk of injury for persons when opening the dampers. Do not deposit objects in front of the
dampers. Do not block the dampers.
X000288251
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
Electrostatic discharges may also occur when using inks that contain metal, e.g. gold ink. Therefore,
inks containing metal should only be used in the last color deck.
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
The drying system has been designed for the use with class T2 solvents for gravure printing and class
T3 solvents for flexographic printing. Solvents containing phenol and epoxide require a special up-
grade to be made to the gas warning device! Only the quantity of solvent that is listed on the dryer
rating plate attached to the machine is to be supplied. Only ever use the data specified on the rating
plate for the dryer attached to the machine to calculate the maximum permitted amount of solvent.
For calculation purposes please refer to the chapter "Drying system" under the heading "Calculation
examples" in the instruction manual.
WARNING
Potentially explosive atmosphere
Explosions cause severe injuries.
If the processing air is heated by heat exchangers, the flow temperature of the heat exchanger must
be set up such that the surface temperature never exceeds 80% of the ignition temperature of the
solvent being used.
The heat exchangers that have been installed for dryers designed for flexographic printing have been
laid out for max. flow temperatures of 240 degrees Celsius / 464 degrees Fahrenheit (80 %, T2). The
T3 approval is voided with flow temperatures greater than 160 degrees Celsius / 320 degrees Fah-
renheit.
The heat exchangers that have been installed for dryers designed for gravure printing have been laid
out for max. flow temperatures of 240 degrees Celsius / 464 degrees Fahrenheit (80 %, T2). The T2
approval is voided with flow temperatures greater than 240 degrees Celsius / 464 degrees Fahrenheit.
NOTE
Hot air mode
The hot air mode may only be used when the machine is running and the blowers are switched on.
The blowers can only be switched off when the machine is at a standstill.
NOTE
Preheating mode
This mode renders possible that the heaters operate although the machine is not running. It takes 5
minutes to switch on this mode. When switching on the machine drive during this period, preheating
mode changes over to heating mode. Switch off the switched on heaters after the machine has stop-
ped. The blowers remain switched on. They can be switched off by pressing the BLOWER button
once again.
The current operating status of the drying system can be retrieved in ' Procontrol '.
Pos. Description
(1) Status symbol of the blowers in the between-color drying
(2) Status symbol of the burners in the between-color drying
(3) Status symbol of the blowers in the tunnel drying
(4) Status symbol of the burners in the tunnel drying
X000288251
NOTE
The burners need to be shut off completely once within 24 hours to ensure troublefree functioning of
the burners.
tro_0268
Cold air operation is now possible. The drying air is not heated.
X000288251
The fan and the burner can be activated and deactivated and the drying parameters can be
changed at any time before switching on the drive.
When the drying system is ready for operation and the drive is not started within approx. three
minutes, the burners go into standby mode. The LED in the drying button (1) flashes green.
X000259773
X000232662
Term Definition
Operating zone 1 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, exceed the threshold.
Operating zone 2 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, are below the threshold.
X000232662
NOTE
The depicted calculations do not come up to reality on the machine. They are only intended as a
possible calculation for the drying system.
NOTE
Minimum exit air flow rate based on 20 degrees Celsius and 1013 millibar.
Given values
Abbreviation Unit Value
Vmin(s) m3(s)/h 4370 m3/h (see rating plate)
CLELperm 20 C % of LEL 40 operating area 1 (see table with default values)
LEL g/m3 40 (unknown solvent)
f 1
LEL %/100K -20 (temperature dependence of LEL)
t C 120
PW m 0.5 m current printing width
S g / m2 4.6 (solvent application)
Term Definition
*Operating zone 1 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, exceed the threshold.
*Operating zone 2 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, are below the threshold.
General formula for calculating the max. throughput of releasable substances (solvent
throughput):
Mmax = (Vmin(s) x LEL x CLELperm 20 C / 100 x (1 - LEL / 10000 x (t - 20))) / 1000
X000260079
CAUTION
Example of dryer labels
Explosions cause severe injuries.
Only the amount of solvent that is listed on the dryer rating plate attached to the machine is to be
supplied. Only the data listed on the dryer rating plate attached to the machine is to be used to
calculate the maximum permitted amount of solvent. For calculation purposes please refer to the
chapter "Drying system" under the heading "Calculation examples" in the instruction manual.
NOTE
Only those values specified on the rating plates attached to the dryers are relevant for your calcula-
tion!
Tro_0257
Designation Explanations
BCD Between-color drying
TD Tunnel drying
PAM Printing area monitoring
ASH n. l. FW Exhaustion after the last color deck (option)
P/I Pressure tranmitter
PS Flow monitor
PT 100.1/2 Redundant temperature monitoring
BCD SA 1 Solvent analyzer Monitoring Europe
Solvent analyzer Control Europe/USA
TD SA 1 Solvent analyzer Monitoring Europe
Solvent analyzer Control Europe/USA
BCD SA 2 Solvent analyzer Monitoring USA
TD SA 2 Solvent analyzer Monitoring USA
P OUT... Connections Solvent sample recirculation
P 3.1.../3.2... Redundant exit air monitoring
X000258363
Designation Explanations
1 Make-up air BCD+TD
2 Make-up air of between-color drying
3 Fresh air of between-color drying
4 Additional fresh air of between-color drying
5 Exhaust air of between color drying
6 Make-up air of tunnel drying
7 Fresh air of tunnel drying
8 Additional fresh air of tunnel drying
9 Exhaust air of tunnel drying
10 Exit air BCD+TD
11 Exhaust air BCD+TD
12 Exhaust air of exhaust hood after the last color deck
Identification of the dampers
K 1.1... Dampers at the distributor pipe Make-up air
K 1.3... Dampers at the distributor pipe Exhaust air
K 1.4 Additional fresh air flap Between-color drying
K 2.31/K 2.32 Dampers Exhaust air Tunnel drying
K 2.4 Additional fresh air flap Tunnel drying
K3 Exit air damper
PW Flow restrictor Make-up air Tunnel drying
DANGER
Fire and explosion hazard due to improper adjustment of the solvent analyzers.
Fire and explosion may hurt persons and cause damage to the machine.
Before starting a new job be sure to check whether the solvent analyzers on the machine have been
adjusted to the correct solvent or solvent mixture.
Response factor:
The response factor specifies the sensitivity of the sensor with respect to a specific solvent relative
to propane.
X000229737
1 2 3
4
11
5
6
7
11
8
12
2 3
11
9
10
3
2
Tro_0248
5
(1) Analyzer Pressure chamber monitoring (2) Flowmeter with ring initiator
(3) Filter element (4) Solvent sample Pressure chamber mon-
itoring On
(5) Compressed air On (6) Injector
(7) Recirculation of sovlent sample (8) Solvent sample Between-color drying On
(9) Analyzer Tunnel drying (10) Solvent sample Tunnel drying On
(11) Terminal box (12) Analyzer Between-color drying
NOTE
For a detailed functional description see the manufacturer's instruction manual.
Setup Solvent
X000229737
Selecting solvents
CAUTION
Knives or blades
Risk of cuts from knives or blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
The slitter is used to cut the web in longitudinal direction at any position desired. To do this, blade
holders fitted with blades are pneumatically pivoted into the web.
The blade holders can be shifted manually across the entire working width.
Adjustable spreader rollers ensure that the cut webs can be rewound without overlapping.
When working with an edge trimming unit the trims may be removed by means of an edge trim removal
system which can be supplied as an option.
X000288417
(1) Knife carrier drive shaft with blade hold- (2) Handwheel for fine adjustment of the
ers knife carrier drive shaft
(3) Lever to swing the swiveling roller in and (4) Handwheel to set up the blade angle
out. Set the wrap angle
(5) Electrical operator panel for the slitting (6) Pneumatic operator panel for the draw
assembly and the web guide control and the rewind (option)
X000288463
CAUTION
Risk of gashes
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
Connect the compressed-air supply line only to those blade holders that are actually required.
(1) Handwheel
(2) Locking lever
Ls_0277
X000288453
CAUTION
Knives or cutting blades
Risk of cuts from knives or cutting blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
Requirements:
The upper part of the blade has been removed and is ready for use at a suitable working place.
(1) Screw
(2) Support
(3) Blade
X000110952
Both sides of the blade can be used without any problem by turning the upper part of the blade holder.
The suction nozzles should be connected to the edge trim removal system.
X000288424
5.13 Rewind
5.13.1 Special function, bypassing the safety light grid................................................................2
CAUTION
Machine starting automatically
Depending on production, various parts of the line may start automatically. Parts of your body, clothes,
hair and objects may be caught and crushed.
Samples may be cut out however, be careful not to separate the web when doing so. Separating the
web may result in rotating movements of the drive. The drive will be switched off in a delayed manner
via the DANCER ROLLER AT MAXIMUM mode. All chucks of the center shafts must be inflated and
covered by winding cores. Pay attention to the visual and acoustic warning signals. Keep a safe
distance.
As a standard feature, every winding station in unloading position is switched off automatically when
opening the safety chain or entering the safety area of the light grid.
The machine can optionally be configured as follows:
After the configuration, the winding station which is in its unloading position remains switched on
even if the safety chain is opened or the safety area of the safety light grid is entered.
The following movements are prevented when opening the safety chain and entering the safety area
of the safety light grid:
The turret does not rotate.
The separating assembly does not traverse.
X000260860
Function
Two motorized winding stations (4) are provided on the turret (1) which can be swiveled at will. De-
pending on the selected operating mode, the web can be wound up either in underwind or overwind
mode The turret renders possible to swivel the ready made core from the unloading position into the
winding position or the finished roll from the winding position into the unloading position. During pro-
duction, the accruing roll should be in the winding position.
If the roll is swiveled from the winding position into the unloading position, idler rollers (3) are provided
to ensure proper web travel. The web is additionally guided by a lay-on roller (8) installed inside the
turret. It can either continually rest against the roll or be swung in on a roll change.
The light barrier and the safety chain (2) secure the interior of the winder against any unauthorized
access.
Automatic roll change without stopping the machine. When initiating a roll change, the separating
assembly moves into its rear limit position. The winding core ready made with glue is swiveled into
the winding position and the finished roll into the removal position. The separating assembly returns
to its front limit position and the nip roll (5) presses the web against the winding core. Depending on
the selected operating mode, one of the two cut-off knives (7) cuts the web. The roll in the unloading
position slows and the relevant drive is switched off. The finish-printed roll can be unloaded by use
of a roll lifting platform (9) which is available as an option.
X000260860
Winding station
DANGER
Exceeding the default speed
Risk of serious injuries to persons and/or damage to machinery.
Please observe the manufacturer's instruction manual with respect to the winding shafts and winding
cores. Limitations resulting from the use of the winding shafts/winding cores must not be exceeded.
If the calculated speed of the winding shaft/winding core exceeds the manufacutrer's specifications
then the machine speed must be reduced when changing the roll.
DANGER
Using winding shafts when defective
Risk of serious injuries to persons and/or damage to machinery.
Winding shafts must be handled in such a way that they are protected against damage (e.g. due to
impacts, crushing or dropping). Damage to winding shafts (even if not visible) could result in winding
shaft breakage under operating conditions.
DANGER
The specified load rating and capacities must be heeded.
Risk of serious injuries to persons and/or damage to machinery.
The winding cores to be provided by the employer should be laid out for the capacities stipulated in
the technical specifications for the winder, especially when working without winding shafts.
DANGER
Clamping elements coming loose
Risk of serious injuries to persons and/or damage to machinery.
During operation, all clamping elements of the winding shafts must be covered with suitable material
(extended cores, additional cores or similar).
DANGER
Inappropriate winding cores
Risk of serious injuries to persons and/or damage to machinery.
During operation, all clamping elements of the winding shafts must be covered with suitable material
(extended cores, additional cores or similar).
1 1
Wic_0348
WARNING
Pneumatically operated separating assemblies
Risk of severe injuries.
Always switch off the compressed air supply at the compressed air conditioner and withdraw the key
before starting any works inside the winder. There is in increased risk of injury from the pneumatically
operated separating assemblies.
NOTE
Never change the maximum or minimum working pressures! The manufacturer's warranty liability
does not include damages in the pneumatic system of the machine caused by impermissible air
pressure settings.
The compressed air provided on site must meet the quality requirements agreed upon. The manu-
facturer's warranty liability does not included damages due to an inappropriate composition of the air.
The working pressure is factory-set and must not be changed. The start-up time at the start-up valve
are factory-set and must not be changed.
X000255291
1
3
Wic_0376
X000239883
Wic_0335
Wic_0336
X000239888
1 2
Wic_0337 4
NOTE
The permissible limits of the core inner diameter must not be exceeded.
(1) Core
(2) Valve
X000239726
The winding shaft including the core has been loaded into the winding shaft supports by use of a
lifting gear or another device provided vor this purpose.
Activation requirements:
The system is powered up ready for operation.
The winder is ready for operation.
A roll is in its winding position and the web is threaded into the machine.
X000302020
1. Enter job data into the winder screen pages or the winder operator terminal.
Flashing orange: The cut-off assemblies of the unwind and rewind move towards the
roll and ascertain the roll diameter.
NOTE
During the switch-on procedure, the cut-off assemblies move up against the roll to ascertain the
diameter. The cut-off assembly at the unwind returns to its limit position. The cut-off assembly on the
rewind stops at the roll.
Wic_0341
X000302020
Before switching off the winding motor, the machine must be brought to a standstill. The main drive
must be switched off.
Wic_0341
NOTE
A roll change must be initiated in due time before reaching the maximum roll diameter of the accruing
roll.
After the roll change, the finished roll should be taken out of the winder immediately. There is a risk
of colliding with the new roll to be wound up in the winding position.
NOTE
The area of the safety light grid must not be accessed once the roll change has been initiated. If the
requested area of the safety light grid is violated, all rotary movements of the turret and all traversing
movements of the cut-off assembly are stopped. The machine stops as quickly as possible.
X000302098
The blocking chain must be connected and the safety light grid activated.
The sleeve diameter must be properly entered into Procontrol or the optional operator terminal .
A fully automatic roll change is carried out by the machine controller and not by the operator. An
acoustic signal makes the operator aware of the roll change.
1. Enter the roll change data.Once the given diameter of the expiring roll has been reached, roll
change is carried out automatically at the set speed.
X000302098
Wic_0342
After switching on the winding motor, the nip roll stops at the roll. Depending on the selected winding
mode, i.e. gap or surface winding, the nip roll either makes contact with the roll or a gap remains
between the nip roll and the material roll. The increasing roll diameter causes the nip roll to be re-
tracted automatically by the amount of the roll diameter increase.
X000239744
By default, the lay-on roller is automatically loaded to the roll to be changed during a roll change.
After completion of the roll change the lay-on roller is unloaded from the roll. This function can be
switched on or off in Procontrol. In addition, there is a possibility to manually load the lay-on roller to
the winding station.
1. Enter the web tension values into the winder operator terminal (optional) or Procontrol.
X000302152
CAUTION
Inappropriate or defective lifting devices
Risk of severe injuries to persons and/or damage to machinery.
Be aware that unsuitable or defective chain hoists may lose their load and thus cause injury to persons
or damage to the machine. Chain hoists and load handling attachment must be in technically perfect
condition when used. Check the hoisting equipment for adequate carrying capacity. Check the hoist-
ing equipment and the load handling attachment for wear at regular intervals and replace whenever
necessary. Never stay or work beneath a suspended load!
CAUTION
The specified load rating and capacities must be heeded.
There is a risk of severe injury to persons and/or damage to machinery.
When using the lifting gear, the manufacturer's instructions and safety regulations must be heeded.
The lifting gear is laid out for certain roll diameters and roll weights. The given limits must not be
exceeded. Staying beneath the lifting table is forbidden. The lifting table must be secured against
inadvertent mechanical lowering before starting any repair or maintenance works.
NOTE
The lifting gear is intended to load or unload a roll into or from the winder.
All use in excess thereof is forbidden.
Make sure that the winding shaft supports are open before loading or unloading the roll.
X000260843
Lift table Up
Wic_0419
Wic_0421
Wic_0420
Close the winding shaft supports, fit the cordon and activate the safety light grid.
Lift table Up
Wic_0419
X000260843
Wic_0421
Close the winding shaft supports, fit the cordon and activate the safety light grid.
5.14.21 Doctor blade chamber profile - Changing the seal in the machine..................................52
Safety instructions.......................................................................................................52
Seal change.................................................................................................................53
X000161919
DANGER
Electrostatic charging
The line can be electrostatically charged. There is a risk of personal injury from electric shocks caused
by electrostatic charging which may result in uncontrolled reactions.
Provide suitable earthing. Equipotential bonding cables must be connected. Keep the contact surfa-
ces clean.It is forbidden to operate the line unless the equipotential bonding cables are properly
connected. Always wear conductive shoes when working on the inking unit.
CAUTION
Liquids under high pressure
Risk of injury from liquid penetration or splash under high pressure. Thrashing of defective pressure
hoses.
Wear personal safety equipment, keep the lids of all ink containers closed and check the pressure
hoses regularly.
If the inking system is equipped with pneumatic ink pumps, the compressed air supplied must meet
the quality requirements specified in the sheet under the heading "General information on com-
pressed air supply". For this reason, it must only be used with the machine or a suitable compressed
air conditioner.
Ink hoses which are not connected to a doctor blade chamber must be connected to the ink hose
parking position of the respective color deck and locked in place.
Make sure to install and attach the ink hoses in a way that they are not energized in any of the selected
color deck positions. Check the ink hoses and the associated quick-acting couplings at regular inter-
vals (see maintenance instructions for the 'Inking unit').
When cleaning the color decks, the exit air fans at the respective color decks must be switched on.
If the machine is provided with anilox roll covers plates or splash guards, these must be mounted in
both the printing mode and in cleaning mode.
When operating the unit without a filling level monitoring system make sure that sufficient clean
cleaning agent is available and that the container for the dirty cleaning agent is sufficiently empty
before starting a cleaning or pump-out cycle. There is a risk that the discharge container spills over
during the wash-up process.
Ink return pipe must be set up correctly and locked in place so that it does not get in contact with the
agitator shaft.
The minimum distance of the agitator shaft from the container bottom or from the ink pipes should be
more than 20 millimeters.
The agitator shaft must be attached to the motor shaft. The locking pin must be locked in place.
The agitator motor must be introduced into the cover flange and the locking screw must be tightened.
Check the agitator shaft for truth of rotation.
The regulating valve is used to set up the operating speed. The operating speed depends on the
viscosity. Low operating speeds result in good agitating effects.
An equipotential bonding conductor is available on the cover and on the ink container and the junc-
tions must be blank.
Agitator monitoring is required. Operating the agitator above ink level is not permitted.
The compressed air motor must be lubricated via oiled compressed air.
The compressed air motor must not be dipped in fluids. Use a solvent-soaked cloth for cleaning.
DANGER
Electrostatic charging
The line can be electrostatically charged. There is a risk of personal injury from electric shocks caused
by electrostatic charging which may result in uncontrolled reactions.
All equipotential bonding cables must be connected.Keep contact surfaces clean. Disconnect the
ground terminal last when removing the ink container and establish the connection to the ground
terminal first when refitting the ink container. Only ever use suitable, static dissipative ink containers
made of low-sparking material. Do not use containers made of aluminimum, titanium or magnesium.
Always keep the covers of the ink containers closed. Only ever open the ink containers for ink re-
plenishment. Always wear conductive shoes when working on the inking unit.
CAUTION
Ink container lid
The ink container lid may snap shut when controlling the ink and crush parts of your body.
Open the lid completely. Do not deposit any objects behind the lid.
X000161919
DANGER
Electrostatic charging
The line can be electrocstatically charged. There is a risk of personal injury from electric shocks
caused by electrostatic charging which may result in uncontrolled reactions.
Only ever use suitable, conductive solvent containers made of low-sparking material. Do not use
containers made of aluminimum, titanium or magnesium. The individual solvent containers on the
color decks providing solvents to control the ink viscosity should only be topped up with the amount
of solvent required for one shift.The solvent containers should be topped up outside the machine.
Solvent containers on color decks not involved in the production process must not contain any sol-
vents. Put the solvent pumps out of service. Keep the lids of the solvent containers closed to prevent
volatilizing and thus interference effects of the ambient air from occurring. The equipotential bonding
cables for the solvent containers provided on the machine must be connected.To make filling safe,
the container to be emptied and the one to be filled must be connected to the equipotential bonding
cable.
X000126602
Function
NOTE
Only aerosol-free and particle-free fluids and gases or gas mixtures must be used.
The inking and wash-up system Turboclean serves to supply the individual color decks on the
machine with inks and to ensure even ink transfer to the anilox roll.
Moreover, it renders possible to automatically clean the entire ink supply system including the
anilox roll and the connecting elements from left-over inks.
The pump and valve unit is the central element. It comprises the necessary pumps and valves for
supplying and cleaning a color deck. A special air conditioner is used for cleaning the compressed
air required for the pump and valve unit.
All of the pump and valve units are supplied with compressed air and cleaning agents via a base
frame. A specially designed supply system provides the cleaning agent. The used agent is collected
in a discharge container.
Hose connectors connect the pump and valve unit to the doctor blade chamber of the respective
color deck. The doctor blade chamber ensures even inking of the anilox roll. For normal printing,
the ink pails supplied by the ink manufacturers can be used. As an option, there are ink containers
which can be moved towards the pump and valve unit via rollers. The ink is pumped out of the
pump and valve unit through the doctor blade chamber and back into the ink container in an en-
closed circuit.
In wash-up mode, the ink is first pumped out of the ink supply system back into the respective
container. The cleaning agent is flushed from the supply system through the entire hose and
chamber system in various sequences. The anilox roll is cleaned as well.
After washing, the dirty cleaning agent is pumped into the discharge container.
All functions of the pump and valve unit are carried out by use of the hand-held panel. The settings
required for operating the unit are made at Procontrol.
The solvent mixture should have an evaporation number similar to ethanol to ensure for a good
washing effect.
X000150591
X000150591
X000126609
X000127624
Notes
Observe the instructions and details given in the manufacturer's installation and instruction manual
for the respective supply system.
The pertaining local safety instructions for the cleaning agents to be used must be adhered to.
Dispose of the dirty cleaning agents environmentally sound in accordance with the pertaining local
regulations.
If the line is not equipped with a filling level monitoring system, make sure that the dirt container is
sufficiently empty before starting any cleaning or pump out cycle. There is a risk that the container
spills over during the wash-up process.
The process fluid of the ink must not necessarily be used as the cleaning fluid, since during cleaning,
the fluid will be collected completely and thus does not get into the ink. (Condensate or solvent mix-
ture)
The manufacturer's instruction manual must be adhered to when filling or emptying the supply system.
The filling process must be monitored.
On a few lines, it may become necessary to switch on control voltage to the machine for filling the
cleaning agents as otherwise the valve in the supply line is locked.
If the dirty fluid container is provided with overfill protection, this unit blocks the supply line to the
container upon reaching the maximum filling quantity. All currently running cleaning and pump-out
programs are aborted. A error message appears on the hand-held panel.
If the cleaning fluid has been completely pumped out of the container, the current program will not
be aborted!
The connectors from the supply system to the central distribution system are described in more detail
in the technical specifications. Keep all connecting lines free from foreign substances.
X000127624
Function
Cleaning media are used for the wash-up process on all color decks. These cleaning media are
provided by a supply system which is laid out for this purpose. The supply system serves to provide
sufficient cleaning media and to collect the dirty medium.
Different types of the supply systems are available according to the inks used and the related safety
instructions.
Connection to the pump and valve system is provided via the central distribution system. According
to the requirements, up to three different cleaning media can be used. The distribution system and
the number of supply containers should be adjusted according to the number of cleaning media used.
Make sure that sufficient cleaning medium for the operation is available in the cleaning container.
The capacity in the dirty fluid container should be sufficient to collect the dirty fluids from the cleaning
process. To ensure this, the fluid filling level should be permanently monitored.
Solvent-based inks:
Filling level monitoring in the containers takes place automatically. The two liquid volumes are per-
manently checked against a corresponding minimum and maximum value. These threshold values
when reached are laid out so that the standard cleaning processes for approx. eight color decks can
still be carried out completely.
If the minimum filling level in the clean cleaning medium container drops below this level or if the filling
level in the dirty medium container is exceeded, the warnings "Dirty liquid container almost full" or
"Solvent container almost empty" appear on the hand-held panel. Cleaning cycles are still possible
if this warning appears. Before starting a cleaning program the operator should check the filling levels
to decide whether the desired program can still be run.
Generally, the dirty fluid container should be emptied and the cleaning container be filled when the
first warning appears.
The dirty fluid container of the supply system has overfill protection. If the container is full all current
cleaning programs are interrupted and the supply line to the container is blocked automatically. A
error message appears on the hand-held panel.If the reservoir is empty the cleaning program will not
be interrupted; cleaning is no longer possible.
Water-based inks:
Due to the low risk potential the fluids are kept in simple metal containers when cleaning with water.
The exact filling level is not recorded.
If the system has no filling level monitoring equipment, the fluid levels in the containers should be
checked prior to every cleaning cycle. Make sure that sufficient cleaning medium is available for the
selected program. Make sure that there is sufficient collecting capacity in the dirty fluid container to
prevent the container from spilling over.
Wash up the selected color decks again using the cleaning medium.Run a special wash-up pro-
gram, if necessary.
(1) F4 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Select the desired color deck using the keys 1
to 10 (4).
A B
Tc__0383
An e is displayed below the selected color
deck. The prompt of the selected color deck
(3) is blinking in the display.
Press the F4 (1) key.
The wash-up program preselected at Procon-
trol is started.
Hold the pump out hose into a suitable container and open the ball valve.
(1) F3 key
WINDMLLER & HLSCHER
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PU2 MENU
F1 F2 F3 F4
flushing.
Tc__0386
X000135673
Use a T-fitting to interconnect the ink hoses on the color deck. Connect a container with ethyl
acetate to the pump and valve unit.
(1) F1 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Select the desired color deck using the keys 1
to 10 (4).
A B
Tc__0381
An a is displayed below the selected color
deck. The prompt of the selected color deck
(3) is blinking in the display.
Press the F1 (1) key.
By use of ethyl acetate for inking, all left-over
dirt particles and deposits are removed.
Thoroughly clean or replace the doctor blade
chamber.
Thoroughly clean or replace the anilox roll (ul-
trasonic equipment, Recyl, Cobra).
(1) F1 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Select the desired color deck using the keys 1
to 10 (4).
A B
Tc__0381
An a is displayed below the selected color
deck. The prompt of the selected color deck
(3) is blinking in the display.
Press the F1 (1) key.
Open the ball valve when program a is running
and press the F4 key on the hand-held panel.
Ethyl acetate is pumped through the pump out
hose.
(1) F2 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Select the desired color deck using the keys 1
to 10 (4).
A B
Tc__0382
A b is displayed below the selected color deck.
The prompt of the selected color deck (3) is
blinking in the display.
Press the F2 (1) key.
The pump out program preselected at Procon-
trol is started.
Re-connect the ink hoses to the doctor blade chamber. In order to prevent contamination to the
system, one WASH-UP cycle should be carried out before INKING is started. This ensures that
the system is free of left-over ink and left-over solvents.
X000126616
Dw__0400
Function keys
(1) TC button
WINDMLLER & HLSCHER
PU2 MENU
(3) A button F1 F2 F3 F4
6 7 8 9 10
Display-dependent keys
(1) F1 to F4 keys
WINDMLLER & HLSCHER
PU2 MENU
TC
1 2 3 4 5
6 7 8 9 10
A B
Tc__0377
X000126616
PU2 MENU
6 7 8
3 9 10
4
B
Only the color decks associated to the printing unit can be selected. The other keys have no function.
PU2 MENU
TC
This screen page renders possible to select between various inking programs (1), pump out programs
(2), pre-conditioning (3) and wash-up programs (4). On this screen page, the respective program for
the required application is selected.
To make handling of this screen page easier, a standard program for all color decks will be selected
in the top line (5). Normally, this will be the program which is used most.
If another program is selected, the screen page returns to the standard program after the selected
program has ended.
X000126647
The respective ink supply system including the ink container is connected and the anilox roll drive is
ready for operation. The doctor blade chamber is prepared and the doctor blade swivel switch is set
to ON.
Before starting the inking program make sure that sufficient collecting capacity is available in the dirt
container.
(1) F1 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Use the keys from 1 to 10 (4) to select the re-
quired color deck.
A B
Tc__0381
The prompt of the selected color deck (3) in the
display is blinking.
Press the F1 (1) key.
An a (2) is displayed below the selected color
deck. The inking program preselected on Pro-
control is started.
Before pumping the ink into the dirt container make sure that suffucient collecting capacity is available
in the dirt container.
(1) F2 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Use the keys from 1 to 10 (4) to select the re-
quired color deck.
A B
Tc__0382
The prompt of the selected color deck (3) in the
display is blinking.
Press the F2 (1) key.
A b (2) is displayed below the selected color
deck. The pump out program preselected on
Procontrol is started.
X000126647
Go to to screen page.25.
Press the choice box (1) for the desired color
deck.
A list appears to select the desired program.
After setting up the viscosity and/or the tem-
perature, a message in Procontrol informs the
operator that the color deck can now be inked
up.
After the program has ended, the program in-
dicator in the display field (2) returns to the
standard program.
(1) F3 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
menu. 6 7 8 9 10
4
Use the keys from 1 to 10 (4) to select the re-
A B
All guards are closed, the fan is switched on, the anilox roll drive is ready for operation, the doctor
blade is loaded and the color deck is selected.
Before starting the wash-up programs make sure that sufficient collecting capacity is available in the
ink and dirt containers.
(1) F4 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
6 7 8 9 10
4
Use the keys from 1 to 10 (4) to select the re-
quired color deck.
A B
Tc__0383
The prompt for the selected color deck (3) in
the display is blinking.
Press the F4 (1) key.
An e (2) is displayed below the selected color
deck. The wash-up program preselected on
Procontrol is started.
X000126647
Changing over from the inking mode to the wash-up mode for all color decks simul-
taneously
This function allows for all color decks to simultaneously change over from the inking mode to the
wash-up mode.
(1) F2 key
WINDMLLER & HLSCHER
F1 F2 F3 F4
ESC
3
Check whether F1, F2, F3, F4 is displayed in
the control key line. If necessary, use the arrow
keys to go to the appropriate submenu.
Press the F2 (1) key. 1 2 3 4 5
blinking.
A B
Tc__0384
Press the ARROW DOWN (3) key.
Press the key several times until main menu 1
appears.
DANGER
Danger due to electrostatic charging.
All equipotential bonding conductors must be connected. It is forbidden to operate the line unless the
equipotential bonding conductors are properly connected.
Keep the contact surfaces clean.
Disconnect the ground terminal last when removing the ink container and establish the connection
to the ground terminal first when refitting the ink container.
(1) F1 key
WINDMLLER & HLSCHER
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PU2 MENU
F1 F2 F3 F4
X000126647
(1) F3 key
WINDMLLER & HLSCHER
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PU2 MENU
F1 F2 F3 F4
Via the pump out hose, the ink will not be pumped into the ink container but into a separate suitable
container. The 'Pump out during inking' mode serves to reduce the ink level in the ink container and
to replenish ink blend, for example.
(1) F4 key
WINDMLLER & HLSCHER
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PU2 MENU
F1 F2 F3 F4
Press and hold the F4 (1) key until the required Tc__0435
level in the ink container is reached.
Clean the ball valve after the pump out and re-
move the container.
If a cleaning program is canceled, the entire ink supply system must be emptied. The filling level for
the fluids in the system is undefined.
It is possible to stop running programs for all color decks simultaneously or individually for each color
deck.
aaaaaaaaaa
PU2 MENU
F1 F2 F3 F4
ESC
number.
6 7 8 9 10
X000126507
Inking programs
Inking Good compromise between ink loss and change in viscosity.
Inking Short A small amount of ink will be pumped into the dirty fluid container. The change
in viscosity is higher than when using inking mode.
Inking Long More ink will be pumped into the dirty fluid container. Minor changes in vis-
cosity. This program is used for example when changing from black to white
or when using water-based inks.
Direct inking No ink will be pumped into the dirty fluid container. Significant change in vis-
cosity.
Flush the heat ex- (only when heat exchanger is optional)
changer
The inking programs six to ten are optional and will be developed on request according to the cus-
tomer's specifications.
Wash-up programs
Short wash-up Cleaning agent consumption of 8 liters
Long wash-up Cleaning agent consumption of 10 liters
Intensive wash-up Cleaning agent consumption of 14 liters
(Washing from
dark to bright)
Wash-up when in When changing the doctor blades
continuous run-
ning mode
Pump ink from ink Pump ink from the ink container into the collecting tray. Carry out the 'Short
container into the wash-up' program.
collecting tray and Cleaning agent consumption of 8 liters
carry out the
'Short wash-up'
program
Pump into dirty Pump ink from the ink container into the dirty fluid container. Carry out the
fluid container and 'Short wash-up' program.
carry out the Cleaning agent consumption of 8 liters
'Short wash-up'
program
'Short wash-up' The left-over ink is pumped out of the ink container and into the ink bucket.
program including The 'Short wash-up' program including pre-cleaning of the ink container is be-
pre-cleaning of ing carried out.
the ink container
'Short wash-up' The left-over ink is pumped out of the ink container and into the dirty fluid
program including container. The 'Short wash-up' program including pre-cleaning of the ink con-
pre-cleaning of tainer is being carried out.
the dirty fluid con-
tainer
Flush the heat ex-
changer
Pre-conditioning programs
Viscosity The ink viscosity is set.
Viscosity ynd tem- The ink viscosity and the ink temperature are set.
perature
X000126517
If inking, wash-up or pump-out programs cannot be carried out, an error symbol appears on the hand-
held panel instead of the program symbol. If the color deck error below which the error symbol appears
is selected by use of the keys from 1 to 10, the associated error message is displayed on the hand-
held panel.
PU2 MENU
A B E
'e' (wash-up)
Select the color deck below which the error
symbol appears by use of the keys from 1 to
10 (2).
1 2 3 4 5
2 6 7 8 9 10
Error messages
1. Unknown error
2. Supply pump frequency reduced
3. Wash-up enable missing
4. Continuous rotation enable missing
5. Anilox roll enable missing
6. Wash-up enable missing
7. Ready-for-operation status for anilox rolls missing
8. Doctor blade chamber not closed
9. Anilox roll drive not switched on
10. Undefined color deck position
11. Fan not switched on
12. Portalift not in garange position
13. Needle bearing not closed
14. Guard door grid open
15. Supply pump error
16. Return pump error
17. Solvent tank Input/Output error
18. Dirty solvent container full
19. No control voltage
NOTE
The connectors need cleaning after every washing cycle and prior to longer shutdown times. This
ensures that the connectors are free from ink and dirt.
When using ink systems which show a tendency to react chemically with each other (e.g. solvent-
based and water-based inks) it becomes necessary to carry out the CLEAN CONNECTORS function
until the solvent used comes out of the connectors.
Pressing the CLEAN CONNECTORS pushbutton causes the supply and return connectors at the
pump and valve system to be cleaned additionally. The pushbutton must be pressed only after the
actual wash-up cycle of the color deck.
(1) Pushbuttons
(2) Ink return hose
(3) Pushbuttons
(4) Ink supply hose
(5) Ink container
X000220346
WARNING
Risk of cuts from knives and blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
WARNING
Risk of crushing when turning down the doctor bar on changing the knives in the machine.
Use the turning handle to lock the doctor blade chamber horizontally in place.
NOTE
Be careful not to damage the impression cylinder when working on the doctor blade unit.
The doctor blade unit illustrated may not be the same as provided on the machine. This procedure
can be followed for all of the machines.
Swing the doctor bar away from the plate cylinder before starting any works on the equipment.
(1) Handle
(2) Turning handle
After completion of the works, swivel the doctor bar back forward and lock in place using the turning
handle.
Pull the locking pin (1) and then turn the doctor
bar stop upwards.
Lock the stop in its new position by releasing
the locking pin (1).
X000220346
Hold the doctor bar by the handles when loosening the rotary handle. The doctor bar flips over.
(1) Handle
(2) Rotary handle
Once finished pivot the doctor bar back upwards again, reposition the doctor bar stop and lock the
doctor bar in place using the rotary handle.
Depending on the machine type, there are different ways to remove the doctor blade chambers.
DANGER
Risk of personal injury from slipping, tripping or falling when stepping on the climbing aids
and carrying the doctor blade chambers.
Climb up to the top color deck and ensure stable standing. Two persons are needed to remove the
doctor blade chamber. Hand down the removed doctor blade chamber. Only ever step on the ladders
without carrying any loads.
WARNING
Risk of gashes from knives and blades.
Remove the doctor blades before dismantling the doctor blade chamber. Wear cut-resistant gloves
as per anti-cut class 5 according to European standard EN 388. Only ever transport the doctor blade
chamber without doctor blades.
X000217598
In order to make it easier to assign the doctor bars to the respective color decks, the drain boxes are
provided with variegated intermediate layers 2 and marking rings 10 and the doctor bars with varie-
gated limit stops.
Doctor bars provided with black intermediate layers, marking rings and limit stops on the chamber
are installed in the inner color decks 1-4 (1-5).
Doctor bars provided with white intermediate layers, marking rings and limit stops on the doctor blade
chamber are installed in the outer color decks 5-8 (6-10).
X000217598
(1) Drain box Drive side Color decks 1-4 (2) Drain box Operator side Color decks 1-4
(1-5) (1-5)
(3) Barrier hole (4) Intermediate layer black
(5) Marking ring black
(1) Drain box Operator side color decks 5-8 (2) Drain box Drive side color decks 5-8
(6-10) (6-10)
(3) Barrier hole (4) Intermediate layer white
(5) Marking ring white
X000217598
Insert the key into the locking lever (1) and turn
the locking lever to the center of the chamber.
Remove the key after turning the locking lever.
Pull the drain box (2) out of the doctor blade
chamber in the direction of the arrow.
NOTE
The sealing cord inserted in the drain box should not be damaged when fitting the drain box in the
doctor blade chamber.
The drain box will be fitted without seal.
(1) Clamping strip for the doctor blade (2) Doctor blade
(3) Ink return hose connection (4) Ink supply connection
X000042670
Rear side
In order to make it easier to assign the doctor bars to the respective color decks, the drain boxes are
provided with variegated marking rings (5) and the doctor bars with differently colored limit stops
(5).
Doctor bars provided with black marking rings and limit stops on the chamber are installed in the inner
color decks 1-4 (1-5).
Doctor bars provided with white marking rings and limit stops on the doctor blade chamber are in-
stalled in the outer color decks 5-8 (6-10).
Arrangement of the doctor blade chambers in the printing unit (right-hand machine)
(1) Doctor blade chamber for the outer color (2) Doctor blade chamber for the inner color
decks 5-8 (6-10). decks 1-4 (1-5).
(3) Barrier hole at the service doctor blade (4) Doctor blade chamber with white mark-
ings on the ink return and supply hoses
(5) Doctor blade chamber with black mark-
ings on the ink return and supply hoses
Doctor blade chambers with black markings on the ink return and supply hoses are installed in color
decks 1-4 (1-5).
Doctor blade chambers with white markings on the ink return and supply hoses are installed in color
decks 5-8 (6-10).
X000042670
Arrangement of the doctor blade chambers in the printing unit (left-hand machine)
(1) Doctor blade chamber for the inner color (2) Doctor blade chamber for the outer color
decks 1-4 (1-5). decks 5-8 (6-10).
(3) Barrier hole in the service doctor blade (4) Doctor blade chamber with black mark-
ings on the ink return and supply hoses
(5) Doctor blade chamber with white mark-
ings on the ink return and supply hoses
Doctor blade chambers with black markings on the ink return and supply hoses are installed in color
decks 1-4 (1-5).
Doctor blade chambers with white markings on the ink return and supply hoses are installed in color
decks 5-8 (6-10).
CAUTION
Risk of gashes from knives and blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
Risk of crushing your fingers. Make sure to switch off the continuous rotation before working on the
doctor blade unit.
NOTE
Be careful not to damage the impression cylinder when working on the doctor blade unit.
DANGER
Press the lateral clamping plates and the sealing plate on the seals of the doctor blade cham-
ber until they hit the limit stop. The clamping plates or sealing plates must not rub against the
anilox roll.
Blade change
(1) Key
(2) Locking lever
Fit the key (1) on the locking lever (2) and hold
it.
X000184358
Fit the key on the locking lever (2) and hold it.
Push the locking lever backwards.
The clamping bar (2) is released.
Withdraw the key from the locking lever.
Carefully take the blade out of the doctor blade
chamber (1).
Mount the blade first, then insert the seals. (see the description of a seal change)
(1) Blade
(2) Locking lever
(3) Clamping bar
5.14.21 Doctor blade chamber profile - Changing the seal in the machine
Safety instructions
CAUTION
Risk of gashes from knives and blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
Risk of crushing your fingers. Make sure to switch off the continuous rotation mode before working
on the doctor blade unit.
NOTE
Be careful not to damage the impression cylinder when working on the doctor blade unit.
DANGER
Fire and explosion hazard
Press the lateral clamping plates and the sealing plate on the profiled seals of the doctor blade
chamber until they hit the limit stop. The clamping plates or sealing plates must not rub against the
anilox roll.
X000043108
Seal change
(1) Seal
DANGER
Fire and explosion hazard due to improper mounting of the clamping and sealing plates.
Fire and explosion may hurt persons and cause damage to the machine.Press the lateral clamping
plates and the sealing plate on the seals of the doctor blade chamber downwards until they hit the
limit stop. The clamping plates or sealing plates must not rub against the anilox roll.
(1) Seal
(2) Doctor blade
(3) Bolt in the support plate
(4) Locking bolt for clamping plate
X000043171
General
Swap all drain boxes every other week for thorough cleaning (e.g. 1 doctor blade chamber every
other day). Make sure that the barrier area is perfectly clean!
When cleaning the doctor blade chamber in the machine special care must be taken to prevent solid
bodies such as dried up ink residues or knife abrasion particles from getting into the ink return hose.
Disconnect the ink return hoses, if necessary.
Venting
Replace both vent pipes contained in the used color decks for cleaning every other day.
Lower anilox roll cover
Also replace the lower cover in the respective color deck when replacing a doctor blade chamber.
Pay attention to the splash guards when cleaning.
Upper anilox roll cover
When inserting an anilox roll into a color deck be sure that the respective upper cover is perfectly
clean.
Blade change
CAUTION
Risk of gashes from knives and blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
The following actions should be taken when doctor blades or seals are worn down:
Remove the doctor blades and seals.
Remove the clamping bars and tie rods for cleaning.
Clean the doctor blade support.
Clean the outlets prior to the barriers.Prevent solid bodies from getting into the ink return hose
during cleaning. Disconnect the ink return hose, if necessary.
Refit the cleaned clamping bars and tie rods.
Fit new doctor blades and seals.
Inspect barriers for damage.
X000043171
NOTE
Prevent damage to the doctor blade chamber from occurring when placing it into the washing ma-
chine.
When cleaning the doctor blade chamber in a washing machine, the doctor blade chamber must be
prepared as follows:
The doctor blade and the clamping device (clamping bars and tie rods) have been removed.
The drain boxes have been removed.
the sealing plate and the intermediate layer have been removed from the drain boxes.
The vent pipes are removed.
Anilox rolls
General cleaning of the anilox roll is required after approx. 200 hours. The anilox roll must be replaced
or thoroughly cleaned when changing the ink system (for example, from NC to PVB).
You must always abide by the general safety and accident prevention regulations.
An additional high-speed doctor blade can be fitted to avoid trapped air when running the machine
at high speeds.
To avoid ghosting, an additional antighosting doctor blade may be fitted.
A steel or plastic doctor blade may be fitted as necessary and according to the application.
The additional clamping rail equipped with the third blade can only be fitted when both the ink supply
lines are open. Where necessary, the doctor blade chamber need to be modified.
Only one of the two additional doctor blades can be fitted.
If a plastic doctor blade is fitted, the contact pressure of the doctor blade unit remains unchanged.
If a steel doctor blade is fitted, the contact pressure of the doctor blade unit needs to be increased to
1.8 bar.
An additional doctor blade should only be fitted if the working and closing doctor blades are removed
from the doctor blade chamber.
CAUTION
Risk of gashes from knives and blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.
Risk of crushing your fingers. Make sure to switch off the continuous rotation before working on the
doctor blade unit.
X000068312
X000068337
(1) Key
(2) Clamping rod
(1) Key
(2) Mounting on the working doctor blade
side
5.15.3 Conversion........................................................................................................................6
Screen page Conversion...............................................................................................6
Entries in the screen page Conversion..........................................................................7
Stopwatch in the Turboclean hand-held panel..............................................................9
(1) Terminal compartment and evaluation (2) Ink chamber with rod for generating vi-
unit brations
(3) Cable gland (4) Ink inlet
(5) Ink outlet to doctor blade chamber (6) Equipotential bonding cable
NOTE
A sealed clip connects the terminal compartment and the ink chamber. When opening the clip and
separating the connection, the viscosity controller becomes defective and must not be used any more.
A viscosity controller is required to keep the ink viscosity specified for the job constant. The sensor
is integrated in the supply line to the doctor blade chamber.
The rod in the ink chamber is set vibrating and the vibrations are transmitted to the ink. The resulting
ink vibrations are measured and evaluated. This value along with the conversion to be carried out
allow conclusions regarding the ink viscosity.
Conversion is to be carried out on every ink change. As to that, the stop watch mode of the hand-
held panel is explained in this chapter.
X000011930
Equipotential bonding
DANGER
It is forbidden to operate the system without the viscosity controller being grounded! The risk
of an explosion being caused by an electrostatic charge exists.
It is forbidden to operate the system without the solvent pump being grounded. The risk of an
explosion being caused by an electrostatic charge exists.
All of the screw connections must be tightened up carefully. It is important that the contact
surfaces are kept clean at all times.
X000307892
5.15.3 Conversion
Screen page Conversion
The service pages can only be accessed by entering a password. Entries in these pages can
only be made after the customer's password has been entered.
X000011574
X000011574
A stopwatch has been integrated into the hand-held panel for converting the viscosity controller.
Change from Main menu screens 1, 2 or 3 to the viscosity measurement screen.
Measuring viscosity
To enable conversion, the viscosity controller fitted in the Procontrol column must be switched to
AUTO (automatic) and must have ascertained a valid measurement.
5.16.4 Changing the web paths towards the web inspection unit..............................................16
Converting the front and reverse side inspection unit..................................................16
Converting the web inspection unit from reverse side to front side inspection............18
DANGER
Machine starting automatically
Depending on the production, various parts of the line may start automatically. Parts of your body,
clothes, hair and objects may be caught and crushed.
The main switch must be turned off and padlocked before carrying out any maintenance work. Ob-
serve the instructions next to the main switch. Visual and acoustic warning signals. Keep a safe
distance.
NOTE
Never change the maximum or minimum pneumatic working pressures! The compressed air supply
from the on-site system must satisfy the quality requirements defined for the utilities.
X000288146
Main switch
The entire electrical power supply to the machine is provided via a main switch. The power element
of the main switch is integrated in the Eltainer. The operating element located outside the Eltainer
switches the power element on or off by means of an electric drive.
Control voltage
The control voltage can only be switched on if no Emergency-Stop pushbutton has been actuated.
The CONTROL VOLTAGE ON pushbutton is integrated in the main operator panel of the machine.
The unwind mode to be selected depends on the provided roll. Normally, the web is treated on one
side and printing takes place on the treated web side. The treated side of the web may either be the
front or reverse side and the roll must be loaded into the winder accordingly. ' Overwind ' or ' Under-
wind ' mode is selected in PROCONTROL or an optional winder terminal.
Settings in Procontrol
X000270644
Rewind mode
X000270644
Settings in Procontrol
DANGER
Always switch off the compressed air supply to the winder and withdraw the key from the
compressed air conditioner before entering the winder. There is an increased risk of injury.
CAUTION
Risk of injury from rotating chains, belts and rotating gears
Parts of your body, clothes, hairs and objects can be pulled in and crushed. Do not open or remove
safety devices. Wear tight-fitting clothes and a hairnet. Work without gloves. Keep a safe distance.
X000288157
CAUTION
Rotating rollers and running threading chain
Parts of your body, clothes, hair and objects may be caught and crushed.
Wear tight-fitting clothing. Work without gloves. Keep your hands away from the nip. Keep a safe
distance.
CAUTION
Sharp edges
Risk of cutting your body on sharp-edged webs.
Web thread-up can only be realized at reduced speed. Wear protective equipment.
(1) Roll
X000288157
Roll make-ready
The threading chain ends at the step behind the rear frame. According to the machine design the
threading chain is separated at the impression cylinder or passed around the impression cylinder.
If no threading chain is available the web must be threaded up manually according to the instructions
in the web travel plan.
(1) Web
Use the threading chain to draw the web behind the rear frame.
CAUTION
Risk of injury from rotating machine parts.
Clean color decks One and Ten and switch off the anilox roll drive.
(1) Ladder
(2) Safety guide
X000288157
Pull the web behind the nip roll (1) of the print-
ing unit according to the web travel plan.
Splice the web onto the impression cylinder
(2).
Only the sliding door on the web infeed side of the printing unit must be open. All other guard doors
must be closed.
X000288157
No threading chain is available in the rewind machine module so that the web must be threaded up
manually.
Pay attention to the selected winding direction when threading up the web in the cut-off assembly of
the rewind.
Close all guard doors, establish readiness for operation and switch on the machine.
Feed the web carefully through the machine until it lies wrinkle-free on all rollers and cylinders.
Then, loosen the provisionally fixed web from the rewind, remove the old winding roll and fix the
web to the sleeve correctly.
5.16.4 Changing the web paths towards the web inspection unit
Converting the front and reverse side inspection unit
1. Separates and fixes the web (3) prior to the idler roller (2).
2. Draw back the separated web (3) up to the first cooling roller.
3. Attach the web (3) to the threading chain follower on the drive side (1). The web forms a loop.
X000267740
1. Actuate the crank handle: At first, the web (1) is misdirected deliberately. Then, the web (1) is
fed towards the rear frame as desired.
2. Actuate the crank handle until the web running upwards through the rear frame reaches the
removal position Support (2).
3. Remove the web from the threding chain follower on the drive side (2) and feed it further through
the machine by hand.
Converting the web inspection unit from reverse side to front side inspection
1. Separate the web (3) after the last color deck and attach it to the threading chain follower on the
operator side (1).
2. Remove the separated web (2) after the last color deck up to the support from the machine.
3. Use the threading thain to thread in the web on the operator side through the drying box and
the rear frame.
4. Remove the web from the threading chain follower on the operator side and thread it further
through the machine by hand.
X000041546
Assembly:
Use assembly belts with high adhesive force.
Mount the adhesive tape free from bubbles with increased hand pressure.
Lay the impact edge of the adhesive tape under the printing plate when possible.
Use reinforced adhesive primer of the respective adhesive tape manufacturer.
Fix the printing plate with nip roll applying medium force.
Mask-off:
allow 0.5 to 1 cm of adhesive tape to protrude.
Fold-free taping of the printing plate edges using one-sided adhesive tape. The adhesive tape should
have a strong bonding to the plate as well as the sleeve.
Integrating the printing plate with a commercially available LDPE (Low Density Polyethylene), approx.
thickness 80 m and width of 15 cm.
X000198620
Material: PE-HD
Material: PE-LD
X000198620
Material: BOPP
Material: ALUMINIUM
X000198620
Material: PAPER
Improper storage conditions have an adverse effect on the properties of the roller covers and leads
to a reduction in the service life of a roller cover.
In order to ensure that the covers have a long service life, please observe the following instructions
on storage, cleaning and operation. Please refer to DIN 7716 (ISO 8331) for other requirements
regarding the storage and cleaning of the roller covers.
Storing
Cleaning
Coated rollers Use solvents which are also contained in the inks, adhesives etc. in
use.
Clean the roller covers with a little bit of solvent keeping the cleaning
time to a minimum, then wipe dry with a clean cloth.
Never use hard objects for cleaning.
Rubberized rollers Only ever use soap, warm water and a lint-free cloth when cleaning
rubberized rollers.
The manufacturer recommends the use of effective and gentle clean-
ing agents.
Counter rollers Remove deposits or contaminations, if any.
Operation
Relieve pressure immediately when roller covers running under pressure come to a standstill. Dry
running of the rollers must be avoided. Regular maintenance of the roller coverings prevents major
damage and downtimes.
Pay attention to the electric conductivity of the surfaces. The surface resistance is defined as < 109
Ohm and must not be exceeded.
6 Maintenance
DANGER
Fire/explosion hazard
Lubricating the ATEX-relevant lubrication points is safety-relevant in terms of a fire/explosion hazard
in the machine.
(1) Sequence number in the alarm overview (2) Date and time of alarm activation
(3) Yellow field = Highlighting of the safety- (4) Text of the safety-relevant alarm
relevant alarm message
(5) 60-hours time block indicating the re- (6) Specification of the lubrication intervals
maining time concerned
A safety-relevant message (4) appears in the 'Alarm list' 60 operating hours before the greasing
interval (6) expires. At the same time, the system-integrated running time meter (5) starts a COUNT-
DOWN (countdown of the 60-hour time block). If no lubrication is carried out within this COUNTD-
OW period and the alarm message is acknowledged by safety acknowledgement, the machine will
be stopped at the end of the COUNTDOWN.
The safety acknowledgement resets the safety-relevant alarm message in the alarm overview. The
associated interval for all ATEX-relevant lubrication points will be re-started until the '60 hours until
end of interval' limit is reached next time.
X000164477
Messages appearing in the alarm overview in the visual display unit of Procontrol activate a virtual
signal lamp (2) in the visual display unit. The signal lamp will also be visible if the 'Alarm overview'
screen page is not displayed.
To have the alarm message(s) displayed, go to the ' Alarm overview ' screen page via the ALARM
OVERVIEW button in the menu bar of the virtual display unit.
A safety-relevant alarm message when received is highlighted in a yellow field (1) in the relevant line.
When the alarm message appears the COUNTDOWN of the system-integrated running time meter
(3) is started beginning with 60 hours (timespan until the end of the lubrication interval).
Touch the Procontrol touch screen with your finger to select the line with the safety-relevant alarm
message (yellow field). The line is highlighted in gray. At the same time, two virtual buttons, namely
SAFETY ACKNOWLEDGEMENT (4) and LUBRICATION (5), become visible.
(1) Yellow field = Highlighting of a safety-rel- (2) Visual signal on activating an alarm
evant alarm message
(3) Running time meter of 60 hours with au- (4) Virtual SAFETY ACKNOWLEDGE-
tomatic updating MENT button
(5) Virtual LUBRICATION button
(1) Depiction of the chart containing the (2) 'Signature' acknowledgement line
ATEX-relevant lubrication points
(3) Example of a safety-relevant message
When acknowledging the virtual LUBRICATION button in the menu bar of the visual display unit, the
lubrication chart containing the ATEX-relevant lubrication points appears in the visual display unit.
The safety-relevant message in the alarm overview (3) informs you of the points needing lubricating.
Print out the chart to have the required information at hand on the ground (at the lubrication point).
After greasing the lubrication point, the operator must acknowledge this by signature in the associated
"Signature" line (2) of the paper printout.
After all of the lubrication points specified in the safety-relevant message have been lubricated, the
complete paper list is being filed centrally.
Delete the safety-relevant message in the alarm overview by safety acknowledgement to complete
the entire procedure.
X000164477
Press the SAFETY ACKNOWLEDGEMENT button in the menu bar of the ' Alarm overview ' screen
page.
The ' Safety acknowledgement ' window pops up in the visual display unit (1).
Touching the SERVICE PASSWORD (2) line makes an alphanumeric keypad available for entering
the customer password.
After the entry, press the virtual ACKNOWLEDGE (3) button in the pop-up window.
(1) ' Safety acknowledgement ' pop-up win- (2) SERVICE PASSWORD entry line
dow
(3) Virtual ACKNOWLEDGE button
Greasing the anilox roll bearings on color decks 1-5 on the drive side
Signature:
Greasing the anilox roll bearings on color decks 6-10 on the drive side
Signature:
X000175254
Greasing the anilox roll spindle bearings on color decks 1-5 on the drive side
Signature:
Greasing the anilox roll spindle bearings on color decks 6-10 on the drive side
Signature:
Greasing the plate cylinder bearings on color decks 1-5 on the drive side
Signature:
Greasing the plate cylinder bearings on color decks 6-10 on the drive side
Signature:
X000175254
Greasing the plate cylinder spindle bearings on color decks 1-5 on the drive side
Signature:
Greasing the plate cylinder spindle bearings on color decks 6-10 on the drive side
Signature:
Greasing the sidelay register spindle bearings of color decks 1-5 on the drive side
Signature:
Greasing the sidelay register spindle bearings of color decks 6-10 on the drive side
Signature:
X000175254
Signature:
Signature:
Signature:
Signature:
X000175254
Signature:
Signature:
Signature:
6.2 Cleaning
6.2.1 Rewind..............................................................................................................................3
Turret.............................................................................................................................3
Winding stations............................................................................................................3
Cut-off assembly............................................................................................................4
Computer.......................................................................................................................4
6.2.2 Unwind..............................................................................................................................5
Turret.............................................................................................................................5
Winding stations............................................................................................................5
Separating assembly.....................................................................................................6
Computer.......................................................................................................................7
6.2.3 Unwinder...........................................................................................................................7
6.2.4 Rewind..............................................................................................................................8
6.2.5 Rewind..............................................................................................................................8
6.2.13 Drying..............................................................................................................................16
6.2.17 Procontrol........................................................................................................................18
6.2.18 Eltainer............................................................................................................................19
Climate control unit......................................................................................................19
Computer.....................................................................................................................20
6.2.19 Easy-Col..........................................................................................................................20
6.2.20 Easy-Set..........................................................................................................................21
6.2.21 Easy-Reg.........................................................................................................................24
X000050971
6.2.1 Rewind
Turret
Winding stations
Cut-off assembly
Computer
(1) Computer
X000110316
6.2.2 Unwind
Turret
Winding stations
Separating assembly
X000110316
Computer
(1) Computer
6.2.3 Unwinder
Cleaning the lenses
(1) Lenses
6.2.4 Rewind
Cleaning the lenses
(1) Lenses
6.2.5 Rewind
Clean the sensor
(1) Sensor
X000109893
(1) Lenses
(1) Reflector
X000055887
(1) Sensor
WARNING
Electrical current
Risk of severe injuries when getting in touch with live components.
Disconnect the main power supply and secure it against unintentional reactivation. Verify the safe
isolation from supply. Ground and short-circuit the machine part. Any adjacent parts that are still live
must be covered. Only electrically skilled personnel should carry out work on the unit.Keep a safe
distance.
X000147794
CAUTION
Surfaces may be hot.
CAUTION
Surfaces may be hot.
(1) Filter
Tunnel drying
CAUTION
Surfaces may be hot.
(1) Drive
CAUTION
Surfaces may be hot.
X000147794
CAUTION
Surfaces may be hot.
(1) Screen
Fan
CAUTION
Surfaces may be hot.
(1) Drive
CAUTION
Surfaces may be hot.
(1) Drive
6.2.13 Drying
Cleaning the fine-mesh filter
CAUTION
Hot surfaces
Risk of burning your skin when getting in contact with hot surfaces.
Leave the machine to cool down before starting any works on the machine. Wear safety gloves, safety
shoes and long-sleeved clothing. Keep a safe distance. Keep away substances with low ignition
temperatures.
X000147811
(1) Drive
(1) Drive
(1) Drive
6.2.17 Procontrol
Cleaning the filters
(1) Filter
X000147827
(1) Computer
6.2.18 Eltainer
Climate control unit
(1) Filters
Computer
(1) Computer
6.2.19 Easy-Col
Cleaning the ink weighing system
X000057496
6.2.20 Easy-Set
Removing leftover film from the camera module
(1) Lighting
(1) Lighting
X000057496
6.2.21 Easy-Reg
Cleaning the sensor glass
1 Swivel arm
2 Sensor glass