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Operating Manual Combined Refrigerated Circulating Water Level CRCWL CRCWL CRCWL CRCWL CRCWL CRCWL

852- 300- 160 852- 400- 160 852- 500- 160 852- 600- 160 852- 1000- 160 852- 1200- 160

HS/ AD ..WAD ..WWAD HS/ AD ..WAD ..WWAD HS/ AD ..WAD ..WWAD HS/ WAD ..WWAD HS/ WAD ..WWAD HS/ WAD ..WWAD

Geräte - Typ Model type Serien- SerialNr.: Elektro - Schaltplan Wiring diagram Nr.: BALDWIN - Ident.-Nr. 01.98/CRCWL852/GB

DOC.0.090151.02

GB

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01.98/CRCWL852/GB

BALDWIN services

Manufacturer

BALDWIN EUROPA

BALDWIN-GRAFOTEC GMBH

Baldwin (UK) Ltd. Unit 13, Apex Business Centre Boscombe Road, Dunstable Bedfordshire LU5 4SB Great Britain Tel. +44-1582-477 449 Fax +44-1582-478 510

DERCHINGER STR.137 D-86165 AUGSBURG

Baldwin France Sarl 30, avenue de Bergoďde F-60550 Verneuil en Halatte Frankreich Tel. +33-3-44 25 06 81 Fax +33-3-44 25 16 40

TELEFAX: (08 21) 7942-222

POSTFACH 41 01 25 (POB) D-86068 AUGSBURG TELEFON: (08 21 ) 79 42-0

BALDWIN AMERIKA Baldwin Graphic Products 12 Commerce Drive Shelton, CT 06484-0941 USA Tel. +1 203-925-1100 Fax +1 203-929-7856

BALDWIN ASIEN Baldwin Graphic Equip. Pty. Ltd. P.O.Box 1234 Rozelle NSW 2039 6/323A Darling Street Balmain NSW 2041 Australien Tel. 612-9555-9975 Fax 612-9555-8246 Baldwin Japan Ltd. 4- 34 Toyo 2- chome Kohtoh- ku J- Tokyo 135 Japan Tel. +81 3- 5606- 2771 Fax +81 3- 5606- 2779 Baldwin Printing Controls Ltd. Unit A, 26th Floor, Seaview Plaza 283 Shaukeiwan Road Hong Kong Tel. 852-811-2987 Fax 852-811-0641

01.98/CRCWL852/GB

Ó All rights reserved. No part of this operating manual may be reproduced or duplicated in any form (printing, photocopying or any other process) without the permission in writing from BALDWIN GmbH.

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Combined Refrigerated Circulating Water Levels by BALDWIN are sophisticated designs based on our years of experience in the development and manufacture of ancillary equipment for the graphic arts, that will always be ready for service and reach a long life, provided they are operated properly and are given careful maintenance in due time.

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01.98/CRCWL852/GB

Contents Page

Page

1.

Introduction ................................................ 7

9.3

2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Basic notes on safety ................................. 8 Warning notes and symbols ......................... 8 Usage to the intended purpose .................... 8 Organisational measures .............................. 8 Selection and qualification of personnel........ 8 Operating modes .......................................... 9 Special dangers ............................................ 9 Operator/customer ....................................... 9

9.4

3. 3.1 3.2

Description ............................................... 11 Usage to the intended purpose ................... 11 Description of the unit ................................. 11

4.

Technical data ........................................... 15

5. 5.1 5.2 5.3

Mode of operation .................................... 27 Fountain solution premixing ........................ 32 Alcohol Control Unit .................................... 34 Return flow filter unit ................................... 36

6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8

Installation ................................................ 38 Unpacking .................................................. 38 Location ...................................................... 39 Hose connections ....................................... 40 Connection to cooling centres .................... 42 Alcohol and additive supply ........................ 42 Filling with alcohol and additives ................. 43 Refrigerant ................................................. 43 Electrical connection .................................. 43

7. 7.1 7.2

7.5

Start-up and Shut-down ........................... 44 Controls ...................................................... 44 Initial operation of the fountain solution cooling RCWL .................. 45 Initial operation of the ink roll heating/cooling IRHC ...................... 48 Setting the bypass valve (wet and/or dry offset) ................................................... 51 Shut-down RCWL and/or IRHC .................. 52

8. 8.1 8.2 8.3

Operation of display ................................. 53 Description of function ................................ 53 Setup .......................................................... 55 Service mode ............................................. 58

9. 9.1 9.2

Adjusting and checking ........................... 59 General ...................................................... 59 Basic settings of the maintenance unit ...... 59

7.3 7.4

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9.5 9.6 9.7

Density measuring with commercial hydrometers ............................................... 60 Additive and temperature setting at Alcohol Control Unit .................................... 61 Setting the thermostat ................................ 62 Checking the sight glass ............................. 62 Checking the water pressure in the IRHC... 63

10. 10.1 10.2 10.3 10.4

Maintenance ............................................. 65 General ...................................................... 65 Maintenance intervals ................................. 65 Replacing the fountain solution filters ......... 68 Cleaning the fountain solution storage tank ............................................................ 68 10.5 Cleaning the entire fountain solution system ........................................................ 68 10.6 Cleaning the Alcohol Control Unit ............... 69 10.7 Cleaning the fresh water filter ..................... 69 10.8 Checking the maintenance unit .................. 70 10.9 Cleaning the filter in alcohol and/or additive storage tanks ................................. 70 10.10 Cleaning the ribs of the condenser ............. 70

11. 11.1 11.2 11.3 11.4

Repairs ...................................................... 72 General ...................................................... 72 Replacing the supply line pump or heat exchanger pump ................................. 72 Replacing the circulating pump IRHC ......... 73 Replacing the thermostats .......................... 73

12. 12.1 12.2

Trouble shooting ...................................... 74 Error messages at the display .................... 75 Failures not indicated at the display ............ 81

13. 13.1 13.2 13.3 13.4 13.5 13.6

Dismounting ............................................. 84 Electric connection ..................................... 84 Hose connections ....................................... 84 Fountain solution, alcohol (alcohol substitutes) and additives .................................... 84 Antifreezer and anticorrosive ...................... 84 Refrigerant ................................................. 84 Scrapping ................................................... 84

14. 14.1 14.2 14.3

Parts list .................................................... 85 General ...................................................... 85 Notes for using ........................................... 85 Illustrated parts list ..................................... 85

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01.98/CRCWL852/GB

Foreword 1.0 Foreword to the operating instructions

These operating instructions are designed to familiarize the user with the machine/plant and its designated use. This manual contains important notes which are to be observed during the installation, operation and maintenance of the device, in order to guarantee a safety, proper and economical use of the system. The obeyance of the instructions helps to avoid dangers. The operating instructions must always be available wherever the machine/plant is in use.

Attention: The markings for transport and stocking indicated on the packaging have to be observed under all circumstances.

Note: Please check the type of manual against the label on your BALDWIN device. This manual is only valid for: (see title-page)

These operating instructions must be read and applied by any person in charge of carrying out work with and on the machine/plant, such as

-

-

operation including setting up, troubleshooting in the course of work, evacuation of production waste, care and disposal of fuels and consumables. Installation, set-up, wiring maintenance (servicing, inspection, repair) transport

In addition to the operating instructions and to the mandatory rules and regulations for accident prevention and environmental protection in the country and place of use of the machine/plant, the generally recognized technical rules for safe and proper working must also be observed.

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Fundamental safety instructions 2.0 Fundamental safety instructions

2.3 Organizational measures

2.1 Warning notes and symbols The headings „Warning, Attention and Note“ marked in this manual have the following meaning:

2.3.1 This manual has to be accomplished by the user/ customer with instructions (national regulations of security, regulations for dangerous goods, environmental protection and possible internal working or security rules) including legal responsibility and compulsory registration in order to take internal company peculiarities, regarding working organization or personnel involved in these working processes into consideration.

Warning: This heading is used whenever the ignorance or inaccurate obeying of factory rules, working rules, laid down work routines, etc.can lead to the death, injuring or an accident of a person.

Attention: This heading is used whenever the ignorance or inaccurate obeying of factory rules, working rules, laid down work routines, etc. can lead to damages on the system.

2.3.2 Check - at least from time to time - whether the personnel is carrying out the work in compliance with the operating instructions and paying attention to risks and safety factors. 2.3.3 For reasons of security, long hair must be tied back or otherwise secured, garments must be closefitting and no jewellery - such as rings - may be worn. Injury may result from being caught up in the machinery or from rings catching on moving parts. 2.3.4 Use protective equipment wherever required by the circumstances or by law. 2.3.5 Observe all safety instructions and warnings attached to the machine/plant.

Note: This heading is used when an exceptional feature should be taken noticeof.

2.2 Basic operation and designated use of the machine/plant 2.2.1 The machine/plant has been built in accordance with state-of-the-art standards and the recognized safety rules. Nevertheless, its use may constitute a risk to life and limb of the user or of third parties, or cause damage to the machine and to other material property. 2.2.2 The machine/plant must only be used in technically perfect condition in accordance with its designated use and the instructions set out in the operating manual, and only by safety-conscious persons who are fully aware of the risks involved in operating the machine/ plant. Any functional disorders, especially those affecting the safety of the machine/plant, should therefore be rectified immediately.

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2.3.6 In the event of safety-relevant modifications or changes in the behaviour of the machine/plant during operation, stop the machine/plant immediately and report the malfunction to the competent authority/ person. 2.3.7 Never make any modifications, additions or conversions which might affect safety without the supplier’s approval. This also applies to the installation and adjustment of safety devices and valves as well as to welding work on load-bearing elements. 2.3.8 Never modify the software of programmable control systems.

2.4 Selection and qualification ofpersonnel Basic responsibilities 2.4.1 Employ only trained or instructed staff and set out clearly the individual responsibilities of the personnel for operation, set-up, maintenance and repair. 2.4.2 Work on the electrical system and equipment of the machine/plant must be carried out only by a skilled electrician or by instructed persons under the supervision and guidance of a skilled electrician and in accordance with electrical engineering rules and regulations.

01.98/CRCWL852/GB

Fundamental safety instructions 2.5 Safety instructions governingspecific operational phases 2.5.1 Take the necessary precautions to ensure that the machine is used only when in a safe and reliable state. Operate the machine only if all protective and safetyoriented devices, such as removable safety devices, emergency shut-off equipment, sound-proofing elements and exhausters, are in place and fully functional. 2.5.2 Check the machine/plant at least once per working shift for obvious damage and defects. Report any changes (incl. changes in the machine’s working behaviour) to the competent organization/person immediately. If necessary, stop the machine immediately and lock it. 2.5.3 In the event of malfunctions, stop the machine/ plant immediately and lock it. Have any defects rectified immediately. 2.5.4 If the machine/plant is completely shut down for maintenance and repair work, it must be secured against inadvertent starting by:

2.6.2 Hydraulic and pneumatic equipment 2.6.2.1 Check all lines, hoses and screwed connections regularly for leaks and obvious damage. Repair damage immediately. Splashed medium may cause injury and fire. 2.6.2.2 Depressurize all system sections and pressure pipes (hydraulic system, compressed-air system) to be removed in accordance with the specific instructions for the unit concerned before carrying out any repair work. 2.6.2.3 Hydraulic and compressed-air lines must be laid and fitted properly. Ensure that no connections are interchanged. The fittings, lengths and quality of the hoses must comply with the technical requirements. 2.6.3 Alcohol, Water additives and other chemical substances 2.6.3.1 Whenever using one of the a.m. substances the security regulations valid for the product must be strictly observed! (Safety data sheet of the manufacturer and generally valid regulations) 2.6.3.2 Only approved containers may be used to store about one day´s supply

- locking the principal control elements and removing the ignition key and/or - attaching a warning sign to the main switch. 2.7 User/Customer 2.5.5 Ensure that all consumables and replaced parts are disposed of safely and with minimum environmental impact.

The safety guard for mobile parts may not be removed while the system is running.

2.6 Warning of special dangers

Work at the cooling unit may only be drained by a specialised firm for refrigeration and air-condition engineering.

2.6.1 Electric energy 1.6.1.1 Work on the electrical system or equipment may only be carried out by a skilled electrician himself or by specially instructed personnel under the control and supervision of such electrician and in accordance with the applicable electrical engineering rules. 2.6.1.2 If provided for in the regulations, the power supply to parts of machines and plants, on which inspection, maintenance and repair work is to be carried out must be cut off. Before starting any work, check the de-energized parts for presence of power and ground or short-circuit them in addition to insulating adjacent live parts and elements.

Leaks (e.g. tube connections) of dangerous liquids (e.g. explosive, toxic, hot) have to be drawn off in such a way that neither persons nor the environment will be endangered. The legal requirements must be fulfilled.

Warning: Ignoring the safety regulations can have a harmful effect on persons or cause damages to the system or environment. Ignoring the safety regulations may cause a loss of claim for damages.

2.6.1.3 The electrical equipment of machines/plants is to be inspected and checked at regular intervals. Defects such as loose connections or scorched cables must be rectified immediately.

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Description 3. Description

alcohol substitutes are metered proportional to volume, alcohol (isopropanol) via density measuring as required.

3.1 Usage to the intended purpose

The evaporated alcohol portion is automatically added by this system and the adjusted alcohol percentage is maintained.

Warning: The unit is to be used only for cooling, premixing and cleaning the fountain solution required for offset printing as well as ink roll heating/cooling.

The ink roll heating/cooling is controlled by a special control unit. The inking unit is cooled by cooled-down fountain solution via a water-water-heat exchanger. Heating the inking unit is by an integrated heating element.

Warning: - Unauthorized modifications of and changes to the unit, - use for any other purpose, and - the use of any other than the above additives

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Fountain solution temperature Alcohol and/or alcohol substitute Additives Consumption of alcohol / additives / water Alarm functions Inking unit temperature Conductivity value (option) 0 - 2000 µS/cm pH-value (option) pH 2 - pH 9

are forbidden for safety reasons. All safety devices such as personnel protecting switches and emergency stop buttons must be available.

3.2 Description of the unit

In emergency mode, the fountain solution temperature is controlled by a thermostat should the control unit fail. In order to maintain the fountain solution circulation during emergency mode, the outputs of the supply line and heat exchanger pump are short-circuited. A conductivity and pH measuring device may be fitted as an option. The value concerned is determined by the conductivity and/or pH measuring device by means of electrodes and is displayed at the digital control unit.

Depending on the configuration concerned, the fountain solution is pumped to one or several fountain pan(s) of the press by the installed submerged pump. Cooling of the fountain solution is by an integrated refrigerating unit with heat exchanger and air-cooled and/or water-cooled condenser or without refrigerating unit by a central refrigeration and a water-water heat exchanger. Control of the refrigerating unit is by the electronics of the control unit to obtain a constant fountain solution temperature during printing. The amount of heat dissipated is given to the room air (air-cooled design) or via a cooling tower (water-cooled design). Cleaning of the fountain solution is by integrated filters of the Combined Refrigerated Circulating Water Level. The CRCWL is provided with an integrated premixing unit - BALDWIN Automix (AMX) - for adding additive and alcohol and/or alcohol substitutes. Additives and

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Description The main components of the BALDWIN CRCWL are: a) Cooling unit with compressor (unit type "AD /WAD") The compressors are driven by internally protected motors.

e) Electric supply The electrical components and safety features as well as additional electrical connections are mounted on a mounting plate in the switchbox.

- Condensator with fans (with air-cooled design "AD") and - condenser with condensation pressure regulator (with water-cooled design "WAD") The heat exchangers and condensator assemblies are made of corrosion-resistant material.

f) Digital control unit The digital control unit comprises all possibilities for operation for fountain solution and ink roll heating/ cooling (IRHC) as well as failure indications and error messages. Connection to the central control console upon prior consultation of BALDWIN.

with central refrigeration (type "WWAD") Cooling of the fountain solution is only by central refrigeration that is made available by a cooling centre. The heat transfer is in a water-water heat exchanger.

g) Temperature control The temperatures are registered for the fountain solution circuit and the ink distributor circuit by one temperature sensor each (Pt 100 = ohmic principle of measurement) and are evaluated in the control unit. Emergency operation via thermostat control is possible.

b) Fountain solution cooling tank with filter unit and pump cover The fountain solution cooling tank serves as storage tank for premixed fountain solution. The fountain solution in the cooling tank is also used as temperature buffer in wet and dry offset as well as for cooling in the ink roll heating/cooling system. The filter unit cleans the fountain solution recirculated from the water pans. An integrated alarm sensor signals any contamination of the fountain solution to the control unit (display and electronic).

c) Alcohol control The actual value of the alcohol percentage is constantly measured by the alcohol control to the density measuring principle (hydrometer) and is reported to the control unit. When the value drops below the setpoint, alcohol is added by the automatic mixing unit.

d) Fountain solution premixing The fountain solution is mixed proportional to volume via piston metering pumps. Input is at the digital control unit.

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01.98/CRCWL852/GB

Description

M

Fig. 3-1

Key to Fig. 3-1 1 2 3 4 5 6 7 8 9

Digital control unit Fountain solution storage tank Heat exchanger pump (HEP) Temperature sensor (fountain solution) Evaporator Cooling unit Fountain solution supply pump Water pan Water-water-plate heat exchanger

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10 Bypass valve 11 Heating 12 Expansion vessel with safety valve and automatic ventilating valve 13 IRHC-pump 14 Temperature sensor (IRHC) 15 Flow monitoring switch 16 Printing unit with inking unit 17 Mixing valve

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01.98/CRCWL852/GB

Technical data 4. Technical data

Water-cooled design

Air-cooled design

Key to model designation Example:

CRCWL

85 2 - 600 - 160 HS / WW A D

Combined Refrigerated Circulating Water Level (CRCWL) Product group Number of circuits Basic performance number of cooling unit or heat exchanger Tank contents in litres (in this case: 160 l) Upright cabinet Omitted = heat dissipation via refrigerant and air-cooled condenser W = heat dissipation via refrigerant and water-cooled condenser WW= heat dissipation only via cooling water (cooling centres) Integrated mixing unit Automix (AMX) Digital control unit

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Technical data Technical data (applies to all units)

General Temperature setting range for fountain solution .......................................................... 8...19°C for ink roll heating/cooling ................................................. 14...40°C Dimensions (length x width x height) ................................. 1450/750/2000 mm Space requirements (length x width x height) .................... approx. 2450/1900/2500 mm Noise emission (A-weighted equivalent continuous mean sound pressure level) ....................................................... £ 70 dB(A) Degree of protection for electrical connection .................... IP 54 EMC .................................................................................. as per EN 55011 B and EN 50082-2 Processor .......................................................................... 80-C-188 Connection to central control console ................................ upon consultation of BALDWIN Remote indication with operator panel ............................... option

Connections, supplies, volumes Fresh water connection (500 kPa; 5 bar max.) .................. dia. 12 mm Fountain solution supply to press ...................................... dia. 19/25/32 mm Fountain solution return from press ................................... dia. 19/25/32 mm IRHC-supply to press ........................................................ dia. 25/32/40 mm IRHC-return from press ..................................................... dia. 25/32/40 mm Alcohol connection ............................................................ dia. 3/8'' Additive connection ........................................................... dia. 12 mm Compressed air connection (tube type: Mecanyl) .............. dia. 8/12 mm Compressed air consumption ............................................ 12.5 Nl/min Recommended additives ................................................... commercial (pH 4.8...5.2 at a dosage of 0...6 %) Alcohol ............................................................................... technically pure isopropyl 99 % Alcohol substitute .............................................................. commercial products Fountain solution storage tank ........................................... 160 l

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Technical data Fountain solution metering Fountain solution additives ................................................ 1 additiv (option: 2 additives) Metering method........................................................... volumetric via metering pumps Setting range ................................................................ 0 - 6 % ±0.5 % (in steps of 0.5 %) Alcohol (isopropanol) Measuring method ........................................................ aerometric (density measuring) Metering method........................................................... volumetric via metering pumps Setting range ................................................................ 0 - 20 % ±0.5 % (in steps of 0.5 %) Alcohol substitute Measuring method ........................................................ -Metering method........................................................... volumetric via metering pumps Setting range ................................................................ 0 - 20 % ±0.5 % (in steps of 0.5 %) Max. fountain solution mixing capacity with addition of 10 % of Al ............................................ 700 l/h with addition of 15 % of Al ............................................ 460 l/h with addition of 20 % of Al ............................................ 350 l/h Max. mixing period with initial filling (100 l) with addition of 10 % of Al ............................................ 6 - 10 min with addition of 15 % of Al ............................................ 9 - 17 min with addition of 20 % of Al ............................................ 15 - 22 min Conductivity measurement (option) Measuring method ........................................................ electrode Measuring range .......................................................... 0 - 2000 µS/cm ±1 µS/cm pH measurement (option) Measuring method ........................................................ electrode Measuring range .......................................................... pH 2 - pH 9 ±0.1

Ambient conditions Temperature, Operation .......................................................................... +5...+40°C Storage/transport .............................................................. -20...+60°C Relative air humidity, no moisture condensation ................ 30...95% (max. permissible) Operation/storage/transport Perm. site altitude (above mean sea level) for air-cooled design ......................................................... up to 1500 m 1) for water-cooled design .................................................... unlimited 1) over 1500 m perm. site altitude the refrigerating capacity decrease

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Technical data Model ........................................................... 852-300-160-HS/AD ..................... 852-300-160-HS/WAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50 (voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. 24.5 .............................................. 24.5 Total power input (kW) ................................. 14.75 ............................................ 14.75 Refrigerating capacity in dry offset 2) (kW) .... 12.0 (50 Hz) / 13.0 (60 Hz) .......... 12.0 (50 Hz) / 13.0 (60 Hz) (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... 8.0 (50 Hz) / 9.0 (60 Hz) .............. 8.0 (50 Hz) / 9.0 (60 Hz) (at 10°C fountain solution temperature and 22°C ink uniting cooling water temperature) Liquefaction temperature2) ............................ approx. 55°C ................................. approx. 55°C Kind / quantity of refrigerant .......................... R 134a / see type plate ................. R 134a / see type plate Total heat dissipation max. (kW) .................. 18.6 .............................................. 18.6 max. air quantity given off (m3/h) ................. * .................................................... -max. required cooling water flow rate at Dt 6°C (m3/h) .................... -- ................................................... 3.0 (60 Hz) Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTE 141 (A/ kW) ........................................................ 1.0/ 0.38 ........................................ 1.0/ 0.38 Heat exchanger pump KTE 141 (A/ kW) ........................................................ 1.0/ 0.38 ........................................ 1.0/ 0.38 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8 Weight (kg) ................................................... approx. 620 ................................... approx. 600

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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Technical data Model ........................................................... 852-300-160-HS/WWAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 (voltage adjustment 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. * Total power input (kW) ................................. * Refrigerating capacity in dry offset 2) (kW) .... * (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... * (at 10°C fountain solution temperature and 22°C inking unit cooling water temperature) Total heat dissipation max. (kW) .................. * max. required cooling water flow rate at Dt 6°C (m3/h) .................... * Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 Weight (kg) ................................................... *

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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Technical data Model ........................................................... 852-400-160-HS/AD ..................... 852-400-160-HS/WAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50 (voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. 30 (60 Hz) ..................................... 28 (60 Hz) Total power input (kW) ................................. 17 (60 Hz) ..................................... 15 (60 Hz) Refrigerating capacity in dry offset 2) (kW) .... 18 (50 Hz) / 21.5 (60 Hz) ............. 18 (50 Hz) / 21.5 (60 Hz) (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... 12 (50 Hz) / 14.4 (60 Hz) ............. 12 (50 Hz) / 14.4 (60 Hz) (at 10°C fountain solution temperature and 22°C ink uniting cooling water temperature) Liquefaction temperature2) ............................ approx. 55°C ................................. approx. 55°C Kind / quantity of refrigerant .......................... R 134a / see type plate ................. R 134a / see type plate Total heat dissipation max. (kW) .................. 37 (60 Hz) ..................................... 37 (60 Hz) max. air quantity given off (m3/h) ................. 6000 (60 Hz) ................................. -max. required cooling water flow rate at Dt 6°C (m3/h) .................... -- ................................................... 5.5 (60 Hz) Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8 Weight (kg) ................................................... approx. 620 ................................... approx. 600

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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Technical data Model ........................................................... 852-400-160-HS/WWAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 (voltage adjustment 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. * Total power input (kW) ................................. * Refrigerating capacity in dry offset 2) (kW) .... * (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... * (at 10°C fountain solution temperature and 22°C inking unit cooling water temperature) Total heat dissipation max. (kW) .................. * max. required cooling water flow rate at Dt 6°C (m3/h) .................... * Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 Weight (kg) ................................................... *

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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Technical data Model ........................................................... 852-500-160-HS/AD ..................... 852-500-160-HS/WAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50 (voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. 31 (60 Hz) ..................................... 31 (60 Hz) Total power input (kW) ................................. 16.5 (60 Hz) .................................. 16.5 (60 Hz) Refrigerating capacity in dry offset 2) (kW) .... 14.5 (50 Hz) / 17.4 (60 Hz) .......... 14.5 (50 Hz) / 17.4 (60 Hz) (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... 12 (50 Hz) / 14.4 (60 Hz) ............. 12 (50 Hz) / 14.4 (60 Hz) (at 10°C fountain solution temperature and 22°C ink uniting cooling water temperature) Liquefaction temperature2) ............................ approx. 55°C ................................. approx. 55°C Kind / quantity of refrigerant .......................... R 134a / see type plate ................. R 134a / see type plate Total heat dissipation max. (kW) .................. 24.3 (60 Hz) .................................. 24.3 (60 Hz) max. air quantity given off (m3/h) ................. 6000 (60 Hz) ................................. -max. required cooling water flow rate at Dt 6°C (m3/h) .................... -- ................................................... 4.4 (60 Hz) Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8 Weight (kg) ................................................... approx. 630 ................................... approx. 610

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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01.98/CRCWL852/GB

Technical data Model ........................................................... 852-400-160-HS/WWAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 (voltage adjustment 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. * Total power input (kW) ................................. * Refrigerating capacity in dry offset 2) (kW) .... * (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... * (at 10°C fountain solution temperature and 22°C inking unit cooling water temperature) Total heat dissipation max. (kW) .................. * max. required cooling water flow rate at Dt 6°C (m3/h) .................... * Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 Weight (kg) ................................................... *

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

01.98/CRCWL852/GB

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Technical data Model ........................................................... 852-600-160-HS/WAD .................. 852-600-160-HS/WWAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50 (voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. 30 (60 Hz) ..................................... * Total power input (kW) ................................. 18 (60 Hz) ..................................... * Refrigerating capacity in dry offset 2) (kW) .... 27 (50 Hz) / 33 (60 Hz) ................ * (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... 14.5 (50 Hz) / 16 (60 Hz) ............. * (at 10°C fountain solution temperature and 22°C ink uniting cooling water temperature) Liquefaction temperature2) ............................ approx. 55°C ................................. -Kind / quantity of refrigerant .......................... R 134a / see type plate ................. -Total heat dissipation max. (kW) .................. 45 (60 Hz) ..................................... * max. required cooling water flow rate at Dt 6°C (m3/h) .................... 6.8 (60 Hz) .................................... * Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 IRHC 4) pump CHI 4-20 (A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8 Weight (kg) ................................................... approx. 640 ................................... approx. 620

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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01.98/CRCWL852/GB

Technical data Model ........................................................... 852-1000-160-HS/WAD ................ 852-1000-160-HS/WWAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50 (voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. 34 (60 Hz) ..................................... * Total power input (kW) ................................. 22 (60 Hz) ..................................... * Refrigerating capacity in dry offset 2) (kW) .... 33 (50 Hz) / 38 (60 Hz) ................ * (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... 20 (50 Hz) / 23 (60 Hz) ................ * (at 10°C fountain solution temperature and 22°C ink uniting cooling water temperature) Liquefaction temperature2) ............................ approx. 55°C ................................. -Kind / quantity of refrigerant .......................... R 134a / see type plate ................. -Total heat dissipation max. (kW) .................. 54 (60 Hz) ..................................... * max. required cooling water flow rate at Dt 6°C (m3/h) .................... 8.1 (60 Hz) .................................... * Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 Heat exchanger pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 IRHC 4) pump CH 12-20 (A/ kW) ........................................................ 2.8/ 1.6 ........................................ 2.8/ 1.6 Weight (kg) ................................................... approx. 650 ................................... approx. 630

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Coolingv

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Technical data Model ........................................................... 852-1200-160-HS/WAD ................ 852-1200-160-HS/WWAD Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50 (voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60 see wiring diagram) Total current input Imax (A) ............................. 45.2 (60 Hz) .................................. * Total power input (kW) ................................. 29 (60 Hz) ..................................... * Refrigerating capacity in dry offset 2) (kW) .... 55 (50 Hz) / 60 (60 Hz) ................ * (at 22°C inking unit cooling water temperature) Refrigerating capacity in wet offset 2) (kW) ... 45 (50 Hz) / 50 (60 Hz) ................ * (at 10°C fountain solution temperature and 22°C ink uniting cooling water temperature) Liquefaction temperature2) ............................ approx. 55°C ................................. -Kind / quantity of refrigerant .......................... R 134a / see type plate ................. -Total heat dissipation max. (kW) .................. 78 (60 Hz) ..................................... * max. required cooling water flow rate at Dt 6°C (m3/h) .................... 11.7 (60 Hz) .................................. * Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz) Supply pump KTB 200 (A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85 Heat exchanger pump KTE 142 (A/ kW) ........................................................ 4,1/ 1,7 ......................................... 4,1/ 1,7 IRHC 4) pump CH 12-20 (A/ kW) ........................................................ 2.8/ 1.6 ........................................ 2.8/ 1.6 Weight (kg) ................................................... approx. 660 ................................... approx. 640

*) not known when this documentation went to print 2) at approx. 40°C ambient- and/or 32°C cooling water temperatur 4) IRHC = Ink Roll Heating/Cooling

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01.98/CRCWL852/GB

Mode of operation 5. Mode of operation (Fig. 5-1 /5-2 / 5-3) Fountain solution premixing Fresh water flows via supply line (1.1) and the filter (1.2) into the fountain solution storage tank (2.1) of the CRCWL. Alcohol (1.10) and fountain solution additives (1.5) are added as required by the pumps (1.8/1.12). The fountain solution premixing unit, that works in cycles and is controlled electronically, is cut in by the solenoid float switch (2.4) and the alcohol control (3.1). The fountain solution level, the fountain solution additives and alcohol percentage in the fountain solution storage tank (2.1) are maintained. The alcohol control (3.1), that is flushed via connection (3.2), measures the actual alcohol percentage in the fountain solution. When this value drops below the setpoint entered at the display (6.4) (caused by consumption and evaporation), alcohol is added to the fountain solution by the metering pump (1.12) in addition to the normal filling cycle in percent by volume. Fountain solution circulation The fountain solution is supplied to the fountain pans of the press (2.7) by the supply line pump (2.2) via the supply line valve (2.3). When the fountain solution returns to the CRCWL, it is cleaned by a filter (2.11). The filter condition in the return flow is monitored by a level sensor (2.12). Contamination and/or required replacement of filter will be indicated by an alarm signal. A return flow filter station (2.9) may additonally be integrated in the fountain solution return flow line. Cooling (type "AD/WAD") Cooling of the fountain solution is by the heat exchanger (4.1). The pump (2.13) in the fountain solution refrigerating circuit recirculates the fountain solution through the heat exchanger to the fountain solution storage tank (2.1). Entering the "setpoint" for the fountain solution temperature is at the control unit (display) (6.4) of the CRCWL, from where it is transmitted to the electronic unit. The temperature control proper is by the electronic unit of the operator panel (6.3). The heat exchanger circuit and the refrigeration circuit are controlled according to the value entered and the data by the temperature sensor (4.16).

pressure (loss of refrigerant), the low-pressure manostat (4.11), in the case of an excess system pressure, the high-pressure manostat (4.13) will automatically cut out the compressor (4.2). Cooling (type “WWAD”) Cooling of the fountain solution is only by central refrigeration that is made available by a cooling centre (4.18).The heat transfer is in a water-water heat exchanger (4.19). The fountain solution temperature entered is controlled by a pneumatically operated 3/2 way valve (4.20). The fountain solution either flows through the water-water heat exchanger or bypasses the heat exchanger by a bypass line. Emergency mode Should the control unit fail, fountain solution cooling and circulation are maintained by emergency mode. Emergency mode is called in by switch S4 (see wiring diagram and/or Fig. 7-1/2), and is indicated by the fault signal lamp (6.5). Control of the fountain solution temperature is taken over by the thermostat (4.16). Measurement is by the capillary measuring line and temperature sensor. The thermostat also supplies an electric signal for cutting the compressor (4.2) in and out. The supply line pump and the heat exchanger pump are cut in in emergency mode to maintain the circulation of the fountain solution. The Ink Roll Heating/Cooling Unit is off during this function. Ink Roll Heating/Cooling System The Ink Roll Heating/Cooling System is a closed-loop system and is completely isolated from the fountain solution circuit. The "setpoint" of the inking unit temperature is entered at the control unit (display). A temperature sensor (5.7) transmits the temperature data to the electronic unit. Based on this information, a mixing valve (5.18) is controlled that directs the cooling water via the water-water heat exchanger (5.1) or via a heating element (5.3). The IRHC pump (5.8) supplies the cooling water to the inking units of the press (5.13) and back. The air in the system escapes automatically via the air relief valve (5.6). The expansion vessel (5.4) with the safety valve (5.5) maintains the water pressure in the system. Power supply Power supply is by the feeder (6.1), the master switch (6.2), and the control box (6.3).

The manostats measure the pressure in the high pressure and the low pressure section. These control signals are supplied by the suction check valve (4.12) and/or the pressure check valve (4.14) via capillary measuring lines. In the case of a drop in the system

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Mode of operation 1.9

1.7

1.8

1.6

1.7

2.7

1.5

2.8 2.9

2.6 F 60 P

1.7

1.8

1.7

1.6 1.5

M 1.1 1.4

1.3

1.7

1.12

1.2

1.6

2.8

1.11

1.7

1.11 1.10

3.2 2.10

3.3 3.1 3.4

1.13

2.3

2.4 2.5

1.14

2.11 2.12

M

2.15

2.1

AL

2.2

2.16

M

2.13

5.14

T 4.16

1

6.3

0

5.13

5.15

5.11

5.16

5.10

2.14

5.17

T

5.18

0

6.2

5.12

5.9

M

4.1 6.4

5.6

6.5

5.5 4.8

6.1

4.9

M

T

4.10

4.7

5.1

5.2

5.3

5.19

5.4

5.7

4.6

LP

4.12

4.11

HP

4.2

4.13

4.14

4.3

4.4

4.5

Fig. 5-1 Diagram CRCWL 852-.. AD with air-cooled condenser Seite / Page 28

01.98/CRCWL852/GB

5.8

Mode of operation 1.9

1.7

1.8

1.6

1.7

2.7

1.5

2.8 2.9

2.6 F 60 P

1.7

1.8

1.7

1.6 1.5

M 1.1 1.4

1.3

1.7

1.12

1.2

1.6

2.8

1.11

1.7

1.11 1.10

3.2 2.10

3.3 3.1 3.4

1.13

2.3

2.4 2.5

1.14

2.11 2.12

M

2.15

2.1

AL

2.2

M

2.16

2.13

5.14

T 4.16

1

6.3

0

5.13

5.15

5.11

5.16

5.10

2.14

5.17

T

5.18

0

6.2

5.12

5.9

M

4.1 6.4

5.6

6.5

5.5 4.8

6.1

4.9 4.10

4.7

5.1

4.3

LP

4.5

5.2

4.11

4.2

5.3

5.19

5.4

5.7

5.8

4.6

HP T

4.12

M

T

4.17

4.18

4.14 4.13 4.15

Fig. 5-2 Diagram CRCWL 852-.. WAD with water-cooled condenser 01.98/CRCWL852/GB

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Mode of operation 1.9

1.7

1.8

1.6

1.7

2.7

1.5

2.8 2.9

2.6 F 60 P

1.7

1.8

1.7

1.6 1.5

M 1.1 1.4

1.3

1.7

1.12

1.2

1.6

2.8

1.11

1.7

1.11 1.10

3.2 2.10

3.3 3.1 3.4

1.13

2.3

2.4 2.5

1.14

2.11 2.12

M

2.15

2.1

AL

2.2

2.16

M

2.13

5.14

T 4.16

1

6.3

0

5.13

5.15

5.11

5.16

5.10

2.14

5.17

T

5.18

0

6.2

4.20

5.12

5.9

M

6.4

5.6

6.5

5.5

4.19

M

T

6.1

5.1

5.2

T

5.3

4.17

5.19

5.4

5.7

5.8

4.18

Fig. 5-3 Diagram CRCWL 852-.. WWAD with water-water-plate heat exchanger and central refrigeration

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01.98/CRCWL852/GB

Mode of operation Key to Figs. 5-1 /5-2 /5-3 1. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14

Fountain solution premixing Fresh water supply Filter Solenoid valve for water supply Flow meter Storage tank for additive Filter with nonreturn valve Nonreturn valve Metering pump for additive (pneumatic) Additive 2 (option) Storage tank for alcohol Solenoid valves for alcohol supply Metering pump for alcohol (pneumatic) Fountain solution supply (water + additive) Alcohol supply

2. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16

Fountain solution circulating Fountain solution storage tank Supply pump Supply line valve Float switch Ventilation Fountain solution supply line Fountain pan in fountain unit Fountain solution return line Return flow filter unit (f.ex.: F 40 P) Connection (return line) Filter foam Sensor for monitoring the filter condition Heat exchanger pump Thermostat for emergency mode Drain for heat exchanger circiut Overflow and discharge for fountain solution storage tank

3. 3.1 3.2 3.3 3.4

Measurement of alcohol concentration Alcohol Control Connection for fountain solution measurement Restrictor Measurement of the alcohol content

4. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14

Refrigerating system Heat exchanger with evaporator Compressor (refrigerating set) Condenser (air and/or water-cooled) Fan motor (air-cooled design) Collector Dry-type filter Sight glass Expansion valve Temperature sensor Pressure compensation line Low-pressure manostat Suction check valve High-pressure manostat Pressure check valve

01.98/CRCWL852/GB

4.15 Cooling water control valve (water-cooled design) 4.16 Temperature sensor (PT100) 4.17 Cooling water thermometer (water-cooled design) 4.18 Cooling centre (cooling tower) 4.19 Water-water-plate heat exchanger 4.20 3/2-way valve 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18

Ink roll cooling/heating Water-water-plate heat exchanger Bypass valve Heating Expansion vessel Safety valve Automatic ventilating valve Temperature sensor (PT100) IRHC-pump Flow monitoring switch Manometer for supply line Check valve supply line Cooling water supply line Printing unit with inking unit Cooling water return line Check valve return line Manometer for return line Dirt trap Mixing valve

6. 6.1 6.2 6.3 6.4 6.5

Miscellaneous Mains feeder (see wiring diagram) Main switch (option) Switchbox Digital control unit (display and electronic) Fault indicator

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Mode of operation 5.1 Fountain solution premixing (Fig. 5-4)

4

5

6

7

Description The fountain solution premixing unit comprises in the main -

a flowmeter (4) for measuring and controlling the amount of water for the damping solution preparation,

-

a metering piston pump (7) for adding alcohol as a function of the adjusted alcohol setpoint and the measured actual alcohol value of the alcohol control,

-

and a metering piston pump (6) for the fountain solution additive as a function of the adjusted additive percentage and the amount of water supplied.

The quantities of alcohol and additive are calculated and controlled by the control system. When the key is pressed, the consumption data for water, additive and alcohol will be displayed.

Mode of operation (Fig. 5-4) When the unit is put into operation, switching point 1 triggers the initial filling as per the basic adjustment When the fountain solution level in the storage tank drops - caused by the consumption of fountain solution during printing - a float switch triggers a contact (switching point 2 is left) for another filling cycle with some 6 litres of premixed damping solution (H2O + additive + alcohol = 6 l).

A filling cycle comprises the following steps: a) Simultaneously -

water is metered via an opened solenoid valve (5) and flowmeter (4),

-

fountain solution additive is metered proportional to volume via pumps (6) by several pump lifts,

-

alcohol is metered proportional to percentage via pumps (7) by several pump lifts.

Switching point 3

Switching point 2 Switching point 1

Fig. 5-4

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01.98/CRCWL852/GB

Mode of operation Attention: Only "technically pure isopropanol" may be used with this fountain solution premixing unit. "Alcohol substitutes", that can be added proportional to volume only, may only be used after the parameters of the control have been altered. A density measuring of the alcohol will not be working in this case. b) The filling cycle will be completed when the adjusted metering quantity has been added and will be repeated until the adjusted level in the damping solution storage tank (float ball at switching point 2) is reached. Note: With the intial service, the tank will first be filled to the upper switching point 3 by the integrated fountain solution premixing unit. The fountain solution circulating pump will only then be cut in by the elelctronic control. During printing, the level will adjust itself at the middle float switching point 2.

c) In the case of a low alcohol percentage during the production run (e.g. caused by evaporation) as measured by the alcohol control, additional alcohol will be metered by several pump lifts until the adjusted value has been reached (also see 5.2). Attention: The pressure reducer must be set to 400 kPa (4.0 bar) to ensure a perfect metering function and error detection.

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Mode of operation 5.2 Alcohol Control Unit (Fig. 5-5)

3

Attention: Only "technically pure isopropanol" may be used with this fountain solution premixing unit. "Alcohol substitutes", that can be added proportional to volume only, may only be used after the parameters of the control have been altered. A density measuring of the alcohol will not be working in this case.

The BALDWIN Alcohol Control continuously measures the actual value of the alcohol percentage in the damping solution by the density measuring principle. The desired alcohol percentage (0 to 20%) can be entered at the display (digital control) of the unit.

4

2

1

The Alcohol Control is calibrated with 0% of alcohol first by means of a metering pipe. This is required since the addition of fountain solution additives will additionally change the fountain solution density. The Alcohol Control comprises the following components:

Fig. 5-5

1) Analysis box with: Fountain solution supply, standpipe 2) Aerometer: comprises a special steel float with screwed-on plastic cap and calibrating discs 3) Housing top with: optoelectronic reticle scanning 4) Metering pipe for the correction of the fountain solution density required by the addition of fountain solution density Note for repair and/or spare parts orders: Since the Alcohol Control is accurately calibrated as an entity with all components, it must be sent as complete unit to BALDWIN in the case of a defect.

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01.98/CRCWL852/GB

Mode of operation Mode of operation of the Alcohol Control (Fig. 5-6) The alcohol portion in the damping solution is measured by the density measuring principle (areometer). Higher alcohol percentages cause the density to decrease, which in turn results in a lower buoyancy of the aerometer float (4), whereas lower percentages cause the density to increase, which results in a higher buoyance of the aerometer float (4).

5

Fountain solution is recirculated in a continuous circuit from the fountain solution refrigerating unit via the connection (1), analysis box (2) and standpipe (3) to the refrigerating unit. When the density in the analysis box is changed, the aerometer (4) moves a position pickup (5) integrated in the housing top upwards and/or downwards. Values are converted by an optoelectronic scanning of this code measure, and the alcohol percentage (actual value) is digitally displayed at the control panel.

6

1

2

3

4

Fig. 5-6

When the value drops below the adjusted alcohol setpoint, alcohol will be metered by several pump lifts in addition to the normal filling cycle proportional to volume by the electronically controlled fountain solution premixing unit (see Section 5.1). The Alcohol Control is calibrated to the different densities of fountain solution additives by means of an adjusting knob (6) at the analysis box (see section "Adjusting and checking"). Note: Alcohol measurement is e.g. upon initial service only 5 minutes after the supply pump has started to run. This On delay ensures a perfect measurement by the analysis box that will then be sufficiently flushed with fountain solution. In the case of an alcohol deviation - to 0.5 % below setpoint, 1 pump lift will be effected per 15 seconds - to 1.0 % below setpoint, 1 pump lift will be effected per 6 seconds

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Mode of operation 5.3 Return flow filter unit (option) (Fig. 5-7) The return flow filter is used for pre-cleaning and recirculating the fountain solution returning from the water pans of the press into the RCWL. It is also used as a collecting tank for the fountain solution when the overall system is switched off. The main components of the return flow filter are: a) filter mat (2) b) filter cage (3) c) float switch (6) d) float (7) e) control and/or float valve (9) f) submerged pump (8) g) tank (5) h) control valve (10)

Mode of operation of the return flow filter The fountain solution returning from the fountain pans of the press is cleaned by the filter mat (2). A float switch (6) monitors the filter condition and signals any clogging of the filter to the electronic control unit. An integrated submerged pump (8) recirculates the fountain solution to the RCWL. The fountain solution return flow is set by the control valve (10). A control and/or float valve (9) restricts the pump flow rate when the fountain solution level in the tank drops, thus preventing the formation of foam to a large extent.

Fig. 5-7

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Installation 6. Installation 6.1 Remove the packing General Check the individual units and components for packing material (protection for transport, protective covers etc.) and remove. Alcohol Control (Fig. 6-1) Take the packing material (serves as protection during transport) out of the analysis box of the Alcohol Control.To do so, loosen the 2 knurled screws (1) at the front and the rear and remove the electronics section (2). Remove the float (4) and take the protection for transport (3) (packing material) out. Align the housing (5) of the Alcohol Control with the aid of a water level (8) at 2 sides (A and B) and adjust by means of the setscrews (7). Now put the float (4) back into the container.

Warning: Prior to mounting the black electronics housing, remove the cap (6) at the bottom without fail, to enable the plunger to move freely and to ensure that the alcohol strength is determined accurately. Failing to remove the cap, alcohol will be overdosed.

Fig. 6-1

Attention: The analysis box must be vertically aligned during mounting by placing a water level at 2 sides (A and B). To do so, adjust setscrews (7) correspondingly. Take the packing material out of the analysis box before putting the unit into operation ! When mounting, make sure that the adjusting knob at the housing top (2) points to the front (operator side).

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01.98/CRCWL852/GB

Installation 6.2 Location Select the location for the unit in such a way that it will always be easily accessible for the operating personnel and that it is not subjected to extreme heat, e.g. near a heating etc. The distance between the rear side and the wall must be at least 40 cm (also see Fig. 6-2).

1480

min. 600

730

Warning: The user must provide adequate ventilation for the dissipation of heat and the removal of harmful vapours, if any (min. 0.5 m to the top).

(1450)

min. 400

CRCWL 852-...

Consult BALDWIN before you install an extraction system that works in upwards direction. min. 400

Place the unit on a firm base. Attention: The ventilation grids at the unit must not be blocked and/or covered, since perfect cooling of the partly very hot components will then no longer be ensured. Fig. 6-2 For troublefree funktion the unit must be align to two faces (see Fig. 6-3). Attention: Place the CRCWL at the same level as the printing press - cooling unit placed at a lower level in the basement will require a pump with a higher capacity, - cooling unit placed at a higher level will require an additional return-flow filter, since there will be no free return flow in this case. Secure the unit against sliding.

Fig. 6-3

01.98/CRCWL852/GB

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Installation 6.3 Hose connections

Warning: Run all hoses in such a way that nobody stumbles over them (protect by means of suitable coverings).

Note: Supply and return flow lines will have to be run along the press by the customer, depending on the configuration concerned. Coordinate this with Messrs. BALDWIN and/or the press manufacturer.

up to unit type 852-600...

Note: The hoses for the ink tempering unit must be run without any bends and as vertically as possible to ensure perfect venting of the system. Provide vent valves at the priting units.

Return flow hoses made of PVC should have a fabric insert due to the hazard of buckling.

1

Hose connections as per Fig. 6-4. Hose and dimensions of connection see section "Technical data".

2

3

4

5

6

5

3

from unit type 852-1000...

1

7

4

2

Fig. 6-4

Key to Fig. 6-4 1 2 3 4 5 6 7 Seite / Page 40

7

Drain Air connection RCWL supply line Fresh water IRHC supply line RCWL return flow line (other point of connection feasible) IRHC return line 01.98/CRCWL852/GB

6

Installation l Drain (Fig. 6-4, item 1)

l Fresh water supply (Fig. 6-4, item 4)

This connection serves as overflow and drain for the fountain solution storage tank.

When the fresh water supply is from the in-house water main to the cooling unit, a pressure reducer is to be connected on the line side. The customer must provide a connection with stop valve and pipe disconnector.

Warning: Dispose of the fountain solution in accordance with the relevant rules in force.

Attention: The fresh water supply pressure to the cooling unit must be between 150 kPa (1.5 bar) and 500 kPa (5 bar).

l Air connection (Fig. 6-4, item 2) The customer must provide a compressed air connection of at least 350 kPa, max. 1000 kPa for the drive of the alcohol and/or additive pumps. Attention: Set the air pressure governor of the unit to 400 kPa (4 bar).

l RCWL supply and return flow line (Fig. 6-4, item 3/6) Make sure that these are run without any bends and as vertically as possible so that the fountain solution flows back into the storage tanks of the cooling unit when the pump is at standstill. Note: These hoses should be insulated to avoid line losses.

l IRHC supply and return flow line (Fig. 6-4, item 5/7) Note: The hoses for the ink roll heating/cooling (IRHC) must be run without any bends and as vertically as possible to ensure perfect venting of the system. Provide vent valves at the printing units.

only applicable to water-cooled design: l Cooling centre supply and return flow line The unit is provided with a cooling circuit with watercooled condenser and/or heat exchanger. The heat exchanger is found at the bottom left in the unit and is connected to a cooling centre via the supply/return line connection. Note: The hoses for supply and return line must be connected to the heat exchanger directly.

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Installation 6.4 Connection to cooling centres Cooling units are suited for a connection to both cooling centres (e.g. cooling tower for chill rollers) and municipal water supply. Attention: A continuously working cooling circuit must be ensured even when the press is at standstill. Ensure that the water from the cooling centres is clean without fail. Any internal contamination will prevent the condenser from working perfectly (filter the cooling water, if required).

out by the high-pressure safety switch, there is no cooling water supply from the cooling centre (check the interlocking contacts to the cooling centre). When the manometer hunts by more than 5°C with the cooling centre running, there is air in the cooling water circuit. Remove this air by venting the circuit, since the chiller will fail very soon with this hunting operation, power consumption will heavily increase, and the refrigerating capacity will drop.

Note: In the case of operation on municipal water, contact Messrs. BALDWIN prior to initial operation. A high pH value may damage the CRCWL. Cooling water pressure: min. 200 kPa (2 bar), max. 600 kPa (6 bar) Cooling water temperature: min. +10°C, max. +40°C

6.5 Alcohol and additive supply Alcohol and additive are mixed to the fountain solution by self-priming pumps from integrated storage tanks (from unit type 852-1200..., the storage tanks are external) .

Cooling water flow rate: see "Technical data" When the condenser is supplied with very cold water (approx. 10- 15°C), e.g. city water, directly from the line, a pressure reducer (200 kPa / 2 bar) should be connected on the line side. Failing this, cutting in and out of the refrigerating set in the low pressure range might occur. Filters with a mesh width of 80 µm are to be installed upstream of the cooling unit.

Warning: Improper handling of additives is a danger to life and limb. Observe the relevant regulations (e.g. safety regulations, regulation governing the handling of hazardous materials etc.) without fail.

Required nominal widths for supply and return line hoses see “Technical data”.

Attention: Only "technically pure isopropyl" may be used with this fountain solution premixing unit. "Alcohol substitutes", that can be added proportional to volume only, may only be used after the parameters of the control have been altered. A density measuring of the alcohol will not be working in this case.

Install stop valves in the cooling lines to allow maintenance or repair work at the refrigerating set. Note: Pressure reducer, filters, air ventilation valves and stop valves are not included in "BALDWIN´s scope of supply".

Note only for refrigeration engineering expert: Set the cooling water regulating valve so that the high-pressure manometer will constantly indicate 40°C + 2°C (liquefaction temperature) with the refrigerating set and the cooling water supply from the cooling centre running!

Attention: The unit may only be used for adding commercial fountain solution additives. When 0...6% of additives are added, a pH-value suitable for printing (4.8...5.2) must be obtained.

When the high-pressure manometer hunts to some 60°C or when the refrigerating set is cut

Seite / Page 42

01.98/CRCWL852/GB

Installation 6.6 Topping-up alcohol and/or additive (Fig. 6-5)

6.7 Refrigerant

Loosen screw caps (1), remove suction pipe (4) with filter (5), top up additive (2) and alcohol storage tank (3). Put suction pipe with filter back in place and mount screw caps.

As a rule, BALDWIN deliver the refrigerating set in filled condition.

1

Warning: Topping-up of the units may only be carried out by a specialised firm for refrigeration and aircondition engineering upon prior consultation of BALDWIN.

2

The refrigerating set may only be filled with and operated on the refrigerants stated in the technical data. Note: Prior to commissioning, leave the unpacked unit in its service position for some 24 hours to allow the refrigerant to gather after transport.

6.8 Electrical connections -

Combined Refrigerated Circulating Water Level additional return flow devices

as per the wiring diagram. 3

5

4

Fig. 6-5 Warning: Work at the electric section must be carried out by an electrician on principle. The appropriate wiring diagram is to be observed. A wiring diagram is supplied with each unit.

Attention: Compare the mains voltage at site with the nameplate of the unit.

Regarding a connection to the central control console consult BALDWIN.

01.98/CRCWL852/GB

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Start-up and Shut-down 7. Start-up and Shut-down 4

7.1 Controls

1

2

3

Legend to Figs. 7-1 and 7-2 1 Display with the functions: - Temperature settings - Request of the current consumption data - Inquiry about errors - Service mode

2 Master switch (option) with: Pos. “0” voltage off Pos. “1” voltage on

3 Fault lamp (group alarm) will light with faults: - Temperature deviation - Motor protection - Tank level - Filter soiled - Additive tank empty

Fig. 7-1 Water-cooled design

4 Switch for emergency mode S4: Should the control unit fail, fountain solution cooling and circulation are maintained by emergency mode.

2

1 3

4

Fig. 7-2 Air-cooled design

Seite / Page 44

01.98/CRCWL852/GB

Start-up and Shut-down 7.2 Initial operation of the fountain solution cooling RCWL

Warning: Study the operating manual, especially the section covering the safety notes first!

Prior to commissioning, leave the unpacked unit in its service position for some 24 hours to allow the refrigerant to gather after transport.

Warning: Improper handling of the additives is a danger to life and limb. Pay attention to the relevant rules and regulations (as e.g. safety regulations, regulation governing the handling of hazardous materials etc.) without fail.

Check whether -

-

connection to the mains is available supply and return hoses have been run properly compressed air is available (max. compressed air connection 1000 kPa / 10 bar). air pressure governor is set to 400 kPa (4,0 bar) fresh water is available from the in-house supply line at the correct admission pressure (min. 150 kPa, max. 500 kPa) containers for additives and alcohol are full

Warning: !! Danger of freezing !! Never start the unit without the tank being filled.

a) Turn on master switch (see Fig. 7-1/2).

BALDWIN RCWL LOCAL SET ACT TEMP °C 10.0 10.5 AL % 8.0 8.0 ADD. 1 % 3.0

F1: AMX ON - OFF F2: COMP/HEP ON - OFF F3: PUMP ON - OFF F4: IRHC

b) Enter desired fountain solution parameters (alcohol strength, concentration of additives, and temperatures in values of % and °C) at the digital control (see section “Operation of display”). c) Turn on maintenance switches F1, F2 and F3; to do so, press the F1, F2 and F3 keys. “ON” will light. F1 switches on the entire Automix. F2 releases the cooling unit. F3 switches the supply and return line pumps on.

01.98/CRCWL852/GB

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Start-up and Shut-down d) Open fresh water supply. The electronic section will be working, and due to switching point 1 (Fig. 7-3) initial filling is initiated as per the basic setting. The fountain solution storage tank will be filled with mixed fountain solution. e) Float reaches switching point 2: The heat exchanger pump and the cooling unit are cut in.

Switching point 3

f) The unit will be filled to switching point 3. Float reaches switching point 3 (see Fig. 7-3): The filling cycle is completed, the fountain solution circulating pump (supply line pump) is switched on and the circulation system is filled, i.e. the tank contents will be diminished by the volume of hoses, water pans etc. Attention: Check sense of rotation of heat exchanger pump (see direction of arrow on the pump housing).

g) Observe positions of ball valves at the water pans of the press, set, if required. With external recirculation systems the corresponding operating manual must be observed.

Switching point 2 Switching point 1

Fig. 7-3 Attention: The setting rings serve as stops, not for adjusting the switching points.

h) The continued consumption of fountain solution during printing will cause the float to drop below switching point 2 and to release a contact for another filling cycle to the electronic section (= normal operation). i) One or several filling cycles will be carried out. k) With normal operating conditions during printing, steps h) i) will be repeated.

Attention: When the float switch drops down to switching point 1 during normal operation, the refrigerating set and the circulation pump to the press will be cut out. At the same time, filling to f), g), h) and i) will be initiated.

Attention: The cooling unit may only be operated with the filter foam put in place.

Seite / Page 46

01.98/CRCWL852/GB

Start-up and Shut-down Note: The NOT READY period is 5 minutes from the time when the heat exchanger pump (HEP-pump) is cut in by the control system. Failures, excess alcohol and temperature, plug X4, and alcohol measurement will not be displayed during this period. Note: Should the cooling unit start running and then switch off for approx. 1 minute or longer, check whether the low pressure manostat is the cause. When this is the case, refrigerant has escaped during transport.

Warning: Sealing the leaks and topping-up of the units may be carried out by an expert firm for air conditioning and refrigeration engineering upon prior consultation of Messrs. BALDWIN only.

01.98/CRCWL852/GB

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Start-up and Shut-down 7.3 Initial operation of the ink roll heating/cooling (IRHC)

Warning: Study the operating manual, especially the section covering the safety notes first!

Prior to commissioning, leave the unpacked unit in its service position for some 24 hours to allow the refrigerant to gather after transport. Attention: Pay attention to the local safety regulations and/ or the EC safety data sheets for the antifreezer and/or anticorrosive used.

Check whether -

-

connection to the mains is available supply and return hoses have been run properly compressed air is available (max. compressed air connection 1000 kPa / 10 bar). air pressure governor is set to 400 kPa (4,0 bar) fresh water is available from the in-house supply line at the correct admission pressure (min. 150 kPa, max. 500 kPa) whether antifreezer and/or anticorrosive are available for initial filling (amount and type as per the press manufacturer´s instructions).

a) Turn on master switch (see Fig. 7-1/2). b) Enter setpoints for ink roll temperature (heating and printing temperature for ink distributor) at the display (see section 8.2 “Setup”). The difference between heating and printing temperature should not exceed 2°C. BALDWIN recommend the following values: - Printing temperature: 25°C - Heating temperature: Printing temperature + 1°C c) Open automatic vent valve (12) and air relief cock (15) (see Fig. 7-4). d) Open all stop valves. e) For fill circuit (ink roll heating/cooling) by opening the feed cock (8) (see Fig. 7-4). Only close air relief cock (15) when cooling water emerges of the air relief cock.

Key to Fig. 7-4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Drain Air connection RCWL supply line Fresh water IRHC supply line RCWL return flow line (other point of connection feasible) IRHC return line Feed cock IRHC Dirt trap IRHC Mixing valve IRHC Supply and return line manometer Automatic vent valve Pressure relief valve Equalizing reservoir Air relief cock

Note: Carefully vent the piping system during filling. Seite / Page 48

01.98/CRCWL852/GB

Start-up and Shut-down

Y

Z

up to unit type 852-600...

from unit type 852-1000...

Y

Y 12 13

12

14

15

13

11

14

15 9

Z

Z 10 11 9

10

8

8

1

2

3

4

5

6

7

1

7

4

2

5

3

6

Fig. 7-4

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Start-up and Shut-down f) Fill the unit to 200 kPa (2 bar) with the pump at standstill; the indication (static pressure) at the supply and return line manometer (11) must be identical. BALDWIN IRHC SET

Attention: The water pressure in the ink roll heating/cooling system must not exceed 200 kPa (2 bar) with the pump at standstill.

TEMP °C HEATING °C PRINTING °C SWITCH POS.

ACT 25.8

F4: F4: IRHC FWT ON - OFF

28.0 26.0 0.0

g) Check the unit for leaks. h) Shortly start the circulating pump IRHC via the F4 key for several times, vent the water circuit by opening the air relief cock (15), if required. Attention: Check sense of rotation of circulating pump IRHC (see direction of arrow on the pump housing). i) Should the pressure at the supply line manometer (11) drop below 200 kPa (2 bar) with the pump at standstill, top up with water and vent subsequently. k) F4 key on. IRHC unit is working.

IRHC = Ink Roll Heating/Cooling

l) Check the service pressure at the manometers. The unit should be filled until the return line manometer indicates a water pressure of min. 50 kPa (0.5 bar). The supply pressure must not exceed 300 kPa (3 bar).

Attention: Only switch on the circulating pump IRHC with an adequate water filling. Danger of running dry!

Attention: Fill in antifreezer and anticorrosive during initial filling. Pay attention to the press manufacturer´s instructions!

Note: When there are still large air bubbles in the system, the circulating pump IRHC is cut out by a protective device against running dry. Subsequently, the unit must be vented and topped up with water, if required. Then start the circulating pump IRHC by the F4 key for several times (switch on/off).

Seite / Page 50

01.98/CRCWL852/GB

Start-up and Shut-down 7.4 Setting the bypass valve (wet and/or dry offset) Wet -> dry offset (Fig. 7-5)

BALDWIN RCWL LOCAL SET ACT TEMP °C 10.0 10.5 AL % 8.0 8.0 ADD. 1 % 3.0

a) Press the maintenance switch F1 (Automix) and F3 (supply line and return flow pumps) to turn them off. „OFF“ will light. Set the setpoint for the fountain solution temperature to 17°C (= temperature in the tank) (see paragraph 8.2 „Adjustments“).

F1: AMX ON - OFF F2: COMP/HEP ON - OFF F3: PUMP ON - OFF F4: IRHC

b) Fully close the bypass valve (4) at the water-water heat exchanger (3) (also see Fig. 10-1). c) Enter the setpoints for the IRHC (heating and printing temperature for ink rolls) at the display (see paragraph 8.2 „Adjustments“).

5

Dry -> wet offset (Fig. 7-5) a) Press the maintenance switch F1 (Automix) and F3 (supply line and return flow pumps) to turn them off. „OFF“ will light. Set the setpoint for the fountain solution temperature to 17°C (= temperature in the tank) (see paragraph 8.2 „Adjustments“).

M

M

b) Half open the bypass valve (4) at the water-water heat exchanger (3) (also see Fig. 10-1). c) Enter the setpoints for the IRHC (heating and printing temperature for ink rolls) at the display (see paragraph 8.2 „Adjustments“).

1 2 3 4 5

Fountain solution circuit IRHC circuit Water-water-heat exchanger Bypass valve Maintenance switch (control unit)

Fig. 7-5

01.98/CRCWL852/GB

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Start-up and Shut-down 7.5 Shut-down RCWL and/or IRHC a) Turn off master switch b) Shut supply and return valves c) Shut and turn off fresh water supply d) Shut compressed air supply

Note: All settings carried out during last startup will be maintained.

Seite / Page 52

01.98/CRCWL852/GB

Operation of display 8. Operation of display 8.1 Description of function

BALDWIN RCWL TEMP AL ADD. 1

°C % %

LOCAL SET 10.0 8.0 3.0

ACT 10.5 8.0

F1: F2: F3: F4:

l Entering setpoints With the "Alcohol %", "Additive", "Temperature" keys the value concerned is indicated with its full number of digits and/or entering setpoints is initiated. The required digit is selected by subsequently pressing the cursor keys ç and è. The value is increased or decreased at the digit concerned (within defined limits) by means of the é and ê keys. When a second additive has been provided (option), a selection must first be made and acknowledged by the ENTER key.

AMX ON - OFF COMP/HEP ON - OFF PUMP ON - OFF IRHC

l Scanning/acknowledging errors The error menu is called in by means of the "Error" key. The LED, integrated in the error key, will start flashing as soon as there is an error. Errors are acknowledged in the error menu by means of the F1 key. Now only those errors will be displayed that are continuously scanned by the program (e.g. errors in the supply by the pump monitoring system will no longer be displayed). The error menu may be called in from anywhere, but not from the service mode. For error messages see the section "Trouble shooting".

l Scanning/clearing consumption data The current consumption data of the available media may be scanned and cleared, if required, by means of the S key. To do so, press the control key in the display associated to the medium concerned (see Section 8.2 /8.3). A warning will be displayed, and you may now clear the consumption value by pressing the ENTER key or you can terminate by pressing any other key.

l Interrupting the "NOT READY" stage The starting stage, that will be active for five minutes after switching the unit on, is interrupted by pressing the RESET key in the RCWL image. A version message will be displayed for 3 seconds, and the flashing display "NOT READY" in the upper right corner of the RCWL image will go out. l Stop key Exit of the menu is by means of the STOP key, unless you are in a menu with direct entering of parameters (e.g. complete entering of setpoints by means of ENTER).

01.98/CRCWL852/GB

Seite / Page 53

tly of be at

by tly

ed ns be et he

ds to

C) mp ow ng

Operation of display l Maintenance switch (F1/F2/F3 keys) The entire Automix is switched on and/or off by means of F1, any active filling cycle will be completed. The refrigerating set is locked or released by means of F2. The supply and return flow pumps are cut in or out by means of F3. l Ink roll heating/cooling (IRHC) If integrated (via the parameter menu), the ink roll heating/cooling can be called by means of key F4.The operating state concerned will be shown in the right upper corner of the display provided the ink roll heating/ cooling has been switched on via key F4. Entering of setpoints for the heating and printing temperature as per item 1 is started by means of the "Temperature" key. l Options - additive 2 - conductivity measurement of the fountain solution - pH measurement of the fountain solution - connection to central control console For further information please contact BALDWIN. l Service mode (only instructed personnel) only when in the "LOCAL" mode

ely

he d. ed

er on is

Attention: The service mode may be used by BALDWIN technicians or personnel instructed by BALDWIN only. When this menu is used by personnel that is not trained in it and should parameters be altered, the unit may no longer operate perfectly. Messrs. BALDWIN cannot be held responsible in such a case. Note: The unit will automatically switch off in the service mode. Settings and changes in the service mode are described in a separate Service Instructions for "Digital Control Unit" (German, English, French).

ity a-

H a-

ral de

Seite / Page 54

01.98/CRCWL852/GB

Operation of display 8.2 Setup

AMX (Automix) ON / OFF BALDWIN RCWL LOCAL SET ACT TEMP °C 10.0 10.5 AL % 8.0 8.0 ADD. 1 % 3.0

Fresh water supply and fountain solution premixing

F1: AMX ON - OFF F2: COMP/HEP ON - OFF F3: PUMP ON - OFF F4: IRHC

COMP / HEP ON / OFF Compressor (refrigerating set) and heat exchanger pump, if any

Pump ON / OFF Pump of supply line to press Note for actuating the 16 keys: The key function will only be initiated when a "click" becomes audible and sensible.

BALDWIN RCWL TEMP AL ADD. 1

°C % %

LOCAL SET 10.0 8.0 3.0

Menu: Ink roll heating/cooling (IRHC)

RCWL setpoints ACT 10.5 8.0

F1: F2: F3: F4:

AMX ON - OFF COMP/HEP ON - OFF PUMP ON - OFF IRHC

RCWL display

Temperature setpoint

enter temperature setpoint

acknowledge

Alcohol setpoint

enter alcohol setpoint

acknowledge

enter additive setpoint

acknowledge

Additive 1

01.98/CRCWL852/GB

Seite / Page 55

Operation of display Ink roll heating/cooling

BALDWIN IRHC SET TEMP °C HEATING °C PRINTING °C

ACT 25.8

F4: F4: IRHC FWT ON - OFF

28.0 26.0

SWITCH POS.

0.0

BALDWIN IRHC SET TEMP HEATING PRINTING

°C °C °C

ACT 25.8

F4:

IRHC ON - OFF

28.0 26.0

SWITCH POS.

0.0

IRHC display

Entering setpoints for IRHC

Select heating or printing temperature

enter temperature setpoint

acknowledge

return to the IRHC menu

return to the RCWL menu

Seite / Page 56

01.98/CRCWL852/GB

Operation of display Display of consumption data

The current alcohol, additive and fresh water consumption data will be indicated at the display.

BALDWIN RCWL (F1) (F2) (F3) (F4)

CONSUMPTION ALCOHOL: 0.0 CONSUMPTION ALC.SUB : 0.1 CONSUMPTION ADD. : 0.0 CONSUMPTION WATER : 323 CLEAR CONSUMPTION -> FX

LITER LITER LITER LITER

The consumption data are cleared by means of the control keys.Function F4 is only assigned when additive 2 (option) has been provided/parameterized.

Return to the RCWL menu.

Error table

The current error table will be indicated at the

(error).

For error messages and elimination of faults see section "Trouble shooting".

Return to the RCWL menu.

Changeover REMOTE LOCAL mode REMOTE:

central control operation (according to protocol specification) - complete data exchange at interface (from the central control it is not possible to enter setpoints, delete consumption data and operate in the service mode)

LOCAL:

display keyboard operation - with service functions

The currently set mode is displayed in the first line in the RCWL menu. Changeover by

+

Select the desired mode by

01.98/CRCWL852/GB

and acknowledge with

.

Seite / Page 57

Operation of display Service mode Attention: The service mode may be used by BALDWIN technicians or personnel instructed by BALDWIN only. When this menu is used by personnel that is not trained in it and when parameters are altered, the unit may no longer operate perfectly. Messrs. BALDWIN cannot be held responsible in such a case.

Settings and changes in the service mode are described in a separate Service Instructions for "Digital Control Unit" (German, English, French).

Seite / Page 58

01.98/CRCWL852/GB

Adjusting and checking 9. Adjusting and checking 9.1 General The adjustments concerned may be made by Messrs. BALDWIN and/or authorized personnel only.

Attention: All adjustments sealed with safety lacquer must not be changed. The unit has been adjusted by Messrs. BALDWIN. For the settings see the enclosed certificate.

9.2 Basic setting of the pneumatic maintenance unit (Fig. 9-1)

1 2

a) Optimum pressure with the metering pumps not running: 400 kPa (4.0 bar) Slightly raise the handwheel (1) and release the pressure reducer by turning counter-clockwise. Turn clockwise until the desired service pressure is indicated on the manometer. Lock the handwheel by pressing it down. b) Setting the amount of oil (2): 1 drop / 40 strokes (metering pump) Turning clockwise “less oil” Turning counter-clockwise ”more oil”.

Fig. 9-1

01.98/CRCWL852/GB

Seite / Page 59

Adjusting and checking 9.3 Density measurement by commercial hydrometers The hydrometer used for measuring the IPA content in the fountain solution is calibrated for mixtures IPA/pure water. There will always be an error of measurement when fountain solution additives are added. The portion of IPA contained in the fountain solution is actually higher than the value indicated at the measuring scale of the hollow body. However, the correct value may be determined on the basis of the measured value by means of a correction table. Density of the fountain solution additive in g/cm3

Portion of additive

Indicated IPA concentration in %

1.05

1% 2% 3% 4%

3.1 2.8 2.5

3.5 5.4 5.0 4.6 4.3

7.2

9.1

11.0 12.9 14.7 16.6 18.5 20.4 10.5 10.1 9.6

12.4 14.2 16.1 17.9 19.7 11.9 13.7 15.5 17.3 19.1 11.4 13.1 14.9 16.7 18.5

1.10

1% 2% 3% 4%

3.2 2.5 1.9 1.2

5.0 4.3 3.6 2.9

6.9 6.1 5.3 4.5

8.7 7.9 7.0 6.2

10.6 9.7 8.8 7.9

12.4 11.4 10.5 9.5

14.3 13.2 12.2 11.2

16.1 15.0 13.9 12.8

17.9 16.8 15.6 14.5

19.8 18.6 17.4 16.1

1.15 *

1% 2% 3%* 4%

2.9 1.9 0.9 0.0

4.7 3.6 2.6 1.5

6.5 5.3 4.2 3.0

8.3 7.1 5.8 4.6

10.1 8.8 7.5 6.1

11.9 10.5 9.1 7.6

13.8 12.2 10.7 * 9.2

15.6 14.0 12.3 10.7

17.4 15.7 14.0 12.3

19.2 17.4 15.6 13.8

1.2

1% 2% 3% 4%

2.5 1.3 0.0 -1.3

4.3 2.9 1.5 0.1

6.1 4.6 3.1 1.6

7.9 6.3 4.6 3.0

9.7 7.9 6.1 4.4

11.5 9.6 7.7 5.8

13.3 11.2 9.2 7.2

15.0 12.9 10.8 8.61

16.8 14.6 12.3 10.0

18.6 16.2 13.8 11.4

14

16 *

18

20

22

6.8 6.4 6.0

8.7 8.2 7.8

4 6 8 10 12 actual IPA concentration in %

Fig. 9-2

Example for using the table (fig. 9-2): A fountain solution contains 3 % of an additive of a density of 1.15 g/cmł. The value determined by the hydrometer test is 11.5 %. Search the line in the table that belongs to a density of 1.15 g/cmł and the additive of 3 %. The indicated value of 11.5 is between the stated values of 10.7 and 12.3; the actual concentration is approx. 17 % (see *).

Seite / Page 60

Note: The hydrometer is calibrated to 20°C as a rule. Measuring in the cooled fountain solution (10°C) results in a further deviation by some 2 %. In the example, the actual alcohol concentration is approx. 19 % at a fountain solution temperature of some 10°C.

01.98/CRCWL852/GB

Adjusting and checking 9.4 Additive and temperature calibration at the Alcohol Control Unit (Fig. 9-3)

BALDWIN RCWL LOCAL SET ACT TEMP °C 10.0 10.5 AL % 8.0 8.0 ADD. 1 % 3.0

The Alcohol Control may be calibrated to the different densities of fountain solution additives by a setting knob (1) with scale (2) at the analysis box. F1: AMX ON - OFF F2: COMP/HEP ON - OFF F3: PUMP ON - OFF

Attention: Complete drain the fountain solution storage tank and the circulation system when you change from one fountain solution additive to the other. Repeat the setting when you change the fountain solution additive and/or when you alter the metering amount. Setting: BALDWIN RCWL TEMP AL ADD. 1

°C % %

LOCAL SET 10.0 8.0 3.0

ACT 10.5 8.0

F1: F2: F3:

AMX ON - OFF COMP/HEP ON - OFF PUMP ON - OFF

a) Completely drain the fountain solution system. b) Enter the desired additive and temperature setpoint at the display and/or the central control console of the press (see 8.2 "Setup"). c) Set alcohol setpoint to 00.0 %. d) Switch the Automix on (F1). The refrigerating unit will start to premix the fountain solution. - Only fountain solution additive (no alcohol) will be added.

2 1

e) Wait until fountain solution premixing is completed and the temperature setpoint has been reached. f) Correcting the specific gravity: - Loosen setting knob (1) and lower the metering pipe to the bottom stop. - Watch the actual alcohol value and slowly lift the metering pipe until the actual alcohol value reaches 00.0 %. - Secure the metering pipe by means of the setting knob (1).

Fig. 9-3

g) Enter the desired alcohol setpoint at the display (and/or central control console). The desired alcohol percentage will automatically be maintained by a piston metering pump.

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Adjusting and checking 9.5 Adjusting the thermostat (Fig. 9-4) Attention: Adjustment only in emergency operation.

1

2

a) The thermostat for the cooling system allows the fountain solution temperature to be set from -5°C to max. +25°C.

Attention: The thermostat must not be set below 8°C. The thermostat has been factory-set to 10°C.

b) Set desired damping solution temperature at the knurled knob (1). c) The value set at the differential scale (2) indicates the max. difference between the max. and min. temperature of the fountain solution at the fountain solution outlet of the cooling unit. Fig. 9-4

Attention: This value, set to 2°C, must not be changed, since due to the higher operating frequency the refrigerating set might be damaged.

9.6 Checking the sight glass (Fig. 9-5) Note: Check the sight glass with the unit running!

CAUTION (Call BALDWIN after-sales service) DRY (Refrigerant circuit ok) WET (Refrigerant circuit not ok, call BALDWIN after-sales service or technician for air conditioning / refrigeration engineering)

Fig. 9-5

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Adjusting and checking 9.7 Checking the water pressure in the IRHC Read off the service pressure at the manometers: a) with the pump at standstill: Return flow and supply line pressure: max. 200 kPa (2 bar) Attention: The water pressure in the IRHC must not exceed max. 200 kPa (2 bar) with the pump at standstill. b) with the pump at running: Return flow pressure: min. 50 kPa (0,5 bar) Supply line pressure: max. 300 kPa (3 bar)

When the minimum setpoint is not reached, top up with water (see putting the IRHC into service). When the setpoints are exceeded, drain cooling water of the circuit.

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Maintenance 10. Maintenance 10.1 General BALDWIN Combined Refrigerated Circulating Water Levels require only little maintenance. The necessary upkeep serves to keep the units ready for service. The periods between servicing depend on the operating conditions concerned.

Attention: The intervals for maintenance stated are minimum recommendations. Exceeding the intervals as well as failure to observe the instructions contained in this operating manual may result in an impairment of the perfect performance of the units. Moreover possible liability claims can be called in question.

10.2 Maintenance intervals Note: Replacing the filter foam in the fountain solution return line and/or the filter candle in the fountain solution supply are not included in the maintenance jobs, since a contamination will be indicated by alarm messages in time.

daily

Checking the fountain solutionfilter foam

Weekly

Clean the fountain solution storage tank

Monthly

Clean the condenser (air-cooled design) Clean the Alcohol Control Checking the pneumatic maintenance unit

Warning: Make the unit dead for maintenance work by means of the master switch and/or by deselecting it from the central control console. The maintenance switches F1, F2, F3 and F4 must be set to "OFF" (see 8.1 "Description of function).

Every 6 months

Clean the entire fountain solution system Clean the filters for fresh water, alcohol and additive

Warning: There are hot components behind the covers. When the covers are removed for maintenance or repair work, make sure not to touch these components !

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Maintenance

Fig. 10-1

CRCWL 852-.. HS AD (air-cooled design) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Control unit Automatic premixing unit AMX (see Fig. 10-2) Heat exchanger pump Supply line pump (mounted behind heat exchanger pump) Condenser Fountain solution storage tank Fountain solution filter foam Standpipe (overflow and discharge) Alcohol Control BC 743 Expansion vessel IRHC-pump Water-water-heat exchanger Bypass valve Dirt trap (IRHC)

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Maintenance

Metering pump for additive Metering pump for alcohol

4/2 way valve (additive)

4/2 way valve (alcohol)

Nonreturn valve for additive

Flow meter

Nonreturn valve for alcohol

Flow regulator

2/2 way valve (fresh water)

Fresh water filter

Food filter with integrated nonreturn valve

Fig. 10-2

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Maintenance 10.3 Replacing the fountain solution filters

Warning: Dispose of the filter foam in accordance with the relevant rules in force!

a) Pull out filter module, wrap up used filter foam and take them out. Attention: When mounting a new filter foam make sure that the filter cage is locked properly. Note: Use original BALDWIN filter foam!

10.4 Cleaning the fountain solution storage tank a) Switch the unit off. b) Pull out filter module, wrap up used filter foam and take it out. c) Drain the fountain solution tank by unscrewing the standpipe and by opening the ball valve.

Warning: Dispose of the fountain solution in accordance with the relevant rules in force!

d) Wipe out the tank and the float switch with a solvent that is commercially available for fountain solution circuits (in accordance with the manufacturer´s instructions). e) Mount standpipe with flat packing and close ball valve for tank discharge.

10.5 Cleaning the entire fountain solution system

Preparatory steps: The F3 maintenance switch remains on. Mark the position of the supply line valve at the supply line pump, then close it. As a result, the entire fountain solution circuit and the connected return flow filters will be pumped empty. Attention: Operate the supply line pump only with an adequate filling of water. Failing this, it may run dry! Next steps see 10.4 a) to e) f) After the fountain solution circuit has been emptied, set the supply line valve at the supply line pump to the marked position. g) Subsequently fill the tank with water and cleaning agent for fountain solution systems (in accordance with the manufacturer´s instructions), then switch the unit on to rinse the entire fountain solution circuit. Duration of cleaning depending on the degree of soiling and/or the manufacturer´s instructions. h) Repeatedly drain the tank and flush the circuit with clean water to ensure that no cleaning agent is left in the unit (also see “Preparatory steps”). Attention: After draining the soiled cleaning agent, flush the system with clean water until all residues are removed without fail!

i) Replace the filter foam in the return flow line by a new one. Note: Use original BALDWIN filter foam! k) Put the unit into service (same as initial operation)

f) Place the filter cage in the tank and mount filter foam (see paragraph 10.3). g) Put the unit into service (same as initial operation).

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Maintenance 10.6 Cleaning the Alcohol Control Unit (Fig. 10-3) The method of cleaning used depends on the user´s experience. Generally the following method has stood the test in practice: a) Switch the cooling unit off. b) Disconnect electric coupler (1) and remove water supply hose (2). c) Remove housing top (3) after loosening the fastening screws (4).

Attention: When you do not remove the housing top but take out the entire Alcohol Control, be sure that it is kept in a vertical position without fail. Since the analysis box is filled with water up to standpipe level, water would penetrate into the housing top when the entire unit is laid on the side and would damage electronic components.

Notes regarding d) e): Be sure to use hot water. Failing this, some deposits such as e.g. gum arabic will not be removed. d) Take aerometer (5) out of the analysis box and remove the deposits by means of a lint-free rag. e) Take out analysis box, drain and clean. Clean standpipe by means of a bottle brush, if required.

Fig. 10-3

f) Mounting is in reverse order.

10.7 Cleaning the fresh water filter (Fig. 10-4)

1

a) b) c) d)

2 3

Switch the unit off. Shut the water supply. Loosen and remove screw plug (1). Take out filter element (3), rinse in clear water and blow out with clean compressed air.

Note: Should the filter element (3) be defective, replace the complete dirt trap by a new one. d) Mount filter, replace gasket (2) by a new one, if required, and tighten screw plug (1).

Fig. 10-4 01.98/CRCWL852/GB

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Maintenance 10.8 Checking the maintenance unit (Fig. 10-5)

3

a) Set maintenance unit to 0 bar (1) b) Drain condensate water (2) c) Top up oil (3)

1 We recommend that you use the following oils for the maintenance unit: Suitable oil grades

Viscosity at 40°C mm˛/s (cSt)

2

Aral Vitam GF 46 BP Energol HPL 46 Esso Nuto H 68 Shell Tellus C 46 Texaco Rando Oil

46 46 68 46 38 38

HD C 38

Fig. 10-5

10.9 Cleaning the filter in alcohol and/or additive containers a) Switch the unit off. b) Pull supply line out of alcohol and/or additive containers . c) Unscrew filter, rinse in clear water and blow out with clean compressed air or replace by a new filter. d) Mount and tighten filter.

10.10 Cleaning the ribs of the condenser (Fig. 10-6) (with air-cooled design)

Warning: Keep your hands out of the range of rotation of the fan blades because of the risk of injuries at the start of the fan blade. a) Switch the unit off, open the cabinet doors. The condenser (1) is located at the top of the unit. b) Unscrew housing cover (2), blow out the ribs of the condenser with compressed air in opposite direction to the air intake.

Fig. 10-6

Note: Use clean compressed air free of oil at max. 200 kPa (2 bar). c) Screw down housing cover, the cover must fit tightly.

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Repairs 11. Repairs 11.1 General We know from experience that mounting and dismounting the components described in the following may be done by shop mechanics and/or works electricians. Should adjustments be required subsequently, these should be carried out by BALDWIN.

Warning: There are hot components behind the covers. When the covers are removed for maintenance or repair work, make sure not to touch these components!

Warning: Work at the closed cooling circuit may be carried out by expert personnel only (expert for refrigeration engineering).

Warning: The compressed air and the fountain solution circuit must be pressureless before any repair is carried out at the unit. Danger of injuries by heavily splashing fountain solution and/or escaping compressed air.

11.2 Replacing the supply line pump or heat exchanger pump; type KTB 200 / KTE 142 (Fig. 11-1)

1

3 2

11.2.1 Dismounting a) Switch the unit off, open both doors. b) Disconnect the electric line of the pump (works electrician) c) Shut fresh water supply and fountain pan supplies d) Unscrew screwed connection (3) at pump supply line e) Loosen 4 screws at the pump flange g) Take out the pump (1) 11.2.2 Mounting Mounting is in reverse order.

Fig. 11-1 Seite / Page 72

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Repairs 11.3 Replacing the circulating pump IRHC; type CHI 4-20 / CH 12-20 (Fig. 11-2) 11.3.1 Dismounting a) Switch the unit off, open both doors. b) Disconnect electric line (2) at the pump (1) (works electrician). c) Close supply and return line valves of the ink roll heating/cooling (IRHC).

Warning: The circuit of the IRHC in the unit must be pressureless before the hoses are removed. Danger of injuries by heavily splashing cooling water.

3

2

5

1

d) Drain the water of the IRHC circuit only in the unit. The circuit must be pressureless! e) Pull off hose at the pump supply line (3). f) Pull off hose at the pump return line (4). g) Loosen 4 screws (5). h) Remove pump (1).

4

Fig. 11-2

11.3.2 Mounting Mounting is in reverse order.

11.4 Replacing the thermostat (Fig. 11-3)

2

11.4.1 Dismounting

5 3

a) b) c) d) e) f) g) h)

Switch the unit off Disconnect power supply Remove rear wall Pull capillary measuring line (1) out of the temperature sensor tube. Loosen housing cover (5) at the thermostat (2). Remove fastening screws (3). Disconnect electrical connections (4). Take out the thermostat with capillary measuring line.

4 11.4.2 Mounting Note: The end of the capillary line has been twisted at the factory.

1

Attention: Make sure that the twisted end reaches at least to the lower third of the temperature sensor. Replace insulation, if required.

Fig. 11-3

a) Mounting is in reverse order.

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Trouble shooting 12. Trouble shooting Attention: Elimination of faults by Messrs. BALDWIN and/ or authorized personnel only.

Warning: Work at the electric section must be carried out by an electrician on principle. The appropriate wiring diagram is to be observed. A wiring diagram will be supplied with each unit. Fig. 12-1

Warning: Work at the closed cooling circuit may be carried out by expert personnel only (expert for refrigeration engineering).

Fig. 12-2

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Trouble shooting 12.1 Error messages at display Trouble

Possible causes

ERROR WATER - Fresh water valve closed - Low flow pressure (min. 1 bar) FEED - Fresh water filter clogged

- Solenoid valve Y5 does not open

Eliminating the fault

Notes

- Check water supply line/valve - Check desired pressure (150 500 kPa / 1.5 - 5 bar)

Carry out H2O -counter test in the service mode (see separate "Service Instructions for Digital Control Unit") to check the flowmeter

- When the float ball is at position 1 -> LED will light and water must be supplied, otherwise -> replace solenoid valve Y5

- Solenoid valve Y5 clogged

- Loosen solenoid valve head and clean tappet

- Solenoid valve Y5 without voltage

- Check electrical connections

- Water flowmeter does not give signal -

HIGH LEVEL

Clean filter, replace, if required Mechanical check -> clean Electrical check -> replace Check flowmeter, replace, if required

- Solenoid valve Y5 does not close - Mechanical check -> clean; Electrical check -> replace (if the LED does not light, water must not be supplied) - Water flowmeter defective - Float switch defective

Check the electronics section via service menu INPUTS/OUTPUTS (see separate "Service Instructions for Digital Control Unit")

- Check flowmeter, replace, if required - Replace switch - Close valve for fresh water supply

Check the water flow rate with H 2O-counter test (see separate "Service Instructions for Digital Control Unit", 233 pulses = 1 l of H 2 O). Check the amount of water by gauging by liters. Check the electronics section via service menu INPUTS/OUTPUTS (see separate "Service Instructions for Digital Control Unit")

LOW LEVEL

- See trouble “Error water feed” - Middle float switching point defective - Check float, replace, if required / float got caught - Standpipe not screwed down - Check standpipe, replace seal, if required properly and/or seal defective - Leakages in the fountain solution - Check hoses, screw connections system

01.98/CRCWL852/GB

Check the electronics section via service menu INPUTS/OUTPUTS (see separate "Service Instructions for Digital Control Unit")

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Trouble shooting Trouble ERROR ADDITIVE 1 FEED Option: ERROR ADDITIVE 2 FEED

Possible causes

Eliminating the fault

- Container for additive empty - Suction line not in container

- Check container / suction line

- Foot filter, filter clogged

- Check filter, replace, if required

- Elektronic unit A1

- Replace elektronic unit

- Compressed air supply missing and/ - Check compressed air supply or incorrectly set air pressure (desired value: 400 kPa / 4 bar) - Stop valve leaky or clogged - Clean stop valve, replace, if required - Air valve Y3 fouled by oil

- Blow out the oil

- Air valve Y4 defective - Check valve Y4 / metering pump, (press red button at the valve, replace, if required switching of the 4/2 way valve (after replacement of the 4/2 way metering of additive will be audible) valve, check the function by pressing the red button at the - Metering pump defective valve/pump) (press red button at the pump, piston movement will be audible)

ERROR ALCOHOL FEED

- Container for alcohol empty - Suction line not in container

- Check container / suction line

- Foot filter, filter clogged

- Check filter, replace, if required

- Elektronic unit A1

- Replace elektronic unit

- Compressed air supply missing and/ - Check compressed air supply or incorrectly set air pressure (desired value: 400 kPa / 4 bar) - Stop valve leaky or clogged - Clean stop valve, replace, if required - Air valve Y3 fouled by oil

- Blow out the oil

- Air valve Y3 defective - Check valve Y3 / metering pump, (press red button at the valve, replace, if required switching of the 4/2 way valve (after replacement of the 4/2 way metering of alcohol will be audible) valve, check the function by pressing the red button at the - Metering pump defective valve/pump) (press red button at the pump, piston movement will be audible)

Seite / Page 76

Notes

Check the electronics section via service menu INPUTS/OUTPUTS (see separate "Service Instructions for Digital Control Unit") too much oil in the air valve indicates excess oil consumption -> reduce oil metering

Check the electronics section via service menu INPUTS/OUTPUTS (see separate "Service Instructions for Digital Control Unit") too much oil in the air valve indicates excess oil consumption -> reduce oil metering

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Trouble shooting Trouble

Possible causes

ACTUAL - Contactor K1 defective TEMPERATURE OUT OF ALARM - Supplied fresh water too warm LIMITS - The variance is above 3°C

Eliminating the fault

Notes

- Replace contactor K1 - Cool fresh water

- Check by means of thermometer whether indication is correct - Refrigerating set (F2) switched off - Turn on cooling unit by key F2 - Heat exchanger clogged

- Clean heat exchanger by means of adequate cleansing agent

- “Not ready" time is active (also see “Error cooling unit”)

- “Not ready” phase not completed, since tank temperature is high, wait until unit advances

- Lack of refrigerant, bubbles in sight - Top up refrigerant glass - Temperature sensor defective - Check temperature sensor at 100W - Expansion valve defective

ERROR ALCOHOL MEASURING

(measurement pick-up faulty)

- Replace expansion valve

- The measured actual alcohol value - Check actual alcohol content by means of hydrometer exceeds 20%

see 9.3

- The position pick up of the Alcohol - Check / clean position pick up, replace, if require Control is tight

see 5.2

- Protection for transport (protective - Replace protective cap at Alcohol Control cap)

see 6.1

- Float immersed too deeply, leaky

- Replace float of the Alcohol Control

- Heavy formation of foam in fountain - Adjust return flow filter unit and/or also see Operating Manual injector at IRE solution

"Return Flow Filter" and "IRE"

- BC 743 defective

- Check BC 743 (the optoelectronic reticle is soiled)

see 5.2

- Measuring vessel must be filled first - Wait until photogrammetric camera is filled see 9.4

- Metering pipe not adjusted correctly - Adjust EMERGENCY MODE

- Emergency mode switch S4 turned - Turn off emergency mode on switch, check cooling unit Electrician Expert for refrigeration engineering

01.98/CRCWL852/GB

In emergeny operation, the control output of the supply line pump, the heat exchanger pump and the refrigerating set is bridged to maintain the fountain solution circuit from and to the press and/or the cooling.

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Trouble shooting Trouble ERROR HEATER IRHC

Possible causes

Eliminating the fault

Notes

- Protective motor switch Q2 heating - Turn on protective motor switch has tripped Q2 and check setting Electrician - Water temperature in IRHC circuit - Check whether IRHC circuit (F4) too high (>45°C), safety switch is on, switch on, if required. Check “excess temperature” has tripped thermostat setting at heating and readjust, if required. - Mixing valve defective

- Protective motor switch Q4 has ERROR PUMP tripped IRHC (NEWSTART -> OFF/ON) - Supply or return line valve in IRHC circuit closed - Air bubbles in IRHC circuit - Low water pressure

- Check / replace mixing valve (after-sales service)

- Turn on protective motor switch Q4 Electrician - Open valves - Vent IRHC circuit - Check pressure indicated at pressure gauge (pressure in return line min. 0.5 bar), inadequate amount of water in circuit —> top up with water

- Flow monitoring switch B5 has not - Check, whether the water flow is switched due to inadequate water blocked at the press flow rate, with the pump running - Check the pressure - Filter clogged - Pump defective

see 9.7

see 9.7

- Clean filter - Replace pump

PRINT - Difference between set RCWL - Readjust via setting the desired desired temperature and set IRHC value (see 8 "Operation of TEMPERATURE desired temperature too small display") IRHC NOT (difference min. 5°C) POSSIBLE

OVERLOAD SWITCH PUMPS (P1/ HEP/RETURN FLOW)

- Mixing valve defective

- Replace mixing valve

- Pump or pump impeller defective - Water flow governor defective

- Replace pump - Check water flow governor, replace, if required

- Overload switch of circulating pump - Turn on overload switch or heat exchanger pump has tripped Electrician - Overload switch of pump for return flow filter (option) has tripped

- Check setting of overload switch (see wiring diagram)

- 24 VAC missing, fuses F4 / F7 - Check fuse defective - 24 VAC module defective - Replace 24 VAC module

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Trouble shooting Trouble

Possible causes

Eliminating the fault

Notes

- Check float switch, replace, if ERROR FLOAT- - Float switch defective - Float switch tight required SWITCH - Float switch or connecting line to - Check switch and/or connecting float switch defective line, replace, if required - Reed contacts soiled

- Clean Reed contacts

RCWL FOUNTAIN SOLUTION EMPTY

- Automix (F1) OFF, see failure “Error water feed ”

ERROR PLUG BC 743

- Plug at BC 743 disconnected - Check plug / connection to BC - Connection to BC 743 interrupted 743 (X7 - X7.1)

ACTUAL ALCOHOL OUT OF ALARM LIMITS

- The variance is above 3%

- See trouble "Error alcohol feed" "Error alcohol measuring"

- New exact alcohol setting - See trouble “Error alcohol feed” - Measuring vessel must be filled first - Wait until photogrammetric camera is filled - Float switch defective - Check switch, replace, if required

RETURN FILTER DIRTY

- Filter foam in the fountain solution - Clean/replace filter foam and/or storage tank and/or filter mat in filter mat return flow filter clogged

when the LED at the filter sensor does not light -> clean or adjust intensity by means of screw driver

- The capacitive filter sensor in the - Clean and/or dry sensor CRCWL is fouled or wet

HIGH PRESSURE PRESSURE SWITCH

- High pressure manostat has tripped, air-cooled design: - Condenser fouled / blocked - Clean condenser, adequate ventilation - Ambient temperature above 44°C

also see Operating Manual "Return Flow Filter"

provide

Check fan (sense of rotation) Check air outlet

- Diameter of exhaust air line inadequate / exhaust air line too long - Cooling unit is placed near a heat - Protect from heat generator, place generator unit elsewhere water-cooled design: - Cooling water control valve set - Check / adjust valve, replace, if incorrectly or defective required (also see page 6.4 - No cooling water supply from "Connection to cooling centres") cooling centre - Preliminary filter clogged - Stop valve closed

01.98/CRCWL852/GB

- Clean filter - Open stop valve

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Trouble shooting Trouble ERROR COOLINGUNIT

Possible causes - Overload switch Q1 has tripped

Eliminating the fault

Notes

- Turn on overload switch Electrician - Check setting of overload switch (see wiring diagram)

Check compressor winding

- Low pressure manostat has tripped - Low water temperature - Low water flow rate through heat exchanger and/or clogged

- Refrigerant missing

- Top up refrigerant Expert for refrigeration engineering

Seite / Page 80

- Pump (F3) switched off

- Turn on pump (F3)

- 24 VAC missing

- Replace fuse F4

- 24 VDC missing

- Replace fuse F7

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Trouble shooting 12.2 Failures not shown at display

Trouble

Possible causes

Eliminating the fault

Refrigerating set and circulating pump do not start running

- Mains feeder missing or dis- - Electric trouble shooting by means connected of the circuit diagram - Back-up fuse defective - Master switch not turned on or Electrician defective - Transformer defective

Refrigerating set does not start running

- Overload switch of refrigerating set - Turn on overload switch (mutual interlocking) has tripped Electrician

Notes

- Fountain solution temp. may already be below adjusted temperature

- Set temperature at the thermostat to a higher value, if required

- Thermostat may be defective

- Remove housing at thermostat and bridge connections (Fig. 12-1) Unit is running - Replace thermostat

only in the emergency mode (also see failure “EMERGENCY MODE”)

- Manostat may be defective

Remove housing cover at manostat and bridge connections (Fig. 12-2) Unit is running - Check at start whether the sight glass (Fig. 9-5) is filled with liquid refrigerant to 3/4. When this is not the case or when bubbles occur, have refrigerant topped up (specialized firm). When the refrigerant filling is found to be perfect during topping up, the manostat must be replaced (specialized firm).

The refrigerating set may only be operated on the refrigerants listed under the „Technical Data“.

- Supply line pump (circulating pump) - Turn on overload switch and check No fountain not running pump and/or return flow filter pump solution supply Electrician - Wrong sense of rotation of pump

- Check power supply at the terminals Electrician

- Fountain solution supply line valve - Open fountain solution supply shut line valve - Low fountain solution level in storage - see trouble "LOW LEVEL" tank - Hose kinked - Check running of hoses - Pump impeller got loose

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- Fasten pump impeller

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Trouble shooting Trouble

Possible causes

Eliminating the fault

Notes

Motor of the cir- - Pump impeller at motor shaft end - Check (after-sales service) loose culating pump seems to over- - Fresh air outlet at motor clogged - Fan blade wheel at motor loose heat Note: The in-service temperature may be up to 70°C, therefore the motor may feel hot to the touch. Since the motor is designed for operation on 50 and 60 Hz, a higher temperature with operation on 60 Hz is considered normal.

Cooling unit heavily oscillating in high pressure range

(water-cooled condenser)

see 6.4 "Connection to cooling centres"

(air-cooled condenser)

see trouble "HIGH PRESSURE PRESSURE SWITCH"

Fountain solution warm

- Position of temperature sensor in - Check (after-sales service) feeler tube not ok - see trouble “Refrigerating set does not start running” in "Emergency mode": - Thermostat set too high

- Check

Fountain solution cold

- Check (after-sales service) - Thermostat set too low - Position of temperature sensor in feeler tube not ok

Circulating pump does not start running

- Overload switch of circulating pump - Turn on overload switch and/or return flow filter pump has Electrician tripped (mutual interlocking) - Check setting of overload switch (see wiring diagram) - Pump may be defective

No fountain solution return flow and/or inadequate circulation and/ or fountain pans in press overflowing

- Replace pump

Return flow line: - Filter in the return flow filter unit - Clean filter clogged - Return flow hose kinked - Check - Pump performance inadequate - Check (after-sales service)

also see Operating Manual "Return Flow Filter" and "IRE"

Injector Recirculation Equipment (IRE): - Injector restricted excessively - Release restriction of injector - Injector clogged

Seite / Page 82

also see Operating Manual "Return Flow Filter" and "IRE"

- Clean injector

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Trouble shooting Trouble

Possible causes

Additives missing

- Additive pump does not draw in 100 - Clean foot valve ml - Replace metering pump - Position of the Reed switch - Set Reed switch to correct position at the front of the centre flange - Reed contacts soiled

Eliminating the fault

Notes

- Clean Reed contacts

- Power supply Reed switch missing - Check power supply, make (LED does not light) connection

Alcohol missing

- Low metering amount

- Clean foot valve - Clean nonreturn valve - Replace metering pump

- Reed switch

- Set Reed switch to correct position at the front of the centre flange

- When the LED at the Reed switch - Check power supply, make connection, replace Reed switch, does not light, power is missing if required

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Dismounting 13. Dismounting

13.4 Antifreezer and anticorrosive

13.1 Electric connection

Warning: Work at the electric section must be carried out by an electrician on principle. The appropriate wiring diagram is to be observed. Make the unit dead.

Warning: When antifreezer and anticorrosive are contaminated or are not required any longer they must be disposed of in accordance with the relevant rules in force.

13.5 Refrigerant

Disconnect the unit from all electrical connections.

13.2 Hose connections Shut all connections for water, compressed air, additives and alcohol and/or alcohol substitutes, drain the lines.

Warning: The closed circuit for compressed air and the fountain solution must be pressureless before dismounting the unit. Danger of injuries by heavily splashing fountain solution and/or escaping compressed air. Loosen and unplug supply lines.

Warning: The refrigerant may only be drained by a specialised firm for refrigeration and aircondition engineering and must then be disposed of in accordance with the relevant rules and regulations.

13.6 Scrapping

Warning: All parts of the unit must be disposed of in accordance with the relevant rules and regulations.

13.3 Fountain solution, alcohol (alcohol substitutes) and additives

Warning: Dispose of the fountain solution and the used filters as well as alcohol and/or alcohol substitutes in accordance with the relevant rules in force.

Drain the fountain solution system and the storage tank. Close containers for alcohol and/or alcohol substitutes and additives.

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Parts list 14. Parts list 14.1 General The following illustrated parts list includes only those parts that can be replaced without any difficulties by shop mechanics or works electricians according to experience. A list of recommended spare parts is given in the annex to this parts list. This list is based on our experience gained up to now. If the user keeps these parts in stock, he will be in a position to repair the unit without delay. Note: When ordering spare parts, please indicate the works number of the unit and the model number.

14.2 Notes for using Abbreviations: "Fig" item = Number of illustration and the corresponding items "No" Pcs =

Number of parts per subassembly; the term subassembly refers to the principal subassembly part, part of the plant or the entire plant.

14.3 Illustrated parts list (please turn over)

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