Kapitelüberschrift

1 Preface
UTK009060001000000000

1.1 Contents

This document contains specifications of the layout,

data and technical features of printing presses and
the related peripheral equipment.

1.2 Utilization

The contents of this document are intended for

D persons who deal with purchasing a printing

press;
D persons who deal with planning a printing press
site.

1.3 Relevance

These specifications correspond to the series ver-

sion of the press equipment at the time of the publi-
cation of this document.
We reserve the right of making modifications that
serve the technical progress.
In case of doubts, please ask your Heidelberg
branch office or factory agency for confirmation.

1.4 Produced by

Heidelberger Druckmaschinen AG
Kurfürstenanlage 52-60
69115 Heidelberg
Federal Republic of Germany

A.1
 Overall chapter overview

Table of Contents

A Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1

Important notes for the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.3
Measures to prepare the press site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1
1 Building structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
2 Power Supplies and Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.6
3 Printshop Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . . . A.2.9
Elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.1
1 Building and installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.3
2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.4
3 Foundation strips for the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.6
4 Bottom plates for collecting lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.13
5 Motor Mounting Base for the Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.15
6 Stairs, catwalks, platforms and railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.20
7 Guards on the Elevated Printing Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.28
Specifications of data networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.1
1 Suitable network versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.3
2 Suitable network servers and their configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.14
3 CP2000 ManagementGate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.16
Electrical installation of the press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.1
1 General information ..................................................... A.5.3
2 Technical specifications of the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.4
3 Basic regulations for mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.6
4 Basic Recommendations and Tips for the Mains Connection . . . . . . . . . . . . . . . . . . A.5.10
5 Connection of the printing press to the three-phase mains . . . . . . . . . . . . . . . . . . . . A.5.12
6 Cross-sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.21
Installation of the air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.1
1 Pneumatic compressor station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.3
2 Suction and blast air generation by the air supply cabinet .................... A.6.5
3 Air-cooled air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.8
4 Water-cooled air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.14
5 Installation of the pneumatic compressor station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.16
6 Installation of the air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.18
7 Air supply via central air supply systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.26
8 Installing the exhaust air cleaning cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.34
Installation of the dampening solution supply . . . . . . . . . . . . . . . . . . . . A.7.1

1
Overall chapter overview

1 Installation of the dampening solution supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7.3

Installation of the dryer units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.1
1 Mains connection of the IR dryer to the three-phase mains . . . . . . . . . . . . . . . . . . . . A.8.3
2 Air-cooled dryer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.11
3 Cooling Water Circuit of the Water-Cooled Guide Plate ...................... A.8.14
4 UV Drying Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.15
Installing the CPTronic and CPC units . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.1
1 Power connection of the CPC units to the AC mains (lighting mains, one phase) . A.9.3
2 Overview of standard mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.5
3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.7
Electronic interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.1
1 Interface adapter STA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.3
2 Interface Input Module SEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.8
3 Interface Output Module SAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.13
4 Single-Fault Fail-Safe Extension Module EEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.19
5 Press cycle position switch 1S65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.21
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.1
1 Particular Conversions and Multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.3
2 Water Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.4
3 Conversion of Fractions into Decimals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.5
4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.7

B Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1

2
A Technical information

A.1
 Chapter overview

Important notes for the user

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.3
1.1 Explanation of the safety instructions and the general notes . . . . . . . . . . . . . . . . . . . A.1.3
1.2 Delivery and installation of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5
1.3 Operation of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.7
1.4 Disassembling (demounting) the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
1.5 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.11
1.6 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.12

A.1.1
Chapter overview

A.1.2
 Important notes for the user

1 Safety
UTKSC9063008000000000

1.1 Explanation of the safety instructions and the general notes

The ”Technical Information” contains three informa-

tion categories which will be explained below.
To give you a better understanding of the information
provided, symbols (pictographs) with a fixed mean-
ing are allocated to each category.

First-degree notes

Meaning:
This safety information warns you of potentially haz-
ardous situations. If not observed, serious injury may
result. In extreme cases there is danger to life!
Apart from that, the presses and additional equip-
ment may be heavily damaged.
Relevant pictographs with signal words:

Warning – <General hazards>

Warning – <Danger from electric

current>

Warning – Rotating rollers, cylin-

ders or gears!

Warning – Hot surface!

A.1.3
Important notes for the user

Example:

Warning – Danger from attaching or

installing third-party devices!
Attaching or installing third-party de-
vices can lead to fatal injuries as well
as serious damage to the press and its
equipment.
Therefore Heidelberger Druckmaschi-
nen AG accepts no warranty or liability
for personal injury or press damage
and neither for defects caused by at-
taching or installing third-party devices.

Second-degree notes

Meaning:
This safety information warns you of potentially haz-
ardous situations.
Nonobservance can damage the presses and addi-
tional equipment.
Relevant pictograph with signal word:

Caution – <short description of the

hazard>

Example:

Caution – Damage and malfunction

on electrical devices due to electro-
magnetic interference!
Third-party equipment used on the print-
ing press must not cause any malfunc-
tions in the electronic system of the
printing press or of the third-party equip-
ment.
Third-party equipment may only be oper-
ated if it conforms to the EMC require-
ments in accordance with EN 50081,
part 1 and EN 50082, part 2, if this was
certified by an authorized office of the
manufacturer and if it is labelled with the
CE sign.
Prior to the installation of third-party
equipment, suitable EMC measures
must be carried out which must always
be coordinated with the Heidelberg Ser-
vice.

A.1.4
 Important notes for the user

Third-degree notes

Meaning:
This message gives you additional information and
provides tips for operating printing presses as well as
additional equipment.
Relevant pictograph with signal word:

Note

Example:

Note

A series transformer is supplied together with the

printing press.

1.2 Delivery and installation of the printing press

Unloading and internal transport of press com-

ponents

D For the unloading work from the transport ve-

hicle and subsequent transport inside the print-
shop, a Heidelberg service technician must al-
ways be present.
D The operator must supply suitable lifting de-
vices and floor conveyors with sufficient loading
capacity.
D Press components must be transported in a
vertical position. Pallets, dispatch cases and
other packaging must therefore never be tipped
over!
D To guarantee efficient assembling of the press,
press components must not be stored prelimi-
narily on the future installation site.

Note

For your orientation when you unload

and put the press components in place,
the labels on the shipping crates (over-
seas packaging) are always at the oper-
ator’s side O.S.

Storage of press subassemblies

D For intermediate storage the press subassem-

blies must be stored in a dry environment.
D The ambient temperature must be between a
minimum of –20 oC (–4 oF) and a maximum of
+50 oC (122 oF).

A.1.5
Important notes for the user

D The relative air humidity must not be higher

than 90%.
D Roller sleeves must be protected from UV and
thermal radiation.

Installation and modification of the printing press

D The various press subassemblies are covered

with a protective foil. The protective foil must
only be opened and removed at the future print-
ing press location when a balance in the tem-
perature of the press and the room has oc-
curred. The temperature will have assimilated
not earlier than 12 hours after bringing the sub-
assemblies into the pressroom.
D When installing the press as well as its other
equipment the prescribed exit and safety routes
must be kept free.
D All the required work for installing the printing
press as well as supply facilities (electrical, wa-
ter and compressed-air supply etc.) must only
be carried out by qualified, specially trained
staff.

D The equipment supplied with the printing press

may only be used for correct installation and
usage.
D Water and air hoses as well as electrical supply
lines must be installed in a way that they do not
obstruct and are protected from damage. The
mentioned supply lines should, if possible, be
laid on cable and hose bridges.

Attaching or installing non-Heidelberg devices

Warning – Danger from attaching or

installing third-party devices!
Attaching or installing third-party de-
vices can lead to fatal injuries as well
as serious damage to the press and its
equipment.
Therefore Heidelberger Druckmaschi-
nen AG accepts no warranty or liability
for personal injury or press damage
and neither for defects caused by at-
taching or installing third-party devices.

A.1.6
 Important notes for the user

1.3 Operation of the printing press

General information

The printshop operator or the management of the

printshop are responsible for all working areas in the
company. Therefore they must ensure that the
following operating conditions are adhered to:

D The press may only be operated by specially

trained and qualified staff who have received
special training at the press with all its addi-
tional devices.
D The following documentation must always be
kept at the press location and be accessible to
all authorized people:
D The operating manual for the press.
D Operating manuals and instructions for
additional devices which are directly and
functionally connected with the Speedmas-
ter.
D The safety data sheets for all chemicals
used in the printing press.

D Every authorized person who operates the

printing press and its additional devices must
have read and understood the operating manu-
als. All safety information and instructions must
be followed.
D The safety devices on the press must never be
removed, manipulated or bypassed. Their func-
tioning must be checked daily.
D After you have switched on the press, the soft-
ware of the press control system carries out a
self-test. Error messages displayed during this
procedure must be observed.

D For all work with and at the printing press the

following safety measures must be followed and
the necessary protective equipment must be
made available and used. This includes:
D Wearing close-fitting work clothes and
safety shoes.
D If necessary, wearing a hairnet.
D Wearing protective gloves when handling
chemicals.
D Removing rings, watches and other
jewellery.

D Naked flames or other flammable sources are

absolutely not permitted. There is a total ban on
smoking in the pressroom!

A.1.7
Important notes for the user

D Good pressroom ventilation must be ensured.

Observe the pertinent explosion prevention
measures, when working with explosive materi-
als (e.g. alcohol).
D The operating staff for the press must receive
an internal safety training at regular intervals.
Among other topics, the training must cover the
following subjects:
D Safe work at the printing press.
D Safe handling of chemical substances
such as oils, greases, inks, varnish, flam-
mable liquids, etc.
D Information and measures for an environ-
mentally friendly disposal of problematic
substances (e.g. ink residues, solvents,
etc.).

D Independent constructional modifications to the

Speedmaster and the additional devices as well
as modification of the accompanying software
are forbidden!

D The printing chemicals used must have a mini-

mum flash point which is above the following
temperatures:
D Inks:
> 100 oC (> 212 oF)
D Varnishes:
> 55 oC (> 131 oF)
D Cleaners:
> 55 oC (> 131 oF).

Printing chemicals of danger class A1 and A2 must

not be used on the printing press.

D Grinding, soldering and welding work in the

pressroom may only be carried out when rele-
vant safety measures are taken. Otherwise
there might be a possible danger of fire or ex-
plosion!
D The applicable documents and the safety in-
structions contained therein must also be ob-
served.

Before starting work

Before starting work you must always check whether

D the CP2000/ CPTronic and CPC devices can be

started;
D the cooling system is switched on and the hose
connections are in proper condition;

A.1.8
 Important notes for the user

D all mechanical and electrical safety and protec-

tive devices are firmly mounted, functional and
in a suitable position. In particular this includes
the following safety devices:
D guard covers;
D emergency stop switch on the press;

D no foreign bodies are in the printing press or

can get into the device during operation.

The Speedmaster must only be put into operation

when all a.m. points have been fulfilled and there are
no faults obvious to the operator.
During operation

D Do not put down any spray cans or containers

of volatile or flammable cleaners in the area of
the Speedmaster!
This can be harmful to your health! Additionally
there is a danger of fire!
D Always keep control cabinets and casings
closed during operation!
D The printing press must always be supervised
by an authorised person during operation!
D Keep unauthorized people out of the printing
press area!
D When the protection grids are open certain
printing press movements are possible.
Negligence can result in crushing fingers!
D Never cover or unscrew grid covers on ventila-
tor rails.
Danger of overheating and injury!
D Any waste occurring (e.g. ink residues, contam-
inated dampening solutions etc.) must be dis-
posed of according to the relevant environmen-
tal regulations.

In case of malfunction or failure of a safety de-

vice

D Shut down the press immediately and secure

against switching back on!
D Notify the Heidelberg service.

After finishing work and for longer breaks in op-

eration

D Switch off the Speedmaster with the main

switch on the control cabinet.

A.1.9
Important notes for the user

Maintenance work and repairs

Warning – Electrical shock when

touching voltage-carrying parts!
Turning off the main switches on the
central control cabinet ZSG and on the
dryer cabinet does not de-energize the
units!
To de-energize the central control cabi-
net and the dryer cabinet, their mains
connections must be separated from
the power supply!
This work may only be initiated by the
user or management of the print shop
and may only be carried out by quali-
fied personnel.

D Maintenance work and repairs may only be car-

ried out by the authorized Heidelberg service
unless anything else is expressly described.
D When exchanging defective parts or press com-
ponents only original Heidelberg spare parts
must be used.
Regarding wear parts such as suction tapes or
CPC ink fountain liners, only original Heidelberg
spare parts must be used.
For consumables and materials such as filter
inserts or washup solutions, only quality parts
or quality materials should be used, which are
offered by the Heidelberg service or by special-
ized dealers.

D All safety devices must be checked for perfect

function at regular intervals.
D Rollers which may be removed by the operator
must be stored on suitable racks on their jour-
nals.

Note

Additional device-related safety informa-

tion can be found at the appropriate
places in the Operating Manual that was
supplied with the printing press.

1.4 Disassembling (demounting) the printing press

D To disassemble the printing press, all supplies

(electricity, water, air) must be disconnected.
Pressurized devices must be switched to a de-
pressurized state.
D The following substances and items must be
removed from the press and the peripheral
equipment and be disposed of in an environ-
mentally-friendly manner in suitable packaging:

A.1.10
 Important notes for the user

D Oils, greases, inks, dampening solutions,

washup solutions and other residues.
D Collection containers installed on the press
for contaminated washup solutions, etc.
D Dirty filters and filter inserts.

1.5 Intended use

D The Speedmaster is a sheet-fed offset press,

which is suitable for printing tabular, flexible
printing materials with the following characteris-
tics:
D Thickness of the printing material:
max. 0.8 mm ( 0.031 in) for SM 102
max. 1.0 mm (0.039 in) for CD 102
D Print format:
max. 720 x 1020 mm
(max. 28.35 x 40.16 in).

D The Speedmaster may only be operated and

used by specifically trained qualified staff.
D The correct use and operation of the Speed-
master must only be effected from the following
work places:
D CP2000 centre or CPTronic central control
console;
D CPC 1-04 control console;
D Control consoles and control panels on the
printing press;
D footsteps and footboards (bulb plates) on
the printing press;
D area at the feeder which supplies printing
material;
D area at the delivery for removing printing
material.

D All operator activities on or with the Speedmas-

ter other than those described above and in the
operating manual are not correct and therefore
not permitted!
D Improper use of the Speedmaster can lead to
health risks and fatal danger as well as to seri-
ous damage to the printing press and its equip-
ment. Furthermore, any claim of warranty or
liability towards Heidelberger Druckmaschinen
AG expires.

A.1.11
Important notes for the user

1.6 Warranty and liability

Warranty and liability claims are always excluded if

personal injuries or material damage is due to an
external effect, overdue maintenance work, or force
majeure.
A possible claim for warranty and liability requires
conformity to the following points:

D Relevant national regulations such as safety,

accident prevention and environmental regula-
tions must absolutely be observed.
D Initial installation, alteration, disassembly and
maintenance of the device may only be carried
out by the authorized Heidelberg service.
D The Speedmaster may only be put into opera-
tion according to the Chapter ”Intended Use”.

A.1.12
 Chapter overview

Measures to prepare the press site

1 Building structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3

1.1 Space requirement and room height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
1.2 Floors, ceilings and floor coverings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
1.3 Supply and disposal conduits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
1.4 Outside and inside walls and door openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.4
1.5 Air conditioning and ventilation in the pressroom . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.4

2 Power Supplies and Supply Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.6

2.1 Electrical Power Supply – Mains Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.6
2.2 Water Supply and Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.6
2.3 Compressed-Air Supply and Compressed-Air Conditioning . . . . . . . . . . . . . . . . . . . . A.2.7
2.4 Suction and Blast Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.8

3 Printshop Planning Department of Heidelberger Druckmaschinen AG . . . . . . . .

A.2.9
3.1 Print Shop Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . . . A.2.9

A.2.1
Chapter overview

A.2.2
 Measures to prepare the press site

1 Building structures
UTKSC9063202001000000

1.1 Space requirement and room height

The space required for printing press, additional de-

vices and peripheral equipment can be found in the
floor plan drawings and the technical specifications
of the peripheral equipment.
There you can also find the individual additional dis-
tances that are required for carrying out the service
and repair work.
In general, good access to the printing press compo-
nents and a satisfactory flow of materials should be
provided.

D Clear height of the pressroom (excluding low-

ered ceilings and double floors):
approx. 4000 mm (158 in) to 5500 mm (217 in).
D Basically: The larger the room volume (air vol-
ume), the more stable the room climate.

1.2 Floors, ceilings and floor coverings

In this context, a decision must be made with respect

to the type of the (industrial) screed that is to be laid.
As a basic rule please note: For great flexibility re-
garding printshop expansions and modernization, the
load carrying ability for floors and ceilings should be
as high as possible.
There are many selection criteria regarding the
selection of the floor. These include in particular a
large oil resistance and abrasion resistance as well
as suitable anti-static properties.
Specialists should be contacted in time to obtain a
precise picture of costs, service life, repair options,
necessary maintenance and exchangeability.

Standard values

D Carrying capacity of floor and ceiling in the

pressroom: approx. 3000 kg/m2 (615 lbs/sq ft).
D Compressive load per unit area at the fork lift
wheel when piles on pallets are transported: up
to 450 N/cm2 (653 lbf/sq in).

1.3 Supply and disposal conduits

It is not advisable to lay the supply and disposal con-

duits for supply lines (electrical energy, water, air,
etc.) in the floor as they restrict the flexibility of the
printing press location.

A.2.3
Measures to prepare the press site

Instead it is recommended to use cable and hose

bridges (extra accessory) which cover the supply
lines and reduce the risk of tripping to a minimum.

1.4 Outside and inside walls and door openings

The layout of the outside and inside walls should be

adapted to the local climate and to the specific re-
quirements of the print shop.
During the operation of the printing press, depending
on the printing press model, medium to large quanti-
ties of heated air are brought into the pressroom.
There should be suitable air openings in the walls
and doors to ensure balanced air pressure condi-
tions.
These points should be discussed in detail between
the commissioned architect, builder and Heidelberg
Service.
The same applies for transporting the printing press
out of the print shop building.
For dimensions and weights of the packing cases of
the press as well as of the peripheral equipment
please refer to publication ”Technical Specifications”.
It must be clarified with the branch office or repre-
sentation whether existing wall openings are large
enough for the printing press to pass.

D The height of the transport machines that move

the components of the printing press and pe-
ripheral units into or out of the print shop build-
ing must always be taken into account.

1.5 Air conditioning and ventilation in the pressroom

The room air conditioning must be adapted to the

local climate and to the specific requirements of the
print shop.
A suitable air circulation must be ensured to obtain a
healthy indoor atmosphere and to reduce the energy
costs. This can, for example, be achieved by in-
stalling air circulation devices (air-conditioning) with
a heat exchanger.
A balanced, constant room atmosphere helps to
minimize interruptions to production.
It is recommended to consult the commissioned ar-
chitect or heating/ventilation engineer for a detailed
planning.

A.2.4
 Measures to prepare the press site

Standard values

D General dust level limit in the room air:

<6 mg/m3
(with a particle diameter of <10 mm)
D Ideal room air temperature (depending on activ-
ity): 18 oC ... 21 oC (64 oF ... 70 oF);
Maximum room air tempera-
ture: 40 oC (104 oF).
D Room air humidity (depending on printing mate-
rial): 50% ... 58%
D Air speed (e.g. through air-conditioning):
<0,2 m/s (<0.65 fps).

A.2.5
 Measures to prepare the press site

2 Power Supplies and Supply Lines

UTKSC9063203000000000

2.1 Electrical Power Supply – Mains Connection

Caution – Damage and malfunction

on electrical devices due to insuffi-
ciently dimensioned mains!

The dimensions of the mains connection

must be determined in time by the print
shop manager in cooperation with the
local energy supply company.
This must also be done if an old printing
press is replaced with a new one. This
may require different power ratings to be
provided.

Running the connection cables overhead in power

cable ducts and/or on cable trays has proved useful
in practice.
Chapter ”Electrical installation of the printing press”
provides you with planning and decision support by
listing the required power supply values for each
press model.

Standard values

D Cross-section of the conductor terminals in the

central control box ZSG: see Chapter ”Cross-
Section of the Conductor Terminals in the Cen-
tral Control Box ZSG”.
D Cross-section of the conductor terminals in the
series transformer: see Chapter ”Cross-Section
of the Conductor Terminals at the Series Trans-
former”.

2.2 Water Supply and Conditioning

Please contact the local water utility to find out

whether or not the water for the printing press opera-
tion requires special treatment.
If the substances contained in the water (for example
carbonates, oxides, metallic salts, etc.) exceed cer-
tain limits, the installation of a water conditioning fa-
cility is necessary to prevent malfunctions.
One of the criteria for water quality is the water hard-
ness. For a water hardness from approximately
12o dH (8.1 mmol/USgal) onwards, the installation of
a water softening unit must be decided from case to
case. For a water hardness above 18o dH
(12.1 mmol/USgal), the installation of a water soften-
ing unit is absolutely necessary.

A.2.6
 Measures to prepare the press site

Standard values

D Water hardness:
8o ... 12o dH (5.4 ... 8.1 mmol/USgal).
D pH value:
4.8 ... 5.5.

Note

Further information regarding the water hardness is

detailed in Chapter ”Definitions”.

2.3 Compressed-Air Supply and Compressed-Air Conditioning

Normally, compressed air is generated by a com-

pressor station which is supplied with the press. For
technical specifications refer to Chapter ”Pneumatic
compressors”.
When planning the pressroom a sufficient and ap-
propriate supply of fresh air for filtering of com-
pressed-air must be considered.
If a compressor station with air filter station and com-
pressed-air ductwork system already exist in the
printshop, the pneumatic system for the printing
press can possibly be connected to it. In this case
the compressor station is not needed. For further
information refer to Chapter ”Installation of the air
supply”.

Standard values

D Operating pressure (excess pressure):

min. 7 bars ... max. 10 bars
(min. 102 psi ... max. 145 psi).
D Air volume flow:
depending on the press model
min. 200 l/min ... min. 350 l/min
(min. 12210 cu in/min ... min. 21360 cu in/min)
for 7 bars (102 psi) excess pressure
(see Chapter ”Compressed-air supply (high
pressure)”, table).
D Air intake temperature:
min. 0 oC (32 oF)
max. 40 oC (104 oF).
D Maximum oil content of the air:
1 mg/m3 (per standard cubic meter atmospheric
air).
D Maximum water content of the air:
5.9 g/m3 for 7 bars (102 psi) excess pressure
(corresponds to dew point for +3 oC (+37 oF)).

A.2.7
Measures to prepare the press site

D Solid content of the air:

Particle size max. 5 mm
Particle number density max. 5 mg/m3.

2.4 Suction and Blast Air Supply

Normally, the suction and blast air is produced via an

air supply unit supplied with the printing press. For
further information refer to Chapter ”Air supply units”.
When planning the pressroom, a sufficient and ap-
propriate fresh air supply for conditioning of suction
and blast air as well as for the cooling of aggregates
must be considered.
If an air supply unit and an air distribution system
already exist in the printshop, the suction and blast
air system of the printing press can possibly be con-
nected to it. In this case the air supply unit is not re-
quired.
The generation of blast air through an expansion
process of the compressed air using ejectors is defi-
nitely not recommended. This would mean high in-
vestment costs and also high energy costs.
Standard values

D Blast air conditioning:

Dry, oil-free, filtered, condensate-free air.
D Operating pressure (absolute pressure):
depending on the press model min. 0.4 bars ...
max. 2.0 bars
(min. 5.8 psi ... max. 29.0 psi)
(see Chapter ”Suction and blast air supply (low-
pressure)”).
D Air volume flow:
D The maximum pressure values should not
be more than 10% above the typical press
standard values (see Chapter ”Suction and
blast air supply (low-pressure)”).
D It should be possible without any problems
to compensate pressure fluctuations of up
to +/– 10%. Also the air hoses should be
designed accordingly.

D Air temperature (process air):

60 oC (140 oF) ... max. 85 oC (185 oF).
D Solid content of the air:
Particle size: max. 10 mm;
Particle number density: max. 10 mg/m3.

A.2.8
 Measures to prepare the press site

3 Printshop Planning Department of Heidelberger Druckmaschinen AG

UTKSC9063204000000000

3.1 Print Shop Planning Department of Heidelberger Druckmaschinen AG

When planning the building, reconstruction, or exten-

sion of printshops, Heidelberger Druckmaschinen
AG offers a special service worldwide.
The Heidelberg printshop planning department offers
manifold assistance for the following crucial points:

D Preplanning for building

D Function planning
D Work and material flow (logistics)
D Building and domestic technique
D Public supply facilities for the printing press
(electricity, water, air, etc.).

In general, the costs for the mentioned services are

only between 0.2% and 1.0% of the total construc-
tion costs, depending on the company size and ex-
tent of service.
Building planning such as drafts, producing building
documents, model drawings, relevant cost calcula-
tions, etc. must be carried out by architects in coop-
eration with specialist engineers for statics, heating
and ventilation, electrics, etc.
This work cannot and may not be taken over by the
Heidelberg Print Shop Planning department.
Address:
Heidelberger Druckmaschinen AG
Print Shop Planning
Kurfürsten-Anlage 52-60
69115 Heidelberg
Germany
Phone +49-(0)6221/92-0

A.2.9
Measures to prepare the press site

A.2.10
 Chapter overview

Elevated printing press

1 Building and installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.3

1.1 Building and installation work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.3

2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.4

2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.4

3 Foundation strips for the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.6

3.1 Elevation by 300 mm (11.81 in) or 500 mm (19.69 in) . . . . . . . . . . . . . . . . . . . . . . . . A.3.6
3.2 Elevation by 700 mm (27.56 in) or 900 mm (35.43 in) . . . . . . . . . . . . . . . . . . . . . . . . . A.3.7
3.3 Weight calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.7
3.4 Making foundation strips directly in the pressroom . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.8
3.5 Making and installing foundation segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.10

4 Bottom plates for collecting lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.13

4.1 Bottom plates for collecting lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.13

5 Motor Mounting Base for the Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . A.3.15

5.1 Motor Mounting Base for the Main Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.15
5.2 Layout with a Foundation Height of 300 mm (11.81 in) or 500 mm (19.69 in) . . . . . A.3.16
5.3 Layout with a Foundation Height of 700 mm (27.56 in) or 900 mm (35.43 in) . . . . . A.3.17
5.4 Weight Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.18
5.5 Installation of the Pre-Manufactured Motor Mounting Base . . . . . . . . . . . . . . . . . . . . A.3.19

6 Stairs, catwalks, platforms and railings . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.20

6.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.20
6.2 Overview of applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.20
6.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.21
6.4 Design of foot steps and stairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.22
6.5 Design of catwalks and platforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.23
6.6 Design of railings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.25
6.7 Additional platform for elevated CP2000 and CPC devices . . . . . . . . . . . . . . . . . . . . A.3.27

7 Guards on the Elevated Printing Press . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.28

7.1 Guarding Feeder and Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.3.28
7.2 Safeguarding the Areas Under the Catwalks, Platforms and Stairs . . . . . . . . . . . . . A.3.28

A.3.1
Chapter overview

A.3.2
 Elevated printing press

1 Building and installation work

UTKSC9063400001000000

1.1 Building and installation work

Warning – Danger in case of im-

properly performed construction
and installation work!
Planning and any other work that con-
cern the elevation of the printing press
must be initiated by the printshop user,
and may only be carried out by quali-
fied experts. Relevant national provi-
sions must also be observed!

A.3.3
 Elevated printing press

2 General information
UTKSC9063401001000000

2.1 General information

Purpose

By elevating the printing press on two special strip

foundations, higher piles of print material can be
used in the feeder and delivery.
Additionally there is the possibility of a fully auto-
matic pile change with the Heidelberg Logistics sys-
tem when elevating the press by at least 300 mm
(11.81 in).

Prerequisite

Specifically adapted feeders and deliveries are avail-

able from Heidelberg as accessories for elevated
machines.
Only printing presses which are equipped with Pre-
set feeders can be elevated.
Structural inspections of press foundations, motor
mounting bases and printshop buildings may only be
carried out by a structural engineer.
For elevated printing presses no oil drip pans for the
floor space between the foundation strips are in-
cluded in the delivery. It is recommended to lay a
suitable floor covering in this area. This includes for
example tiles or an epoxy-coated floor covering.
The maximum pile weight on feeder and delivery
must not exceed the following values:

D 1100 kg (2425 lbs) for printing presses without

Heidelberg Logistics;
D 1000 kg (2200 lbs) for printing presses with
Heidelberg Logistics.

A.3.4
 Elevated printing press

Possible heights

It is possible to elevate the printing press by the

following values:

Elevated by Printing press

[mm] ([in]) model
without logis- with logistics
tics
300 (11.81) * *
500 (19.69) * *
700 (27.56) *
900 (35.43) *
Tab. 1 Possible elevations of the printing press

* Elevation possible
Necessary additional equipment

The following additional equipment must be planned

and installed for elevated presses according to
Heidelberg specifications:

D Strip foundations for the installation of the press

(see Chapter ”Foundation Strips for the Printing
Press”).
D Oil drip pans for collecting small amounts of
lubricants released during the operation of the
press (see Chapter ”Bottom Plates for Collect-
ing Lubricants”).
D Motor mounting base for installing the main
drive (see Chapter ”Motor Mounting Base for
the Main Drive”).
D All stairs, catwalks and railings in the area of
the press, with the exception of the catwalks
and stairs on drive side D.S. (see Chap-
ter ”Stairs, Catwalks, Platforms and Railings”).
D Safeguarding of service openings on operator’s
side O.S. (see Chapter ”Safeguarding of Ele-
vated Printing Presses”).

The following parts are offered by Heidelberg as ex-

tra accessories for elevated printing presses:

D Foundation strip segments for elevating the

press by 300 mm (11.81 in) or
500 mm (19.69 in).
D Oil drip pans for strip foundations.
D The necessary motor mounting base.

A.3.5
 Elevated printing press

3 Foundation strips for the printing press

UTKSC9063402001000000

3.1 Elevation by 300 mm (11.81 in) or 500 mm (19.69 in)

Possible models

Depending on requirement, the foundation strips can

be produced as continuous strips or in segments.
The decision as to whether use complete strips or
single segments depends primarily on the composi-
tion of the floor at the future location of the printing
press.
The installation of complete strips can for example
be advantageous if the print shop floor has one or
several expansion joints in the future installation site.
It is absolutely necessary to consult a structural engi-
neer.

Possible production methods

These foundation strips can be produced or supplied

as follows:

D Direct production (reinforcing, lining and cast-

ing) in the pressroom.
D Production in accordance with Heidelberg spec-
ifications in a concrete factory.
D Direct order from Heidelberg.

Note
Depending on the type of concrete, it
takes between 10 and 14 days until the
foundation strips in the pressroom are
hard. This must be taken into account in
the time schedule of the press installa-
tion.

A.3.6
 Elevated printing press

3.2 Elevation by 700 mm (27.56 in) or 900 mm (35.43 in)

Possible models

Stability reasons require the foundation strips to be

made as a continuous strip.
It is absolutely necessary to consult a structural engi-
neer.

Possible production methods

These foundation strips can only be made on site

(reinforcement, forming, and casting in the press-
room).
Depending on the type of concrete, it takes between
10 and 14 days until the foundation strips in the
pressroom are hard. This must be taken into account
in the time schedule of the press installation.

3.3 Weight calculation

For all concrete building work it is recommended that

heavy-duty concrete of the concrete property class B
35 is used.
Parameters of heavy-duty concrete of the concrete
property class B 35:
Concrete group: B II
Density:
approx. 1.9 ... 2.8 kg/dm3 (0.067 ... 0.101 lbs/cu in)
Nominal compressive strength:
bWN = 35 N/mm2 (bWN = 5080 lbf/sq in)
Series compressive strength:
bWN = 40 N/mm2 (bWN = 5080 lbf/sq in).
The mass of one cubic meter of hardened cement of
the cement property class B 35 is approx. 2500 kg
(5510 lbs). An average density of 2.5 kg/dm3
(0.090 lbs/cu in) is assumed here.
The following table shows the mass of each metre of
a foundation strip made from the above-mentioned
concrete type:

A.3.7
Elevated printing press

Technical specifications of the foundation

strips
Height Width Mass per
[mm] ([in]) [mm] ([in] meter
[kg/m] ([lbs/ft])
300 (11.81) 300 (11.81) 225 (150)
500 (19.69) 300 (11.81) 375 (250)
700 (27.56) 350 (13.78) 615 (410)
900 (35.43) 350 (13.78) 790 (530)
Tab. 2 Technical specifications of the foundation
strips

Note
Static calculations must take into ac-
count that the density and, consequently,
the mass of the foundation strips can
vary considerably according to the type
of concrete and the gravel proportion.

3.4 Making foundation strips directly in the pressroom

When foundation strips are produced in the press-

room, the following points are to be taken into ac-
count:

D Dimensions of the foundation strips: see Chap-

ter ”Dimensions”.
D Recommended concrete property class: B 35.
Parameters of the concrete: see Chapter
”Weight Calculations”.
D Prior to making the foundation strips ensure
that there is an adequate foundation all over the
potential installation area of the printing press.
The weights of the foundation strips must be
considered, particularly if there are critical floor
loads and ceiling load capacities. Inspection by
a structural engineer is absolutely necessary.
GR SG9043400000000000

D The diagonal height deviation for both founda-

max. 10 mm tion strips must not exceed 10 mm (0.39 in).
(max. 0.39 in)
D To provide for an appropriate installation of
cables and hoses, the foundation strips should
have circular openings. Depending on the rein-
forcement, the openings should have the
following diameter:

Fig. 1 Maximum diagonal height deviation of

both foundation strips

A.3.8
 Elevated printing press

Height of the founda- Diameter of the open-

tion strips [mm] ([in]) ings [mm] ([in])
300 (11.81) 100 ... 120
(3.94 ... 4.72)
500 (19.69) 150 ... 180
(5.91 ... 7.09)
700 (27.56) 150 ... 180
(5.91 ... 7.09)
900 (35.43) 150 ... 180
(5.91 ... 7.09)
Tab. 3 Diameter of the openings

D The steel reinforcements in the foundation strip

segments should end on the side turned to-
wards the feeder approx. 150 to 200 mm
(approx. 5.91 to 7.87 in) before the strip end.
This facilitates the production of bore holes re-
quired to affix the feeder.
D The hardening time of the cement must be
taken into account.
D When the press is elevated by 700 mm
(27.56 in) or 900 mm (35.43 in), the two founda-
tion strips must be stabilized with crosstie rods
(threaded rods, for example).
D All dimensions that concern the crosstie rods
are shown in Figure 2. The distance between
two crosstie rods is always 2440 mm (96.06 in).
D Up to the CD 102-2 unit, the distance between
the first and second cross bar is exceptionally
1220 mm (48.03 in).

A.3.9
Elevated printing press

GR SC9063412000000000
AS

BS

Ø 20 / 24
(Ø 0.79 / 0.94)

2440 (96.06)
150 (5.90)
Ø 25 / 30
(Ø 0.98 / 1.18)
100 (3.94) 2440 (96.06)
( CD 102-2:
100 (3.94) 1220 (48.03))

1140 (44.88)

Fig. 2 Crosstie rod for stabilizing the foundation strips upon an elevation by 700 mm (27.56 in) or
900 mm (35.43 in) (example of the foundation strip for the CD 102-5 + L unit). All dimensions in
mm (in).

D The number of crosstie rods for series printing

presses is between a minimum of two
(CD 102-1 + L) and a maximum of six
(CD 102-8 + LX).
D To be able to lead the threaded rods through
the foundation strips, openings of a diameter of
25 mm (0.98 in) or 30 mm (1.18 in) must be
provided. This can be done by casting-in con-
duits whose protruding ends are cut after the
concrete has hardened.
D We recommend threaded rods of a diameter of
20 mm (0.79 in) or 24 mm (0.94 in) and a mini-
mum quality of 8.8 to be used for propping. Us-
ing flange plates and nuts, these rods are
screwed at the foundation strips. At the outside
of the foundation strips, each nut must be
locked with a second nut.

3.5 Making and installing foundation segments

When the machine is elevated by 300 mm (11.81 in)

or 500 mm (19.69 in), the foundation strips may also
be made in segments.

A.3.10
 Elevated printing press

When ordering and installing prefabricated founda-

tion strip segments, make sure to observe the
following points:

D Recommended concrete property class: B 35.

Parameters of the concrete: see Chapter
”Weight Calculations”.
D Prior to setting the premanufactured foundation
strip segments, ensure that there is an ade-
quate foundation all over the potential installa-
tion area of the printing press.
The weights of the foundation strip segments
are to be taken into account particularly for criti-
cal floor loads and ceiling load capacity.
Inspection by a structural engineer is absolutely
necessary.
D The individual foundation strip segments must
join together lengthwise so that there are no
gaps.
D The actual height of the foundation strip seg-
ments must always be 20 mm (0.79 in) lower
than the nominal height:

Nominal height of the Actual height of the

foundation strips segments
[mm] ([in]) [mm] ([in])
300 (11.81) 280 (11.02)
500 (19.69) 480 (18.90)
Tab. 4 Nominal height of the foundation strip and
actual height of the segments

D The 20 mm (0.79 in) that are missing to the full

nominal height are compensated by cement or
washed-in material when the foundation strip
segments are set.

A.3.11
Elevated printing press

D To ensure appropriate installation of cables and

hoses, the foundation strip segments should
have circular openings. Depending on the rein-
forcement, the openings should have the
following diameter:

Height of the founda- Diameter of the open-

tion strips [mm] ([in]) ings [mm] ([in])
300 (11.81) 100 ...120 (3.94 ... 4.72)
500 (19.69) 150 ... 180 (5.91 ... 7.09)
Tab. 5 Nominal height of the foundation strips and
diameter of the openings

D The steel reinforcements in the foundation strip

segments should end on the side turned to-
wards the feeder approx. 150 to 200 mm
(approx. 5.91 to 7.87 in) before the strip end.
This makes it easier to set the boreholes that
are required for fixing the feeder. The concrete
builder must make a visible mark at the founda-
tion strip segment that faces the feeder.
GR SG9043400000000000

D The diagonal height deviation for both founda-

max. 10 mm tion strips must not exceed 10 mm (0.39 in).
(max. 0.39 in)

Fig. 3 Maximum diagonal height deviation of

both foundation strips

A.3.12
 Elevated printing press

4 Bottom plates for collecting lubricants

UTKSC9063403001000000

4.1 Bottom plates for collecting lubricants

During printing press operation small amount of lubri-

cants are released (especially press oil). Press oil
which penetrates the foundation strips makes the
cement brittle over time and reduces its resistance.
Therefore those areas of the foundation strips partic-
ularly exposed must be protected from the oil with
cover plates. This especially affects the surface and
partly the side areas of the foundation strips.

D Heidelberg offers premanufactured bottom

plates for the standardized foundation strips.
Each bottom plate has a raised edge on all four
sides. The frame height is 25 mm (1 in) or
40 mm (1.57 in).
At the front, the bottom plates are screwed to-
gether with threaded tubes through which the
machine oil can flow, if necessary.
In each case, the first and the last bottom plates
are equipped with a drain tube and a stop-cock.
This allows to drain the collected machine oil
into a canister or some similar container.
D The bottom plates can, however, also be pro-
duced by a tinsmith according to the following
specifications and the following figure:
D Corrosion-proof plates (e.g. galvanized
steel plate) or special steel plates should
be used as the material for cover plates
and collection containers.
D To reduce the risk of injury during cleaning
work or similar, all plate edges must be
trimmed and flattened down.

D For elevated presses, no bottom plates for the

floor space between the foundation strips are
supplied. It is recommended to lay a suitable
floor covering in this area. This includes for ex-
ample tiles or an epoxy-coated floor covering.

A.3.13
Elevated printing press

GR SC9063401000000000
DS
1255 (49.41)

1220 (48.03)

1220 (48.03)

O 1220 (48.03)
S 102,5 (4.04)
1210 (47.64)

505 (19.88)
102,5 (4.04) 745 (29.33)

25 (0.98)
40 (1.57)

277 (10.91)
565 (22.24)
Fig. 4 Layout of bottom plates; example of the foundation strips for the elevated CD 102-4 + LX,
500 mm (19.69 in) unit. All dimensions in mm (in).

A.3.14
 Elevated printing press

5 Motor Mounting Base for the Main Drive

UTKSC9063404000000000

5.1 Motor Mounting Base for the Main Drive

For raised printing presses the main drive is

mounted on a separate base.

Notes

D Due to technical reasons, the motor mounting

base cannot be mounted before the installation
of the printing units.
D The installation of the main drive on a steel sup-
port frame is not permitted!

Possible production methods

The mounting procedure requires the motor mount-

ing base to be completely premanufactured as a
single element.
Thus the motor mounting base can be produced or
supplied as follows:

D Production in accordance with Heidelberg spec-

ifications in a concrete factory.
D Direct order from Heidelberg.

Possible heights for the motor mounting base

The height of the motor mounting base must be iden-

tical to the selected height of the foundation strips.
Thus motor mounting bases can have the following
heights:

D 300 mm (11.81 in);

D 500 mm (19.69 in).
D 700 mm (27.56 in);
D 900 mm (35.43 in).

A.3.15
Elevated printing press

5.2 Layout with a Foundation Height of 300 mm (11.81 in) or 500 mm (19.69 in)

GR SG9043402000000000
300 (11.81)/
500 (19.69)

30 (1.18)
Threaded insert Through bore O.S.
M20 Ø 25 (1.0)

1000 (39.37)
300
(11.81) D.S.

150 (5.9)

150 (5.9)
300 (11.81)
250 (9.84)
1000 (39.37)

Fig. 5 Dimensioning and installation of the motor mounting base – height 300 mm (11.81 in) and
500 mm (19.69 in). All dimensions in mm (in).

Notes

D Using four threaded bolts (e.g. M20), the motor

mounting base must be fixed with shear con-
nectors in the pressroom floor. This requires
one through-hole (diameter: 25 mm)(1.0 in)) in
each of the four corners of the motor mounting
base.
D The motor mounting base must be made such
that it rests level on four feet (see Figure
above).
D To transport the motor mounting base (for ex-
ample using eye bolts and a spreader) the four
threaded inserts (for example M 20) must be
cast in on the upper side.

A.3.16
 Elevated printing press

5.3 Layout with a Foundation Height of 700 mm (27.56 in) or 900 mm (35.43 in)

GR SC9063413000000000
600 (23.62) 200 (7.87) Threaded
sleeve
M20

ÉÉÉÉÉÉ
700 (27.56)/

ÉÉÉÉÉÉ
900 (35.43)

ÉÉÉÉÉÉ
300 (11.81)/
Polystyrene
500 (19.69) 250

ÉÉÉÉÉÉ
core
(9.87)
150 (5.91)
O
30 (1.18) 100 S
Threaded insert (3.94)
M20

ÉÉÉÉÉÉ
200 (7.87)

ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
ÉÉÉÉÉÉ
Polystyrene 1000 (39.37)
600 (23.62)

ÉÉÉÉÉÉ
core
300 DS
ÉÉÉÉÉÉ
(11.81)

200 (7.87) ÉÉÉÉÉÉ 200

(7.87)

100 (3.94)
300 (11.81)
250 (9.84)
1000 (39.37)

Fig. 6 Dimensioning and installation of the motor mounting base – height 700 mm (27.56 in) or 900 mm
(35.43 in). All dimensions in mm (in).

Notes

D To save weight, the motor mounting base

should be cast around a polysterene core.
D Eight screw sockets (M20, for example) must
be included when the motor mounting base is
cast.
At the installation site, four U-shaped steel sec-
tions, each with a welded-on flange plate, must
be screwed onto these screw sockets.
Together with four bolts (M20, for example) and
shear connectors, the flange plates (with one
through-hole each) are used for attaching the
motor mounting base to the pressroom floor.

A.3.17
Elevated printing press

D The motor mounting base must be made such

that it rests level on four feet (see Figure
above).
D To transport the motor mounting base (for ex-
ample using eye bolts and a spreader) the four
threaded inserts (for example M 20) must be
cast in on the upper side.

5.4 Weight Calculations

For all cement building work, we recommend to use

heavy-weight cement of the cement property
class B 35 (parameters of the cement: see Chap-
ter ”Foundation Strips for the Printing Press / Weight
Calculations”).
The mass of one cubic meter of hardened cement of
the cement property class B 35 is approx. 2500 kg
(5510 lbs). An average density of 2.5 kg/dm3
(0.090 lbs/cu in) is assumed here.
The following table shows the mass of the motor
mounting base made from the above-mentioned con-
crete type:

Weights of the motor mounting base

Height [m Length Width Mass
m] ([in]) [mm] ([in]) [mm] ([in]) [kg] ([lbs])
300 1000 1000 750
(11.81) (39.37) (39.37) (1650)
500 1000 1000 1250
(19.69) (39.37) (39.37) (2760)
700 1000 1000 1400
(27.56) (39.37) (39.37) (3090)
900 1000 1000 1700
(35.43) (39.37) (39.37) (3750)
Tab. 6 Weights of the motor mounting base

Note

D The hardening time of the cement must be

taken into account.
D The mass values of the motor mounting base of
700 mm (27.56 in) or 900 mm (35.43 in) height
takes the embedded polysterene core into ac-
count (see Chapter ”Layout of the Motor Mount-
ing Base with a Foundation Height of 700 mm
(27.56 in) or 900 mm (35.43 in)”).

A.3.18
 Elevated printing press

5.5 Installation of the Pre-Manufactured Motor Mounting Base

D At the future location of the motor mounting

base, four holes must first be drilled in the floor
and be provided with suitable shear connectors
(for example M 20).
D With motor mounting bases of 300 mm
(11.81 in) or 500 mm (19.69 in) height, the
locations and distances of the boreholes in
the printshop floor correspond to the ones
of the through-holes in the motor mounting
base.
D With motor mounting bases of 700 mm
(27.56 in) or 900 mm (35.43 in) height, the
locations and distances of the boreholes in
the printshop floor correspond to the ones
of the flange plates that are fixed to the
motor mounting base.

D The motor mounting base must be screwed to

the shear connectors in the printshop floor us-
ing four threaded bolts (M20, for example) and
matching washers (minimum quality 8.8).

Note

In general, the main drive is mounted on the motor

mounting base by the Heidelberg service.

A.3.19
 Elevated printing press

6 Stairs, catwalks, platforms and railings

UTKSC9063406001000000

6.1 Warning

Warning – Improperly designed

stairs, catwalks and railings present
a hazard!
Planning and any other work that con-
cern the making of stairs, catwalks,
platforms and railings must be initiated
by the printshop user, and may only be
carried out by qualified experts.
In automated feeder and delivery
zones, ensure that there are no haz-
ardous crushing areas between pallets
and fixed components (such as cat-
walks, pillars, etc.) that may cause in-
juries during the delivery or removal of
printing material plates.

6.2 Overview of applicable standards

The recommendations in the following chapters

about stairs, catwalks, platforms and railings are
based on the following European standards.

D prEN 1010: Safety of machinery – Safety re-

quirements for the design and construction of
printing and paper converting machines.
Part 1: Common requirements.
Part 2: Printing and coating presses including
prepress machinery.
D prEN 12437: Safety of machinery – Means of
permanent access to machines and industrial
plants.
Part 2: Working platforms and catwalks.
Part 3: Stairs, step ladders and railings.

A.3.20
 Elevated printing press

6.3 General Information

GR SG9043403000000000
Fig. 7 Possible implementation of the elevation by 500 mm (19.69 in); example of the CD 102-4 + LX
unit. The shaded catwalks, platforms and stairs are special components whose design and
construction must be initiated by the user according to the Heidelberg specifications.

D The minimum headroom of all accessible areas

must be 2000 mm (78.74 in). This is of signifi-
cance for example when a cable bridge with
electric cables or supply lines is installed above
the printing press.
D The material used for stairs, catwalks, platforms
and railings should exclusively be sheet metal
(e.g. bulb plates) which prevents slipping.
D To be able to adjust catwalks, platforms and
stairs to the height of the printing press, as well
as level out unevenness in the floor, the height
of the supports must be adjustable.
The recommended adjustable height of a sup-
port which is 1000 mm (39.37 in) long should
be +/–40 mm (+/–1.57 in).

A.3.21
Elevated printing press

6.4 Design of foot steps and stairs

Foot steps

GR SG9043404000000000
Specifications for design and manufac-
ture

min. 500 mm D Minimum possible surface load along the bear-

(min. 19.69 in)
ing surface:
Fmin. = 1500 N Surface load of 1500 N (337 lbf) relative to a
(Fmin. = 337 lbf) 300 mm surface of 100 mm x 100 mm (3.94 in x 3.94 in).
(11.81 in)
D Minimum usable step width: 500 mm (19.69 in);
D Step depth: 300 mm (11.81 in);
D Maximum step height: 300 mm (11.81 in).
max. 300 mm
(max. 11.81 in)

Fig. 8 Design of foot steps

Stairs
GR SG9043405000000000

Specifications for design and manufac-

ture

D For a flight of stairs all steps must have identi-

cal step depths and heights.
D Maximum angle of inclination of the stairs: 45o.
D For stairs with a total height of more than
500 mm (19.69 in) it is necessary to provide a
railing with a handrail and a knee rail.
D The railing of stairs of an overall height of more
than 1600 mm (63.0 in) must have a bottom rail
max.
fitted (see also Chapter ”Design of Railings”).
45°
D The stairs width should correspond to the width
of the catwalk if possible.

Fig. 9 Design of stairs

A.3.22
 Elevated printing press

6.5 Design of catwalks and platforms

GR SG9043406000001000
min. 500 mm
(min. 19.69 in)

Fmin. = 1500 N
(Fmin. = 337 lbf)

min. 1000 mm
(min. 39.37 in)
ca. 300 mm
(ca. 11.81 in)

Fig. 10 Example of the design of catwalks and platforms

Specifications for design and manufac-

ture

D Minimum possible surface load: Surface load of

1500 N (337 lbf) relative to a surface of
200 mm x 200 mm (7.87 in x 7.87 in).
D Minimum usable width of catwalks and plat-
forms: 500 mm (19.69 in).
D For catwalks and platforms higher than 300 mm
(11.81 in) it is necessary to mount special foot
steps and/or stairs.
D For catwalks and platforms higher than 500 mm
(19.69 in) it is necessary to mount a railing with
a handrail and knee rail.
D The railing of catwalks and platforms of an
overall height of more than 1600 mm (63.0 in)
must have a bottom rail fitted (see also Chapter
”Design of Railings”).
D Main work places like for example in the feeder
and delivery zone or on the main control panels
must have a clear minimum surface of at least
1.5 m2 (16.15 sq ft). The minimum width must
be 1000 mm (39.37 in).

A.3.23
Elevated printing press

D Catwalks and platforms should be split up into

sections of 1220 mm (48.03 in) or a maximum
of 2440 mm (96.06 in). This ensures optimum
access to the printing units for maintenance and
service work.
D Safety reasons and better accessibility of the
control panel require a platform to be installed
at the end face of the delivery.
D There should be a foldable or movable platform
in the feeder area that permits two functions:
D When it is closed, adjustments on the suc-
tion head must be possible during produc-
tion;
D When it is open, pile changes must be
possible.

D For ergonometric reasons, the height of the

platforms at feeder and delivery should corre-
spond to the height of the strip foundations.
D Foldable or movable platforms (such as in the
feeder area) require the following safety-related
requirements to be fulfilled:
D Complying with stability requirements at
the above named surface load.
D Can be stopped both in an open as well as
closed state.
D Automatically operating brakes and fixing
devices for movable catwalks, to prevent
accidental travelling movements (for ex-
ample when operating staff are walking on
them).
D Flush with the feeder and delivery col-
umns.

A.3.24
 Elevated printing press

6.6 Design of railings

General Information

GR SG9043407000000000
Specifications for design and manufac-
ture of horizontal railings

Lmax. = 1500 mm
D Stairs and catwalks must be safeguarded with
(Lmax. = 59.06 in)
railings from a height of 500 mm (19.69 in) or
higher.
D Maximum spacing Lmax. between two railing
posts: 1500 mm (59.06 in).
D Diameter of the handrail:
Ø 25 ... 50 mm
D minimum: 25 mm (1.0 in);
(Ø 1.0 ... 2.0 in)
D maximum: 50 mm (2.0 in).

D The stable knee rail should always be mounted

exactly at half the height between handrail and
catwalk.

Fig. 11 Configuration of handrail and knee rail

GR SG9043408000000000

D Calculation of the minimum resistance capabil-

Fmin. = 300 N/m × L ity of the handrail over the horizontally applied
(Fmin. = 20.56 lbf/ft × L) force Fmin. It is effective in the middle on the
handrail between two consecutive posts:
Fmin. = 300 N/m x L [N]
(Fmin. = 20.56 lbf/ft x L [lbf])
max. 30 mm where:
(max. 1.18 in) Fmin.: horizontal force [N] or [lbf];
L: spacing between two consecutive railing
posts [m] or [in], relative to its axial centre lines.
D Deflection of the handrail permitted at maximum
when affected by Fmin.: 30 mm (1.18 in). There
must not be any permanent deformation.

Fig. 12 Lowest resistance capability of the

handrail

A.3.25
Elevated printing press

Special requirements of the railings for catwalks

and platforms

GR SG9043409000000000
Specifications for design and manufac-
max. 120 mm ture
(max. 4.72 in)

D Recommended hand rail height, measured on

the upper edge: 1100 mm (43.31 in).
D Additional foot rail from a catwalk height of
more than 1600 mm (63.0 in).
D Minimum height of the foot rail: 100 mm
(4.33 in).
D Minimum spacing between two railing segments
min. 100 mm 1100 mm where there is a gap in the handrail: 120 mm
(min. 3.93 in) (43.31 in) (4.72 in).
D The stable knee rail should always be mounted
at half the height between the handrail and foot
bar.

Fig. 13 Design of the foot rail NOTE

The foot rail with a minimum height of
100 mm (3.93 in) is to be attached
above the catwalk level at a maximum of
10 mm (0.39 in).

Special requirements of the stair railings

GR SG9043410000000000

Specifications for design and manufac-

ture

D Minimum vertical height of the handrail, mea-

sured on the upper edge: 900 mm (35.43 in).
D Minimum height of the foot rail: 100 mm
(4.33 in).

max.
45°

Fig. 14 Design of the stair railings

A.3.26
 Elevated printing press

6.7 Additional platform for elevated CP2000 and CPC devices

D If the CP2000 centre and the CPC devices are

also to be elevated e.g. in the delivery area,
they should be positioned at the same level as
the surrounding catwalks, for safety reasons.
D For elevating the CP2000 centre and the CPC
devices, metal frames are particularly suitable
to be used as substructures.

A.3.27
 Elevated printing press

7 Guards on the Elevated Printing Press

UTKSC9063407000000000

7.1 Guarding Feeder and Delivery

Safety reasons and better accessibility of the control

panel require a platform to be installed at the end
face of the delivery. A platform should also be fitted
at the feeder end.
The hazardous areas (shear points) that result from
the vertical movement of the pile support against the
adjoining platforms must be guarded by one of the
following measures:

D 180 mm (7.00 in) minimum distance between

the platform edge and the pile board edge.
D Guarding feeder and delivery by deflecting ele-
ments.
The deflecting elements must guarantee a hori-
zontal safety distance of 300 mm from the pile
board edge. They may not be higher than
1500 mm above the platform.

7.2 Safeguarding the Areas Under the Catwalks, Platforms and Stairs

Warning – Working under the run-

ning printing press represents dan-
ger to life
Any service and repair work on or un-
der the printing press and the periph-
eral equipment may only be carried out
by the authorized Heidelberg Service.

The elevation of the press makes it possible to get

under the printing press. To be guarded against po-
tential hazards, the following access protection mea-
sures must be taken:

A.3.28
 Elevated printing press

GR SG9043411000000000
D The access guards (such as protection grids or
cover plates) must be fixed in a way that tools
must be used for removing them.
D The areas beneath catwalks, platforms and
stairs must be protected by continuous close-
meshed protection grids.
D The guards must be designed such that, in par-
ticular, the access to the area underneath the
printing press and/or reaching into the installa-
tion openings is only possible after the protec-
tion grids have been dismantled.
D If possible, the protection grids should be fixed
to the catwalk frame, not to the foundation
strips.
D If additional devices (washup solution contain-
ers, etc.) are positioned under the catwalk at
the operator’s side, the protection grids must be
Fig. 15 Example of the layout of protection grids provided with openings for the supply lines near
under the catwalk the floor.

A.3.29
Elevated printing press

A.3.30
 Chapter overview

Specifications of data networks

1 Suitable network versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.3

1.1 Hardware requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.3
1.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.4
1.3 Network variant 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.4
1.4 Network variant 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.5
1.5 Network variant 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.7
1.6 Network variant 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.9
1.7 Network variant 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.11
1.8 Selecting a suitable network version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.13

2 Suitable network servers and their configurations . . . . . . . . . . . . . . . . A.4.14

2.1 Server PC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.14

3 CP2000 ManagementGate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.16

3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.16
3.2 Connecting CP2000 ManagementGate to a host (trade-specific software system) A.4.17
3.3 Linking CP2000 ManagementGate to DataControl . . . . . . . . . . . . . . . . . . . . . . . . . . . A.4.18

A.4.1
Chapter overview

A.4.2
 Specifications of data networks

1 Suitable network versions

UTKSC9065802001000000

1.1 Hardware requirements

Hardware Prepress interface -CIP3 Plate Image Reader Online Prepress Interface -CIP3
(exclusive installation) (exclusive installation) and Plate Image
Reader Online
(common installation)
Processor Pentium processor, min. Pentium processor, min. Pentium processor, min.
clock frequency 100 MHz, clock frequency 100 MHz, clock frequency 100 MHz,
333 MHz recommended 333 MHz recommended 333 MHz recommended

Main memory Min. 64 MB RAM, recom- Min. 64 MB RAM Min. 64 MB RAM, recom-
mended 128 MB RAM mended 128 MB RAM

Graphics Min. 4 MB memory, resolu- VGA graphics module Min. 4 MB memory, resolu-
board tion min. 1024 x 768 pixels at tion min. 1024 x 768 pixels at
32768 colours 32768 colours

Hard disk Min. 4 GB for operating sys- Min. 4 GB for operating sys- Min. 4 GB for operating sys-
tem, application and user tem, application and user tem, application and user
data data data

Network Ethernet adapter for the con- Ethernet adapter for the con- Ethernet adapter for the con-
board nection to the pre-press nection to the printing nection to the pre-press
stage and the printing presses stage and the printing
presses presses

Monitor Monitor with a resolution of at VGA monitor Monitor with a resolution of at

least 1024 x 768 pixels least 1024 x 768 pixels

Interfaces One parallel interface for the One serial interface (RS232) One parallel interface for the
connection of the external for the online connection of connection of the external
system job memory card the plate image reader system job memory card
drive and the Prepress- drive and the Prepress-
Interface dongle Interface dongle
and
one serial interface (RS232)
for the online connection of
the plate image reader

Additional Keyboard, mouse, disk drive Keyboard, mouse, disk drive Keyboard, mouse, disk drive
equipment (3.5 inch) and CD-ROM drive (3.5 inch) and CD-ROM drive (3.5 inch) and CD-ROM drive

Tab. 1

A.4.3
Specifications of data networks

1.2 General information

The following pages show five possible versions for

the integration of Heidelberg presses and peripherals
into electronic networks.
A printshop network is only required if the ”Preset-
Link” or ”ManagementGate” software modules are
used.
Irrespective of the network variant, the ”Online Assis-
tance” function requires an analog or ISDN connec-
tion to exist.

1.3 Network variant 1

Concept of the network version 1

Network connection of one printing press and one

Systems peripheral unit. The units employ the NET-
BEUI protocol for communicating with each other.

System configuration

A maximum of one printing press and one Systems

peripheral unit shall be interconnected in a network.
They are positioned in such a way that the network
cable is not longer than 100 m (328 ft).
To establish the connection to other networks (to a
pre-press network, for example), a second network
interface board (NIC) may be installed in the server
PC. Any network protocol can be used on this sec-
ond card.

A.4.4
 Specifications of data networks

Installation overview

GR SG9065800000001000
5

4 7
6

Fig. 1 Network version 1: Interconnecting one printing press and one CPC peripheral unit (here: plate
image reader)

1 Speedmaster SM/CD 102 printing press

2 Central control cabinet ZSG
3 CP2000 centre with CP2000 software
4 Local area network LAN (here: Ethernet)
5 Plate image reader
6 PC for the installation of the ”Online kit for plate
image reader” and/or ”PrepressInterface”
7 Drive for the job memory card (Flash-Memory
Card)
8 Possible connection to another network of the
print shop through a second network interface
card (NIC).

1.4 Network variant 2

Concept of the network version 2

Network connection of several printing presses and

several Systems peripheral units. The units employ
the NETBEUI protocol for communicating with each
other.
Connection to other networks of the print shop by
means of a second network card in the PC for the
installation of the ”Online kit for plate image reader”
or ”PrepressInterface”.

A.4.5
Specifications of data networks

System configuration

Several printing presses and several peripheral units

(Systems equipment, PCs, etc.) shall be intercon-
nected in a network.
The printing presses and peripherals are positioned
in a way that the network cables are up to 100 m
(328 ft) in length each.
To establish the connection to other networks (to a
pre-press network, for example), a second network
interface board (NIC) may be installed in the server
PC. Any network protocol can be used on this sec-
ond card.
Installation overview

GR SG9065803000001000
7

9
11

10 5 6 8

9
3
4 2

Fig. 2 Network version 2: Network interconnection of several printing presses and several peripheral
units

1 Speedmaster SM/CD102 printing press

2 Central control cabinet ZSG
3 CP2000 centre with CP2000 software
4 ImageControl; this device has a direct data con-
nection to the CP2000 centre and is additionally
equipped with its own network board.
5 Plate image reader

A.4.6
 Specifications of data networks

6 PC for the installation of ”Online kit for plate

image reader” and ”PrepressInterface” as well
as their connection to the local network (LAN).
7 Drive for job memory card (Flash-Memory-
Card); drive not provided when press is
equipped with DataControl.
8 Network connection, e.g. for connecting a ser-
vice notebook of the Heidelberg Service
9 Local area network LAN (here: Ethernet)
ß Hub (is needed when more than two printing
presses or peripherals are interconnected)
q Possible connection to another network of the
print shop through a second network interface
card (NIC).

1.5 Network variant 3

Concept of the network version 3

Network connection of several printing presses and

several CPC peripheral units. The units employ the
NETBEUI protocol for communicating with each
other.
Connection to other networks in the print shop by
means of a hub.

System configuration

Several printing presses and several peripheral units

(Systems equipment, PCs, etc.) shall be intercon-
nected in a network.
The printing presses and peripherals are positioned
in a way that the network cables are up to 100 m
(328 ft) in length each.
For connection to other networks, e.g. a prepress
network, only the hub which was used for intercon-
necting printing presses and peripherals, can be
used. It is not permissible to install and use a second
network interface board (NIC) in the PC for the
installation of the ”Online kit for plate image reader”
or ”PrepressInterface”.

A.4.7
Specifications of data networks

Installation overview

GR SG9065818000001000
7

9
11

10 5 6 8

9
3
4 2

Fig. 3 Network version 3: Networking of several printing presses with several peripherals and additional
connection to an already existing Prepress network by means of a hub.

1 Speedmaster SM/CD 102 printing press

2 Central control cabinet ZSG
3 CP2000 centre with CP2000 software
4 ImageControl; this device has a direct data con-
nection to the CP2000 centre and is additionally
equipped with its own network board.
5 Plate image reader
6 PC with one network interface board (NIC) for
installation of ”Online kit for plate image reader”
and ”PrepressInterface” as well as their connec-
tion to the local network (LAN)
7 Drive for job memory card (Flash-Memory-
Card); drive not provided when press is
equipped with DataControl.
8 Network connection, e.g. for connecting a ser-
vice notebook of the Heidelberg Service
9 Local area network LAN (here: Ethernet)
ß Hub (is needed when more than two printing
presses or peripherals are interconnected)
q Possible connection to another network of the
print shop via the hub

A.4.8
 Specifications of data networks

1.6 Network variant 4

Concept of the network version 4

Integrating several printing presses and several pe-

ripheral units into an existing print shop network by
means of a hub. The units employ the TCP/IP proto-
col for communicating with each other. In this ver-
sion, the Windows NT PC must be set up as a DHCP
server. It also fulfills the function of a WINS server if
no WINS server is installed in the network.

System configuration

Several printing presses and several peripheral units

(Systems devices, PCs, etc.) are to be incorporated
in an existing print shop network by means of a hub
and a DHCP server.

A.4.9
Specifications of data networks

Installation overview

GR SG9065806000001000
9

10

14
11 13
5

12
8
7

3 2
4

Fig. 4 Network version 4: Connecting several printing presses and several peripherals to an existing
print shop network by means of a hub

1 Speedmaster SM/CD 102 printing press

2 Central control cabinet ZSG
3 CP2000 centre with CP2000 software
4 ImageControl; this device has a direct data con-
nection to the CP2000 centre and is additionally
equipped with its own network board.
5 Network connection, e.g. for connecting a ser-
vice notebook
6 Local area network (LAN; here: Ethernet) for
Heidelberg presses and peripheral units
7 Hub

A.4.10
 Specifications of data networks

8 Existing print shop network

9 Production control area with DataControl and
special trade software
ß DTP area (desktop publishing) with PCs, scan-
ners and printers
q Pre-press area with pre-press interface, RIPs
(Raster Image Processors), proofing equip-
ment, image setters/developers and
CPC31 (plate image reader)
w Post-press area with cutting machines, folding
machines and gatherer-stitchers
e Windows NT PC functioning as DHCP server
or, if necessary, as a WINS server too;
equipped with one network card.
r Connection to another local area network (e.g.
administration)

1.7 Network variant 5

Concept of the network version 5

Using hub and router for linking several printing

presses and several peripherals to an existing print
shop network. The units employ the TCP/IP protocol
for communicating with each other. In this version,
the Windows NT PC must be set up as a DHCP ser-
ver and WINS server. In addition, it performs router
functions.

System configuration

Several printing presses and several peripheral units

(Systems equipment, PCs, etc.) are to be linked to
an existing print shop network by means of a router.

A.4.11
Specifications of data networks

Installation overview

GR SG9065807000001000
9

10

14
11 13
5

12
8
7

3 2
4

Fig. 5 Network version 5: Connecting several printing presses and several peripherals to an existing
print shop network by means of a router

1 Speedmaster SM/CD 102 printing press

2 Central control cabinet ZSG
3 CP2000 centre with CP2000 software
4 ImageControl; this device has a direct data con-
nection to the CP2000 centre and is additionally
equipped with its own network board.
5 Network connection, e.g. for connecting a ser-
vice notebook
6 Local area network (LAN; here: Ethernet) for
Heidelberg presses and peripherals (”HDM net-
work”)

A.4.12
 Specifications of data networks

7 Hub
8 Existing print shop network
9 Production control area with DataControl and
special trade software
ß DTP area (desktop publishing) with PCs, scan-
ners and printers.
q Pre-press area with pre-press interface, RIPs
(Raster Image Processors), proofing equip-
ment, image setters/developers and
CPC31 (plate image reader)
w Post-press area with cutting and folding ma-
chines and gatherer-stitchers.
e Windows NT PC as router, DHCP server and
WINS server. Equipped with two network cards.
r Connection to another local area network (e.g.
administration)

1.8 Selecting a suitable network version

If the version used in the print shop can freely be

selected, version 5 should be implemented. This is
the optimum solution.
Versions 1, 2 and 3 are suitable solutions, too.
Albeit version 4 is technically feasible, it should be
avoided for reasons of data integrity.

A.4.13
 Specifications of data networks

2 Suitable network servers and their configurations

UTKSC9065806001000000

2.1 Server PC requirements

The server PC plays a central role within the network

structure. Among other functions, it can have the
function of a router. A breakdown of this PC can lead
to operation disruptions because the individual net-
work clients (presses and devices) cannot communi-
cate anymore. This also means that the online con-
nection is no longer available.
Therefore the failure safety of the PC is very impor-
tant. To ensure fail-safe operation, the server PC
should meet the following specifications:

Special hardware requirements

D System components of high technical standard,

particularly with regard to hard disks and fans;
D redundant power supply units;
D uninterruptable power supply (UPS) as an
emergency power supply in the event of a
power failure;
D redundant and mirrored hard disks (two hard
disks in the server PC).

System requirements

D PC: Windows-NT-PC, fully compatible with Win-

dows NT 4.0 according to the Hardware Com-
patibility List (HCL) by Microsoft;
D Processor: Intel Pentium II with a clock fre-
quency of at least 200 MHz;
D Main memory (RAM): min. 64 MB;
D Graphics board: min. standard VGA;
D Hard disk: min. 4 GB unused hard disk capac-
ity;
D Monitor: min. standard VGA, corresponding to
the graphics board;
D Network board: Ethernet board according to the
following specifications:
D Data transmission rate: 10 Mbps or
100 Mbps (megabits per second); auto-
sensing function;
D suitability for Ethernet cabling with RJ45
connectors;
D at least two ports for connection to one or
several hubs (see also Chapter ”Network
Board”);

A.4.14
 Specifications of data networks

D one network board for variant 4 (see

Chapter ”Network Variant 4”), two network
boards for variant 5 (see Chapter ”Network
Variant 5”).

D Peripherals: Keyboard, mouse, disk drive

(3.5 inch) and CD-ROM drive;
D Operating system: Microsoft Windows NT,
English version 4.0 (server version) with ”ser-
vice pack 3”;

A.4.15
 Specifications of data networks

3 CP2000 ManagementGate
UTKSC9065812000000000

3.1 General information

Heidelberger Druckmaschinen AG provides the

GR MG1100003000000000
”CP2000 ManagementGate” software module to sup-
CP2000 Center port the requirements for an EDP-based integration
in order to obtain consistent job handling and pro-
duction data acquisition for printing presses with
CP2000 ManagementGate CP2000 control systems. CP2000 ManagementGate
permits the integration of the printing presses in the
pressroom via an open interface to a hierarchically
upstream EDP system (trade-specific software).
CP2000 ManagementGate supports the connection:

D to a host (trade-specific software system)

host D to DataControl
(trade–specific soft- or DataControl
ware)

Fig. 6 Connecting CP2000 ManagementGate

with a host or DataControl

A.4.16
 Specifications of data networks

3.2 Connecting CP2000 ManagementGate to a host (trade-specific software system)

The interface between CP2000 ManagementGate

GR MG1100000000000000
and host complies with the same conventions as the
host with trade–specific previously introduced interface between DataControl
software and trade-specific software.
The interface is deliberately kept simple. It is based
on a file transfer of ASCII files. The trade-specific
software can transfer job data to presses with
CP2000 control systems, and receive PDA data from
job list
PDA data such a press. This does not require a DataControl
system to be installed at the customer’s.
When the interface was designed, care was taken to
provide the best possible decoupling between the
systems. The data exchange files that can be read
file server
and written with the usual editors facilitate the com-
missioning and diagnosis work on the interface. A file
transfer mechanism permits different computer
worlds to be linked with each other.
PDA data
job list

CP2000 ManagementGate

CP2000 Center

Fig. 7 Job data transfer between

CP2000 ManagementGate and a host

A.4.17
Specifications of data networks

3.3 Linking CP2000 ManagementGate to DataControl

The connection of CP2000 ManagementGate to

GR MG1100004000000000
DataControl is made via the DataControl Workplace
DataControl Interface. Thus, the data from the DataControl data-
base (presetting data, inking unit settings, and repeti-
tion data) is available at the CP2000 Center. The
printing press supplies PDA data to DataControl.
job list,
presetting data,
PDA data,
repetition data,
repetition data
area coverage va-
lues

CP2000 ManagementGate

CP2000 Center

Fig. 8 Data transfer between CP2000 Man-

agementGate and DataControl

A.4.18
 Chapter overview

Electrical installation of the press

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.3

1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.3

2 Technical specifications of the electrical equipment . . . . . . . . . . . . . . A.5.4

2.1 Technical specifications of the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.4

3 Basic regulations for mains connections . . . . . . . . . . . . . . . . . . . . . . . . . A.5.6

3.1 Basic regulations for mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.6

4 Basic Recommendations and Tips for the Mains Connection . . . . . . A.5.10

4.1 Basic Recommendations and Tips for the Mains Connection . . . . . . . . . . . . . . . . . . A.5.10

5 Connection of the printing press to the three-phase mains ....... A.5.12

5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.12
5.2 Overview of the standard mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.5.13

6 Cross-sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . A.5.21

6.1 Cross-section of the conductor terminals in the central control box ZSG . . . . . . . . A.5.21
6.2 Cross-section of the conductor terminals at the series transformer . . . . . . . . . . . . . A.5.21

A.5.1
Chapter overview

A.5.2
 Electrical installation of the press

1 General information
UTKSC9063800001000000

1.1 General information

This chapter contains information about the electrical

installation of the press.

Warning – Danger when installation

work is not carried out correctly!
Planning and any other work that con-
cern the electrical installation for the
printing press must be initiated by the
user, and may only be carried out by
qualified experts.
Especially EN 60 204, part 1 and
IEC 204, part 1 must be observed.
Relevant national provisions must also
be observed!

Note
This Chapter must also be made avail-
able to the experts appointed for plan-
ning the necessary installation work.

A.5.3
 Electrical installation of the press

2 Technical specifications of the electrical equipment

UTKSC9063801001000000

2.1 Technical specifications of the electrical equipment

The technical specifications for the electrical equip-

ment of a printing press are provided at the central
control cabinet ZSG, which is part of every printing
press.

Location of the rating plates on the central con-

trol box (ZSG)

GR SG9043800000001000
The rating plates are provided at the following posi-
tions of the central control cabinet ZSG:

D Rating plate for the central control cabinet ZSG:

In the ZSG in the equipment zone ”Electrics
and electronics” 1.
D Rating plate for the electrical equipment of the
press 2:
D On the outside of the ZSG above the cable
entry.
D Inside the ZSG, in the mains connection
area to the left of the main switch.

Fig. 1 Central control cabinet ZSG

Rating plate of the central control box

1
GR SG9043801000000000

Number of the central control cabinet ZSG

2 Mains voltage required, type of voltage and
mains frequency

XXXX
XXX V X  XX Hz

xx.xxx.xxxx

Fig. 2 Rating plate with technical specifica-

tions for the central control cabinet ZSG

A.5.4
 Electrical installation of the press

Rating plate for the electrical equipment of the

printing press

GR SG9043802000000000
Press model
2 Press serial number
3 Mains voltage required, type of voltage and
mains frequency
XX
4 Nominal current and nominal power
XXXXXX
XXX V X  XX Hz
5 Recommended building-side back-up fuse
XXX A / XXX kW

XXX A
xx.xxx.xxxx

Fig. 3 Rating plate with technical specifica-

tions of the printing press

A.5.5
 Electrical installation of the press

3 Basic regulations for mains connections

UTKSC9063802001000000

3.1 Basic regulations for mains connections

Types of the power supply systems

D To operate the printing press and its peripheral

equipment, two different power supply systems
are required:
D A three-phase system with a protective
earth (PE) for the power supply of the
printing press. The phase angle must be
120o. The three-phase system must fulfill
the requirements described below.
D An AC system (lighting system) with one
or two phases and a protective earth (PE)
for the power supply to certain peripheral
equipment. The AC system must fulfill the
requirements described below.

Dimensioning the mains connection

D Power rating: The layout of the mains connec-

tions depends on the power required by printing
press and peripheral equipment.
The layout must always be made in agreement
with Heidelberg Service.
D Reactive power: The power factor of the press
during standard operation can be determined
using the specifications on the rating plate. The
value can be improved by an ”inductor-capaci-
tor” compensation.

Fusing and protective measures

D In all current-carrying feeder lines, appropriate

fuses must be installed next to the mains tap.
Since the inrush current of the series trans-
former can briefly rise to a multiple of the nomi-
nal current, it must be ensured that these fuses
are not released by the magnetizing currents
that occur when the press is switched on.
The guidance values for fusing (column ”Electri-
cal fusing”) are dimensioned such that the fuses
do not release during normal operation.
D The protective earth (PE) must be a separate
conductor that must be connected to the protec-
tive earth system of the printing press.
D The protective earth system must clearly be
identified by shape, arrangement, colour or
marking.
If solely colour is employed for identification, the
total length of the protective earth conductors
must be marked in green and yellow.

A.5.6
 Electrical installation of the press

EMC measures

All electric and electronic subassemblies of Heidel-

berger Druckmaschinen AG comply with EN 50081,
part 2 and EN 50082, part 2.
Caution – Damage and malfunction
on electrical devices due to electro-
magnetic interference!

External equipment used on the printing

press must not cause any malfunctions
in the electronic system of printing press
or of third-party equipment.
Third-party units may only be distributed
and used if they comply with the EMC
requirements to EN 50081, Part 2 and
EN 50082, Part 2; if this compliance was
certified by an approved department of
the manufacturer, and the unit is marked
by a CE sign.
The necessity of EMC measures must
be checked before a third-party unit is
installed. EMC measures must always
be agreed with Heidelberg Service.

The following measures could be considered:

D Installation of external controls outside the

CPTronic control cabinet in a separate,
screened casing.
D Power supply of all non-Heidelberg equipment
via a separate feeder line from the mains.
D Appropriate filtering measures for the power
supply.
D Electrical isolation for the signal lines to the
HDM control.
D Interference suppression of the grounding con-
tacts of one- and three-phase loads using suit-
able RC elements.
D Interference suppression of the protective coils
and switching contacts:
D by RC elements for AC voltage;
D by interference suppression diodes for DC.

D Laying three-phase/AC lines separately from

data/control cables.
D Using screened data and control lines for the
connection of units that are connected to the
interface adapter STR (see also Chapter ”Elec-
tronic Interface”).
Connecting the shield at both cable ends.

A.5.7
Electrical installation of the press

D If printing press and third-party unit are installed

at a distance and, at the same time, are con-
nected to different mains, adequate equipoten-
tial bonding must be provided between the two
components in order to prevent equalizing cur-
rent from flowing on the screen. The cross-sec-
tion of the protective earth conductor must be at
least 10 mm2 (0.016 sq in).

Tolerances

D The following variations may exist in the power

supply system:
D Voltage:
max. +/– 10%;
D Frequency:
permanently max. +/– 1%,
transient max. +/– 2%.

D The total difference between the nominal mains

voltage (point of supply from the public utility)
and the terminal voltage on the printing press
must not exceed 10%.
D Agreement with Heidelberg Service must be
reached if the voltage differences exceed the
above-mentioned tolerance ranges.

Power cable requirements

D The print shop user must provide and install the

cables between the mains and the main switch
in the central control cabinet ZSG.
D Power cables and PE conductor must be se-
lected such that they will be suitable for the oc-
curring operating conditions, and are rugged
enough to withstand external influences.
D The minimum cross-section of power conduc-
tors and PE conductor must be dimensioned for
the printing press requirements. The following
factors should be considered:
D Power required and load current;
D Ratings of the back-up fuse (see also
graphs in the Chapter ”Standard Mains
Connection, Versions A1 to A5” and/or
”Standard Mains Connection, Versions B1
to B2”);
D Short-circuit capability;
D Fusing characteristics of the connection to
the power supply;
D Setting data of the main switch (safety
switch) fusing;
D Insulation type;
D Installation method;

A.5.8
 Electrical installation of the press

D Cable length;
D Cable grouping and heat generation;
D Ambient temperature.

The minimum cross-sections can, for example, be

found in DIN EN 60204 and IEC 204.

D Ensure that the cross-section of the conductor

terminals in the central control box ZSG is ade-
quate (see Chapter ”Electrical Power Supply –
Mains Connection”).

GR SG9043803000001000
Layout of the mains connection

D The power cables must be laid in a suitable way

to the site of the load. Auxiliary means: Power
cable ducts, cable racks, etc.
D All connections must be carried out properly.
The connections must not be soldered.
Stranded conductors must be provided with fer-
rules to prevent spreading.
D To prevent unacceptable tensile force on the
cable ends, the cable ends must be fixed in a
suitable way (by cable clamps, for example).
D The power cable must be laid in an adequate
length from the cable entry at the central control
box ZSG up to the mains connection terminals
in the control box.
D Only the skilled personnel appointed by the
Fig. 4 Entry of the power cable into the central user may lay the power cable in the control cab-
control box ZSG inet and connect the mains connection.

Checking the mains connection

During and after the connection to the power supply,

the following tests must be carried out by the quali-
fied personnel commissioned by the print shop user.
These include, for example:

D Verifying that there is a clockwise rotating field.

D Verifying that mains voltages are within the volt-
age tolerance values.
D Verifying that the protective earth (PE) conduc-
tor has an appropriate cross-section.
D Verify that there is a proper and sufficient con-
nection between the protective earth system of
the printing press and the protective earth (PE)
of the higher-level mains.

A.5.9
 Electrical installation of the press

4 Basic Recommendations and Tips for the Mains Connection

UTKSC9063803000000000

4.1 Basic Recommendations and Tips for the Mains Connection

Design of the connection to power supply

D The electrical equipment of the printing press

that is fed via the central control box ZSG
should be connected to one mains connection.
The installation must be clearly arranged and
retraceable.
D All cables must be laid continuously from termi-
nal to terminal, without intermediate coupler.

Selecting the material of power cables and PE

conductor

D Copper conductors should be used as power

and PE conductors.
Relevant national provisions must be observed.
The minimum cross sections can, for example,
be found in DIN EN 60204 and IEC 204.
D To ensure that the cable losses between the
mains (point of supply of the public utility) and
the printing press are as low as possible, the
conductor cross sections should be as large as
possible.
D Using larger cable cross-sections may become
necessary in order to keep the voltage drop be-
tween the power mains and the mains connec-
tion area inside the permissible limits.

Safety and protective measures

D We urgently recommend not to use any earth-

leakage circuit-breakers as triggering through
electrical filter measures is to be expected at
small leakage currents (approx. 30 mA).

Switching on, starting and running up the print-

ing press

D When switching on, starting and running up the

printing press, the load current is at maximum
20% above the nominal current.
Fuse protection in the central control cabi-
net ZSG has been designed accordingly and
should only be modified in special cases and
after consultation of the Heidelberg service.

A.5.10
 Electrical installation of the press

Load characteristics and harmonics

D During operation (production run), the load cur-

rents can briefly rise up to 20% above the nomi-
nal currents.
D To assess the harmonics in the loading case, all
the units of a customer must be analyzed that
are fed via the same mains connection.
For a precise analysis of the effect of electrical
devices on the mains, refer to EN 60555 (corre-
sponds to DIN VDE 838) and EN V 61000 (cor-
responds to DIN VDE 839), for example.

A.5.11
 Electrical installation of the press

5 Connection of the printing press to the three-phase mains

UTKSC9063804001000000

5.1 General information

Warning – Electrical shock when

touching voltage-carrying parts!
Any electrical installation work may
only be carried out by qualified experts
and when the mains is switched off.
The mains connection must be
installed according to the specifications
from DIN EN 60204, Part 1 and/or
IEC 204, part 1.
The connection elements must be able
to withstand the occurring electrical,
thermal, and mechanical stress.
Relevant national provisions must also
be observed!

In general, the printing press is connected to the

three-phase mains via the central control cabi-
net ZSG.
Besides the printing press, the ZSG provides the
following units with electrical power:

D the CPTronic central control console and/or the

CP 2000 centre;
D the CPC 1-04 control console and/or the
CP 2000 centre;
D the QualityProof quality assurance;
D the pneumatic compressor;
D the air supply units and/or the air supply cabi-
net;
D the dampening solution supply unit;
D various other peripheral units (e.g. powder
spray device, varnish supply unit, etc.).

A.5.12
 Electrical installation of the press

5.2 Overview of the standard mains connections

Nominal voltages Mains connection version

and frequencies of
the
three-phase mains
AC 200 V 50 Hz Version B1
60 Hz Version B2
AC 208 V 50 Hz Version B1
60 Hz Version B2
AC 220 V 50 Hz Version B1
60 Hz Version B2
AC 230 V 60 Hz Version B2
AC 240 V 60 Hz Version B2
AC 350 V 50 Hz Version B1
AC 380 V 50 Hz Version A3
60 Hz Version A4
AC 400 V 50 Hz Version A3
AC 415 V 50 Hz Version A3
AC 440 V 50 Hz Version A1
60 Hz Version A2
AC 480 V 60 Hz Version A5
AC 600 V 60 Hz Version A2
Tab. 1 Overview of standard mains connections
Note
Please contact Heidelberg Service to
agree the mains connection if the table
above does not permit any allocation to
be made.

Description of the mains connection versions

D Standard mains connection, versions A1 to A5:

see Chapter ”Standard Mains Connection, Ver-
sions A1 to A5”.
D Standard mains connection, versions B1 to B2:
see Chapter ”Standard Mains Connection, Ver-
sions B1 to B2”.

Example taken from the opposite table

The machine version CD 102-4+L was ordered.

The local voltage of the three-phase mains is as-
sumed to be AC 350 V, the mains frequency is
50 Hz.

A.5.13
Electrical installation of the press

Version B1
results from the ”AC 350 V/50 Hz” row.

General information

D The operating voltage of the printing press is

AC 400 V.
D For a mains frequency of 60 Hz, Heidelberger
Druckmaschinen AG always supplies an addi-
tional series or matching transformer (including
connecting cables) that may only be installed by
Heidelberg Service.
In order to enable the units with a frequency-de-
pendent working point (e.g. asynchronous mo-
tors) to be used, the matching transformer
raises the voltage from AC 400 V to AC 480 V.

5.2.1 Standard mains connection, versions A1 to A5

Connection diagram

GR SG9043806000001000

Responsibility of Heidelberg service Responsibility of customer

Fig. 5 Layout of the mains connection according to versions A1 to A5

1 Mains
2 Fuses
3 Supply lines to the central control cabinet ZSG
4 Central control box ZSG with mains connection
area
5 Series or matching transformer
6 Cables between mains connection area and
series transformer (contained in the delivery)

A.5.14
 Electrical installation of the press

Note
The mains connection to be provided by
the print shop user must be implemented
for versions A1 through A4 on the series
terminals of the central control cabinet
ZSG.

Standard mains connection, version A1

Valid for the following electrical ratings:

D AC 440 V/50 Hz

GR SG9043810000001000
Power Mains connection area
supply system (central control box ZSG)

PE
Series transformer

3 AC 400 V/
Back–up fuses 50 Hz
L1
L2
L3

Responsibility of customer Responsibility of Heidelberg service

Fig. 6 Wiring diagram for mains connection version A1

Standard mains connection, version A2

Valid for the following electrical ratings:

D AC 440 V/60 Hz
D AC 600 V/60 Hz

A.5.15
Electrical installation of the press

GR SG9043809000001000
Power mains connection area
supply system (central control box ZSG)

PE
Series transformer
3 AC 480 V/
60 Hz

Back–up fuses
L1
L2
L3

3 AC 400 V/
60 Hz

Responsibility of customer Responsibility of Heidelberg service

Fig. 7 Wiring diagram for mains connection version A2

Standard mains connection, version A3

Valid for the following electrical ratings:

D AC 380 V/50 Hz
D AC 400 V/50 Hz
D AC 415 V/50 Hz

GR SG9043808000001000
Power Mains connection area
supply system (central control box ZSG)

PE
Back–up fuses
L1
L2
L3

Responsibility of customer Responsibility of Heidelberg service

Fig. 8 Wiring diagram for mains connection version A3

A.5.16
 Electrical installation of the press

Standard mains connection, version A4

Valid for the following electrical ratings:

D AC 380 V/60 Hz

GR SG9043807000001000
Power Mains connection area Matching transformer
supply system (central control box ZSG)
3 AC 480 V/
60 Hz

PE
Back & dash up fuses
L1
L2
L3

Responsibility of customer Responsibility of Heidelberg service

Fig. 9 Wiring diagram for mains connection version A4

Standard mains connection, version A5

Valid for the following electrical ratings:

D AC 480 V/60 Hz

A.5.17
Electrical installation of the press

GR SG9043814000001000
Power Mains connection area
supply system (central control box ZSG)
3 AC 480 V/
60 Hz

PE
Series transformer

Back–up fuses
L1
L2
L3

3 AC 400 V/
60 Hz

Responsibility of customer Responsibility of Heidelberg service

Fig. 10 Wiring diagram for mains connection version A5

5.2.2 Standard mains connection, versions B1 to B2

Connection diagram

GR SG9043811000000000

Responsibility of Heidelberg service Responsibility of customer

Fig. 11 Layout of the mains connection according to versions B1 to B2

1 Mains

A.5.18
 Electrical installation of the press

2 Fuses
3 Supply lines to the central control cabinet ZSG
4 Central control box ZSG with mains connection
area
5 Series transformer (included in the delivery
package)
6 Matching transformer (for mains frequency
60 Hz)
7 Cables between mains connection area and
series transformer (contained in the delivery)

Note
A series transformer is supplied together
with the printing press. With versions B1
and B2, the mains is always connected
to the series transformer. This connec-
tion must be initiated by the user.

Standard mains connection, version B1

Valid for the following electrical ratings:

D AC 200 V/50 Hz
D AC 208 V/50 Hz
D AC 220 V/50 Hz
D AC 350 V/50 Hz

GR SG9043812000001000
Power Mains connection area
supply system (central control box ZSG)

PE
Back–up fuses
L1
L2
L3
3 AC 400 V/50 Hz

Series transformer

Responsibility of customer Responsibility of Heidelberg service

Fig. 12 Wiring diagram for mains connection version B1

Standard mains connection, version B2

Valid for the following electrical ratings:

D AC 200 V/60 Hz
D AC 208 V/60 Hz

A.5.19
Electrical installation of the press

D AC 220 V/60 Hz
D AC 230 V/60 Hz
D AC 240 V/60 Hz

GR SG9043813000001000
Power Mains connection area Matching transformer
supply system (central control box ZSG)
3 AC 480 V/
60 Hz

PE
Back–up fuses
L1
L2
L3
3 AC 400 V/60 Hz

Series transformer

Responsibility of customer Responsibility of Heidelberg service

Fig. 13 Wiring diagram for mains connection version B2

A.5.20
 Electrical installation of the press

6 Cross-sections of the conductor terminals

UTKSC9063805000000000

6.1 Cross-section of the conductor terminals in the central control box ZSG

Nominal voltages Cross sections of the conductor terminals

and frequencies of [mm2] ([sq in])
the
three-phase mains
Number of units 2 3 4 5 6 7 8 9 10
AC 200 V – 240 V 50 Hz 150 150 150 150 150 2x120 2x120 2x120 2x120
60 Hz 150 150 150 150 150 2x120 2x120 2x120 2x120
60 Hz 2x120 2x120 2x120 2x120 2x120 2x120 2x120 2x120 2x120
(USA)
AC 350 V 50 Hz 150 150 150 150 150 2x120 2x120 2x120 2x120
AC 380 V 60 Hz 150 150 150 150 150 2x120 2x120 2x120 2x120
AC 380 V – 415 V 50 Hz 150 150 150 150 150 2x120 2x120 2x120 2x120
AC 440 V 50 Hz 120 120 150 150 150 150 2x120 2x120 2x120
60 Hz 2x120 2x120 2x120 2x120 2x120 2x120 2x120 2x120 2x120
AC 480 V 60 Hz 120 120 2x120 2x120 2x120 2x120 2x120 2x120 2x120
AC 600 V 60 Hz 120 120 120 120 2x120 2x120 2x120 2x120 2x120
Tab. 2 Cross-sections of the conductor terminals in the central control box ZSG
The conductor terminals on the terminal strip with a
maximum cross-section of 70 mm2 (0.108 sq in) per-
mit round stranded wires of a minimum of 16 mm2
(0.025 sq in) and a maximum of 95 mm2
(0.147 sq in) to be used.
The conductor terminals on the terminal strip with a
maximum cross-section of 150 mm2 (0.232 sq in)
permit round stranded wires of a minimum of
35 mm2 (0.054 sq in) and a maximum of 185 mm2
(0.286 sq in) to be used.

6.2 Cross-section of the conductor terminals at the series transformer

Warning – Danger if the following

safety instructions are not ob-
served!

D The series transformer must only be used for

the power supply of the central control box and
the electrical consumers connected to it and
intended for by Heidelberg.
D Don’t connect any additional consumers like, for
example, non-Heidelberg units to the series
transformer.

A.5.21
Electrical installation of the press

D A maximum of two current conductors per ter-

minal can be connected to the series trans-
former. Clamp the cables such that they cannot
work loose during operation.
D With respect to the requirements to the power
lines and type and test of the mains connection,
the rules from the Chapter ”Basic Regulations
for Mains Connections” apply.

Note
The following table is only significant if
the printing press with series transformer
has to be connected according to variant
B1 or B2 (see Chapter ”Overview of the
standard mains connections”).

”Units” stands for the overall number of

print units and coating units.

Nominal voltages Cross sections of the terminalson the series transformer [mm2] ([sq in])
and frequencies of
the
three-phase mains
primary side secondary side
Machines with up to 3 units
AC 200 – 240 V 3 x 240 (3 x 0.37) 3 x 70 (3 x 0.11)
AC 350 V 3 x 95 (3 x 0.15) 3 x 70 (3 x 0.11)
Machines with 4 to 7 units
AC 200 – 240 V 3 x 2 x 150 (3 x 2 x 0.23) 3 x 150 (3 x 0.23)
AC 350 V 3 x 150 (3 x 0.23) 3 x 150 (3 x 0.23)
Machines with 8 and more units
AC 200 – 240 V 2 x 4 x M12 2 x 2 x M12
Tab. 3 Cross-sections of the conductor terminals at the series transformer
Note
”M12” stands for the borehole of the
cable lug for the connection cable. The
electrician determines the cable cross-
section according to the local require-
ments.

Conductor terminals and possible cable cross-

sections

The cross-sections of the conductor terminals permit

the following cable cross-sections (stranded wires):

A.5.22
 Electrical installation of the press

Cross-section of the Possible conductor

conductor terminal cross section
[mm2] ([sq in]) [mm2] ([sq in])
70 (0.108) 10 ... 95
(0.015 ... 0.147)
150 (0.232) 35 ... 185
(0.054 ... 0.286)
240 (0.372) 70 ... 240
(0.108 ... 0.372)
Tab. 4 Conductor terminals and possible cable
cross-sections

Note
Conductor terminal for the protective
earth (PE) conductor: eyelet terminal,
diameter = 8.5 mm (0.33 in) (M8 thread).
For machines with more than units: M12
thread

Example taken from the opposite table

”3 x 2 x 150” (3 x 2 x 0.23) means:

The terminals L1, L2 and L3 exist twice, each with a
cross-section of 150 mm2 (0.232 sq in).

A.5.23
Electrical installation of the press

A.5.24
 Chapter overview

Installation of the air supply

1 Pneumatic compressor station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.3

1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.3
1.2 Overall Air Throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.4

2 Suction and blast air generation by the air supply cabinet ....... A.6.5
2.1 Generation of suction and blast air by the air supply unit . . . . . . . . . . . . . . . . . . . . . . A.6.5
2.2 Guidance values for existing suction and blast air supply . . . . . . . . . . . . . . . . . . . . . . A.6.6

3 Air-cooled air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.8

3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.8
3.2 Overall air throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.8
3.3 Air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.10
3.4 Process air supply for the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.11
3.5 Removing the process air from the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.13

4 Water-cooled air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.14

4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.14
4.2 Overall air throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.15
4.3 Process air supply for the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.15
4.4 Removing the process air from the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.15

5 Installation of the pneumatic compressor station . . . . . . . . . . . . . . . . . A.6.16

5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.16
5.2 Minimum distances at the installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.16
5.3 Installation site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.17

6 Installation of the air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.18

6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.18
6.2 Minimum distances at the installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.18
6.3 Installation site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.18
6.4 Pressure drops when using exhaust-air hoods for the air-cooled AirStar unit . . . . . A.6.19
6.5 Changing the diameter of an air pipe length to the printing press of > 10 m (> 33 ft) . . . . . . . . . . . .
A.6.22

7 Air supply via central air supply systems . . . . . . . . . . . . . . . . . . . . . . . . A.6.26

7.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.26
7.2 Compressed-air supply (high pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.27

A.6.1
Chapter overview

7.3 Suction and blast air supply (low pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.30

8 Installing the exhaust air cleaning cabinet . . . . . . . . . . . . . . . . . . . . . . . A.6.34

8.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.34
8.2 Installing the exhaust air cleaning cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.34
8.3 Air throughput in the exhaust air cleaning cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.35
8.4 Suction points of the CleanStar unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6.35

A.6.2
 Installation of the air supply

1 Pneumatic compressor station

UTKSC9064001001000000

1.1 General Information

Printing presses are fitted as standard with compres-

sor stations for supplying the pneumatic components
with compressed air. Consumers are, for example,
pneumatically controlled valves or pneumatic cylin-
ders.
The compressor station version supplied depends on
the printing press size.
Depending on the size of the compressor station, the
standard installation location is planned to be at the
drive side at the following point:

D Beneath the foot step (Boge SBD-R 250) or

D In the row of the peripheral cabinets in the de-
livery area (ScrollStar plus).

The compressor station is supplied with power via

the central control cabinet ZSG. The compressor
station is always connected by Heidelberg Service.
The compressor station consists of the following
components:

D compressor;
D air dryer;
D compressed-air reservoir;
D pressure control.

Please refer to the document ”Specifications” for a

list of the technical specifications of the various com-
pressor stations .
The information given there exclusively refers to the
larger pneumatic compressor station which is nor-
mally installed next to the dampening solution supply
unit.

A.6.3
Installation of the air supply

1.2 Overall Air Throughput

GR SG9044000000001000
The ScrollStar plus contains a radial blower (delivers
5 83 mbar) and a compressor (delivers 10 bar). The
compressor can be left out if a central air supply unit
1 is installed in the print shop.

1 Air suction for the radial blower

2 Air suction for the compressor; cooling air in-
2 take
6
3 Compressed air:
max. 10 bar (145 psi),
max. 14.94 m3/h (530 cu ft/h)
4 Blast air:
3 max. 83 mbar (1.2 psi),
max. 1400 m3/h (50000 cu ft/h)

4
5 Cooling air inlet
6 Cooling air outlet

Fig. 1 Overall air throughput; example of the The volume of cooling air amounts to approx.
ScrollStar plus 720 m3/h (25500 cu ft/h). No provisions are made to
concentrate and extract the heated cooling air out of
the pressroom.
If several bigger ScrollStar cabinets are installed in
the pressroom, please check whether a uniform air
suction system with heat exchanger could be
installed.

A.6.4
 Installation of the air supply

2 Suction and blast air generation by the air supply cabinet

UTKSC9064002001000000

2.1 Generation of suction and blast air by the air supply unit

The AirStar air supply unit supplies the printing press

with the necessary suction and blast air during the
printing process. In this process, suction and blast air
with different pressure and vacuum levels is supplied
to components such as suction head, governor foot,
front lay, etc..
Two types of air supply units are available:

D Air-cooled air supply unit. The waste heat of the

air supply aggregates is extracted by a fan via
the air.
Once the electrical connection and the connec-
tion of the air supply lines have been estab-
lished by Heidelberg Service, the air-cooled air
supply cabinet is ready for operation.
D Water-cooled air supply unit. The waste heat of
the air supply aggregates is extracted by an
integrated air-water heat exchanger.
In addition to its electrical connection and its
connection of the air supply lines, the cooling
water circuit of the water-cooled air supply cabi-
net must be connected to an external re-cooling
system.
Planning and installation of this re-cooling sys-
tem must be initiated by the user or manage-
ment of the print shop and may only be carried
out by qualified personnel.
Both versions are provided with identical units
to generate suction and blast air for the
presses.

Compared to the air-cooled version the water-cooled

air supply unit has the following advantages:

D The waste heat can better be ”seized” and eas-

ier be fed to a waste heat recovery system.
D Less air eddies in the pressroom due to a lower
amount of air needed (the cooling air is circu-
lated in the cabinet).
D This results in less dirt accumulation in the cabi-
net caused by air containing powder particles
and thus in longer service life.
D The waste air can be dissipated with cooling
water through pipes with a small cross section.
This is especially advantageous when installing
hoses in pressrooms of low height.

The air supply unit is normally installed on the drive

side D.S. by the second printing unit.

A.6.5
Installation of the air supply

The standard equipment is designed such that the

air supply cabinet can be installed at a distance of up
to 4 m (13 ft) from the main air distribution unit. The
main air distributor is installed on the level of the sec-
ond printing unit at the drive side D.S.
A hose extension kit is offered as optional accessory.
This allows you to install the air supply unit within a
radius of up to 10 m (33 ft) from the main air distribu-
tor.
1

GR SG9044009000000000
Air supply unit
Standard: 4 m (13 ft) 2 Main air distributor
Option: 10 m (33ft)
The air supply unit is supplied with power via the
central control cabinet ZSG. This connection is al-
ways made by Heidelberg-Service.
The air pipes coming from the air supply unit are
connected to the main air distributor as well as to the
feeder and to the delivery.

Fig. 2 Installation of the air supply unit

2.2 Guidance values for existing suction and blast air supply

If an air supply unit and an air distribution system

already exist in the printshop, the suction and blast
air system of the printing press can possibly be con-
nected to it. In this case the air supply unit is not re-
quired.
You are strongly advised not to produce blast air via
an expansion process of the compressed air by
means of ejectors. This would mean high investment
costs and also high energy costs.
D Blast air conditioning:
Dry, oil-free, filtered, condensate-free air.
D Operating pressure (absolute pressure):
depending on the press model min. 0.4 bars ...
max. 2.0 bars
(min. 5.8 psi ... max. 29.0 psi)
(see Chapter ”Suction and blast air supply (low-
pressure)”).
D Air volume flow:
D The maximum pressure values should not
be more than 10% above the typical press
standard values (see Chapter ”Suction and
blast air supply (low-pressure)”).
D It should be possible without any problems
to compensate pressure fluctuations of up
to +/– 10%. Also the air hoses should be
designed accordingly.

A.6.6
 Installation of the air supply

D Air temperature (process air):

60 oC (140 oF) ... max. 85 oC (185 oF).
D Solid content of the air:
Particle size: max. 10 mm;
Particle number density: max. 10 mg/m3.

A.6.7
 Installation of the air supply

3 Air-cooled air supply cabinet

UTKSC9064003001000000

3.1 General information

The compressors and rotary pumps that generate

the suction and blast air in the air supply cabinet pro-
duce heat.
In the air-cooled air supply cabinet, an air flow (fan)
ensures the cooling of the compressors and rotary
pumps, and removes the produced heat.
The air-cooled air supply unit consists of the
following components:

D Electric module for control and adjustment

D Basic module for generation of suction and
blast air
D On presses with increased amount of air re-
quired: extension module for the generation of
suction and blast air.

To keep the temperature level in the pressroom as

constant as possible we recommend to concentrate
the waste air in a suitable form and to lead it out of
the pressroom.

3.2 Overall air throughput

The total air consumption of the air-cooled air supply

unit is described below. The individual air volumes
are specified in the tables in the publication ”Techni-
cal Specifications” and ”Suction and Blast Air Supply
(Low Pressure)”.

A.6.8
 Installation of the air supply

GR SG9044002000001000
6
2

4
1

Fig. 3 Overall air throughput; example of the AirStar-LGK C3. Left-hand side: cooling air flow; right-
hand side: process air flow

1 Cooling air intake:

Vertically arranged air inlet grid at the service
side above the base.
2 Cooling air outlet: Centrally via the cabinet top.

3 Blast air intake:

Vertically arranged gills at mid-height at the
connecting side.
4 Suction air from the printing press:
Suction air socket above the base at the con-
nection side.
5 Blast air outlet to the printing press:
Air connection socket at the connection side
above the base.
6 Suction air outlet: Centrally via the cabinet top.

General information

D Process air is the suction air and the blast air

for the printing process.
D The exhaust air consists of:
D cooling air for the cooling of the aggre-
gates;
D exhaust air from vacuum generation (suc-
tion air);

A.6.9
Installation of the air supply

D blast air which is not required depending

on the operating status of the press and
which is carried off via the pressure relief
valves.

D The cooling air represents the biggest share in

the overall air consumption. The share of the
process air is relatively small. It depends on the
operating condition of the printing press.

3.3 Air cooling

Waste air removal

GR SG9044003000001000
The air-cooled version of the air supply cabinet can
optionally be equipped with an exhaust-air hood. The
exhaust-air hood can be ordered from Heidelberg
Service. It is mounted on top of the air supply unit
and leads the exhaust air blown off through the top
of the air supply unit into an exhaust pipe via a con-
nection piece.
In order to not impair the cooling system in the elec-
tric module of the AirStar unit, the relatively small
exhaust air quantity is not removed from the electric
module.
Air friction causes pressure losses in the exhaust-air
hood and the exhaust pipe. To avoid a stagnation of
the cooling air, one (or more) suction fans must be
installed in the socket of the exhaust-air hood and/or
the exhaust pipe.
In this context it is irrelevant whether only an ex-
haust-air hood or an exhaust-air hood and an ex-
haust pipe are installed.
The suction fan must start up when the printing press
is switched on at the main switch on the central con-
trol box ZSG.
Any planning for removing the cooling air through an
exhaust air duct, including the related suction fans
must be initiated by the user and/or the management
of the printshop. The installation must be planned
Fig. 4 Dissipation of cooling air on the exam- and carried out by qualified experts.
ple of the AirStar-LGK-C4 The Chapter ”Pressure Losses when Exhaust-Air
Hoods are Used for the Air-Cooled AirStar” informs
about exhaust-air hoods and exhaust pipes, how an
estimate calculation of the air pressure losses in the
hose and pipe systems can be made, and how these
losses can be compensated.

A.6.10
 Installation of the air supply

3.4 Process air supply for the printing process

GR SC9064004000001000
S1 S8
S2 S9
S3 S10
S4 S11
S5
S6
S7
S2
S3
S4
S5
S6
S7

Fig. 5 Assignments of the connection sockets; example of the air supply cabinets. Left-hand side: Air-
Star-LGK C3; right-hand side: AirStar-LGK C6

Note
The numbering of the connection sock-
ets is valid across all air supply cabinets.

Connection Air Star version

socket no.
LVS-LGK 91 LGK C2 LGK C3 LGK C4 LGK C5 LGK C6
S1 *
S2 * * * *
S3 * * * * * *
S4 * * * * * *
S5 * * * * * *
S6 * * * * * *
S7 * * * * * *
S8 * * *
S9 * * *
S10 * * *
S11 * *
Tab. 1 Assignments of the connection sockets of the air-cooled air supply cabinets

A.6.11
Installation of the air supply

Technical specifications of the process air sup-

ply

Connection Outside diameter of Generation of suction and blast air Type of air
socket no. socket [mm]([in])
Compressor principle Interconnection princi-
ple
S1 65 (2.56) High-velocity air suction Pressure-pressure, par- Blast air
system allel
S2 65 (2.56) High-velocity air suction Pressure-pressure, par- Blast air
system allel
S3 65 (2.56) High-velocity air suction Pressure-vacuum Blast air
system
S4 32 (1.26) Tooth-type or vane com- – Suction air
pressor
S5 40 (1.57) High-velocity air suction Pressure-pressure, se- Blast air
system ries
S6 40 (1.57) Tooth-type or vane com- – Blast air
pressor
S7 55 (2.17) High-velocity air suction Vacuum-vacuum, series Suction air
system
S8 65 (2.56) High-velocity air suction Pressure-pressure, par- Blast air
system allel
S9 65 (2.56) High-velocity air suction Pressure-pressure, par- Blast air
system allel
S10 65 (2.56) High-velocity air suction Pressure-pressure, par- Blast air
system allel
S11 65 (2.56) High-velocity air suction Pressure-pressure, par- Blast air
system allel
Tab. 2 Technical specifications of the process air supply

Connection Feeding point Consumer

socket no.
S1 Central air distributor Delivery; printing units
S2 Central air distributor Delivery; printing units
S3 Central air distributor Delivery; printing units
S4 Feeder Suction nozzles at the suction head; sheet catcher
S5 Feeder Forwarding flap; lateral, diagonal and rear edge blowers
Delivery Lateral sheet separation blowers; version: (customer’s request)
Blowing through suction tapes
S6 Feeder Governor foot at the suction head
S7 Delivery Sheet brake above the yellow filter; sheet catcher
S8 Central air distributor Delivery; printing units; feeder

A.6.12
 Installation of the air supply

Connection Feeding point Consumer

socket no.
S9 Central air distributor Delivery; printing units; feeder
S10 Central air distributor Delivery; printing units; feeder
S11 Central air distributor Delivery; printing units; feeder
Tab. 3 Technical specifications of the process air supply
Note
For standard volume flows, absolute
pressures, maximum air temperatures
under operating conditions, etc. please
refer to the Chapter ”Suction and Blast
Air Supply (Low Pressure)”.

3.5 Removing the process air from the printing process

Extracting the process air (blast air) that is brought in

during the printing process from the printing press is
not planned.
The standard volumetric flow of the process air must
be included in the air throughput calculations for the
pressroom if the air supply cabinet is not installed in
the pressroom but, for example, in a separate equip-
ment room (see Chapter ”Installation of the Air Sup-
ply Cabinet at a Point Different to the Standard
Installation Place”).

A.6.13
 Installation of the air supply

4 Water-cooled air supply cabinet

UTKSC9064004001000000

4.1 General information

The water-cooled air supply unit LVS has a cooling

module (from version AirStar-LGK C4 onwards two
cooling modules) with integrated air-water heat ex-
changer. It carries off the heat which is generated
through the production of suction and blast air thus
preventing heat accumulation or overheating of ag-
gregates.
1

GR SG9044005000001000
Heat exchanger
2 Fan
3 Guide plate
4 Electric module
5 Basic module
6 Cooling module

Fig. 6 Air circulation in the water-cooled air

supply unit

The fact that the cooling air only circulates inside the
cabinet is a characteristic feature of the water-cooled
air supply cabinet. It is not released to the environ-
ment in a heated condition as is the case with the
air-cooled air supply unit.
The water-cooled air supply unit consists of the
following components:

D Electric module for control and adjustment

D Basic module for generation of suction and
blast air
D On presses with increased amount of air re-
quired: extension module for the generation of
suction and blast air;
D Cooling module with fan and air-water heat ex-
changer (one cooling module each for basic
and extension modules).

A.6.14
 Installation of the air supply

A separate re-cooling system is needed to re-cool

the cooling water in the basic module (or if available
in the extension module).
The task of the re-cooling system is to dissipate the
heat from the cooling water of the cooling module.
The user must initiate the planning work for the sep-
arate re-cooling system. The installation must be
planned and carried out by qualified experts.

4.2 Overall air throughput

Due to the internal air circulation, the overall air con-

sumption of the water-cooled air supply unit is much
smaller than of the air-cooled air supply unit.
Only the cooling air for cooling the electronics sys-
tem and the suction air of the printing press is re-
leased via the cabinet top. These air volumes are
relatively small and do not need to be considered in
calculating the air consumption for the pressroom.
Therefore an exhaust-air hood is not needed for the
water-cooled air supply unit.

4.3 Process air supply for the printing process

Please refer to the Chapter ”Air Supply Cabinets”

and, analogously, to the Chapter ”Process Air Supply
for the Printing Process” for the technical specifica-
tions of the water–cooled air supply units

D AirStar-WGK 91
D AirStar-WGK C2
D AirStar-WGK C3
D AirStar-WGK C4
D AirStar-WGK C5
D AirStar-WGK C6

4.4 Removing the process air from the printing process

Extracting the process air (blast air) that is brought in

during the printing process from the printing press is
not planned.
The standard volumetric flow of the process air must
be included in the air throughput calculations for the
pressroom if the air supply cabinet is not installed in
the pressroom but, for example, in a separate equip-
ment room (see Chapter ”Installation of the Air Sup-
ply Cabinet at a Point Different to the Standard
Installation Place”).

A.6.15
 Installation of the air supply

5 Installation of the pneumatic compressor station

UTKSC9064005001000000

5.1 General information

The pneumatic compressor station ScrollStar plus is

installed in the row of the peripheral cabinets in the
delivery area. The best position is between the ex-
haust-air cleaning cabinet and the air supply cabinet.
The Boge SBD-250 pneumatic compressor station
can be installed at a distance of up to 30 m (98 ft)
away from the printing press.
To ensure safe operation of the printing press, the
pressure in the compressed-air line must not drop
below 7.5 bar (109 psi) when the distance exceeds
30 m (98 ft).

Note
At an air pressure of < 6,5 bar (< 94 psi),
the printing press is shut down automati-
cally (print interruption).

5.2 Minimum distances at the installation location

1
GR SG9044006000001000

connection / service side

2 rear

To be able to carry out maintenance work at the

pneumatic compressor station, the following mini-
mum distances to surrounding objects must be ob-
served.

D Distance at the connection / service side:

min. 750 mm (30 in).
D Distance at the rear: min. 400 mm (min. 16 in).

min. 400 mm
min. 750 mm (min. 16 in)
(min. 30 in)

Fig. 7 Minimum clearances; example of the

ScrollStar plus

A.6.16
 Installation of the air supply

5.3 Installation site requirements

D Room temperature:
min. 0 oC(32 oF);
max. 40 oC(104 oF).
D Air humidity:
50% ... 58%.
D Steady temperature conditions must be en-
sured.
D The air quantity removed from the installation
site must be returned in a suitable form.
D Air velocity of the ambient air for installation in
the pressroom:
<0.2 m/s (<0.65 fps).
D Air velocity of the ambient air for installation in a
separate equipment room:
<1.0 m/s (<3.28 fps).

A.6.17
 Installation of the air supply

6 Installation of the air supply cabinet

UTKSC9064006001000000

6.1 General information

If the air supply unit is installed at a distance of more

than 10 m (33 ft) from the printing press, special
measures must be taken during the installation.

6.2 Minimum distances at the installation location

GR SG9044007000001000
To be able to carry out maintenance work at the air
supply unit, the following minimum distances to sur-
rounding objects must be observed.
These minimum distances correspond to those of the
standard installation and are valid for the air-cooled
unit as well as for the water-cooled air supply unit.
Increasing the distances facilitates service work and
the replacement of filters.

Note
Adequate cooling air supply must be en-
sured if only the above-mentioned mini-
mum distance is available at the service
side. This requires a distance of at least
one cabinet width between one of the
two end faces of the air supply cabinet
and other units or walls.
With this type of installation, the access
min. 300 mm to the electronic components is very re-
min. 1000 mm (min. 12 in) stricted. The power to the cabinet must
(min. 40 in) be switched off before service and main-
tenance work can be started.

Fig. 8 Minimum clearances; example of the

AirStar-LGK C3

6.3 Installation site requirements

The following requirements must be satisfied for

both, the air-cooled and the water-cooled air supply
cabinet:

D Room temperature:
min. 0 oC(32 oF);
max. 40 oC(104 oF).
D Air humidity:
50% ... 58%.
D Steady temperature conditions must be en-
sured.
D The air quantity removed from the installation
site must be returned in a suitable form.

A.6.18
 Installation of the air supply

D Air velocity of the ambient air for installation in

the pressroom:
<0.2 m/s (<0.65 ft ps).
D Air velocity of the ambient air for installation in a
separate equipment room:
<1.0 m/s (<3.28 ft ps).

6.4 Pressure drops when using exhaust-air hoods for the air-cooled AirStar unit

The effects of air friction lead to pressure loss in

hoses and pipe systems.
When installing an exhaust-air hood on the air-
cooled air supply unit, the inevitable pressure loss
must be compensated by the installation of an extra
suction fan in the exhaust air duct.
For a rough calculation of partial and overall pres-
sure loss and of pneumatic power loss, all necessary
data can be taken from the following table.

Version Exhaust-air volume Diameter of connection Max. flow

[m3/h] ([cu ft/h]) piece for exhaust-air velocity at the
hood connection piece
[mm] ([in]) [m/s] ([ft ps])
AirStar-LGK 91 2100 (74150) DN 400 (15.75) 5.9 (19.35)
AirStar-LGK C2 2100 (74150) DN 400 (15.75) 5.9 (19.35)
AirStar-LGK C3 2200 (77680) DN 400 (15.75) 6.2 (2.34)
AirStar-LGK C4 4000 (141240) DN 500 (19.69) 7.2 (23.62)
AirStar-LGK C5 4100 (144790) DN 500 (19.69) 7.4 (24.28)
AirStar-LGK C6 4200 (148320) DN 500 (19.69) 7.6 (24.93)
Tab. 4 Exhaust-air volume, diameter of connecting socket and maximum flow rate on the air-cooled air
supply unit

Version Pressure loss [Pa] ([lbf/sq ft])

through exhaust-air per meter air pipe per 90o tube bend
hood
AirStar-LGK 91 40 (0.84) 1.0 (0.021) 7 (0.15)
AirStar-LGK C2 40 (0.84) 1.0 (0.021) 7 (0.15)
AirStar-LGK C3 45 (0.94) 1.2 (0.025) 8 (0.17)
AirStar-LGK C4 60 (1.25) 1.6 (0.033) 15 (0.31)
AirStar-LGK C5 75 (1.57) 1.6 (0.033) 15 (0.31)
AirStar-LGK C6 70 (1.46) 1.7 (0.036) 16 (0.33)
Tab. 5 Pressure loss when using exhaust-air hoods on the air-cooled air supply unit

A.6.19
Installation of the air supply

GR SG9044008000001000
Device configuration for the following example

1 Large exhaust-air hood

2 Exhaust pipe
3 90o tube bend
4 Suction fan

Typical calculation using the table above (metric

values):

D Using the AirStar-LGK C4 air supply unit with

large exhaust-air hood.
D Distance between installation site of the air sup-
ply unit and printing press: l = 20 m.
D Number of 90o tube bends in the air pipe: n = 4.
D Cooling air volumetric flow: dV/dt = 4000 m3/h.
Fig. 9 Pressure loss on the example of Air- D Overall efficiency of the suction fan: h = 0.5.
Star-LGK C4
Calculating the overall pressure drop Dp in the pipe
system by adding the partial drops (pressure drop
values see table in Chapter ”Pressure drop when
using exhaust-air hoods in the air-cooled air supply
cabinet”):
Dp = p1 + p2 + p3
= 60 Pa + (20 m x 1,6 Pa/m) + (4 x 15 Pa)
= 152 Pa = 152 kg/ms2
Calculation of the pneumatic power Ppneu to com-
pensate the overall pressure loss Dp:
Ppneu = dV/dt x Dp
= 4000 m3/h x 152 kg/ms2
= 1.1 m3/s x 152 kg/ms2
= 169 kg x m2/s2 ca. 170 W
To overcome the frictional drags in the pipe system,
the suction fan must be able to achieve an increase
in pressure of 152 Pa at a volumetric flow of
4000 m3/h.
For our example, removing the cooling air would re-
quire a suction fan of an electrical rating Pel of
approximately 1 kW to be installed in the exhaust air
duct after the exhaust-air hood.

A.6.20
 Installation of the air supply

Typical calculation using the table above (ANSI

values):

D Using the AirStar-LGK C4 air supply unit with

large exhaust-air hood.
D Distance between installation site of the air sup-
ply unit and the printing press: l = 66 ft.
D Number of 90o tube bends in the air pipe: n = 4.
D Cooling air volumetric flow: dV/
dt = 141256 cu ft/h
D Overall efficiency of the suction fan:
h = 0.5.

Calculating the overall pressure drop Dp in the pipe

system by adding the partial drops (pressure drop
values see table in Chapter ”Pressure Drop When
Using Exhaust-Air Hoods in the Air-Cooled Air Sup-
ply Cabinet”):
Dp = p1 + p2 + p3
= 1.25 lbf/sq ft + (66 ft x 0.033 lbf/sq ft)
+ (4 x 0.31 lbf/sq ft)
= 4.67 lbf/sq ft
Calculation of the pneumatic power Ppneu to com-
pensate the overall pressure loss Dp:
Ppneu = dV/dt x Dp
= 141256 cu ft/h x 4.67 lbf/sq ft
= 659665 lbf x ft/h
= 659665 lbf x ft/3600 s
= 180 W
To overcome the frictional drags in the pipe system,
the suction fan must be able to achieve an increase
in pressure of 4.67 lbf/sq ft at a volumetric flow of
141256 cu ft/h.
For our example, removing the cooling air would re-
quire a suction fan of an electrical rating Pel of
approximately 1 kW to be installed in the exhaust air
duct after the exhaust-air hood.

A.6.21
Installation of the air supply

D The pneumatic power Ppneu must not be con-

fused with the electrical power Pel on the rating
plate of the suction fan.
The pneumatic power of a suction fan is much
lower than its electrical power.
D To ensure correct dimensioning, the selection of
suitable suction fans must be made on the ba-
sis of the characteristic curves from their
manufacturers.
D There is a small clearance between the upper
edge of the cabinet top and the bottom edge of
the exhaust-air hood.
If air escapes from this clearance, the blower
output of the suction fan in the exhaust air duct
is insufficient. In this case, a stronger suction
fan must be used to ensure an adequate cool-
ing of the air supply cabinet.

6.5 Changing the diameter of an air pipe length to the printing press of > 10 m (> 33 ft)

The air-cooled as well as the water-cooled air supply

unit is delivered with air pipes of 14 m (46 ft) length
for the installation at a distance of up to 10 m (33 ft).
If the air supply cabinet is installed at a location that
is more than 10 m (33 ft) away from the printing
press, the diameter of the full length of air pipes be-
tween the air supply cabinet and the printing press
must be increased in order to compensate too large
a pressure drop.
Extending the standard air pipes with air pipes of a
larger diameter is not permitted!
The new inside diameter of an air pipe is determined
as follows on the basis of the so-called supplemen-
tary length:
x = l + (n x 1 metre) [m]
or
x = l + (n x 3.3 feet) [ft]
Whereby:
x ... supplementary length [m] or [ft];
l ... actual distance between air supply unit and print-
ing press in [m] or [ft];
n ... number of 90o tube bends in the air pipe.
With the outside diameter dS of the cabinet connect-
ing socket and the calculated equivalent length x, the
related inside diameter dL of the air pipe can be read
from the following table:

A.6.22
 Installation of the air supply

Outside diameter Supple- Inside diameter of

of socket mentary air pipe
dS[mm] ([in]) length x dL[mm] ([in])
[m] ([ft])
15 (49) 35 (1.38)
20 (66) 38 (1.50)
32 (1.26)
25 (82) 40 (1.57)
30 (98) 42 (1.65)
15 (49) 44 (1.73)
20 (66) 46 (1.81)
40 (1.57)
25 (82) 48 (1.89)
30 (98) 50 (1.97)
15 (49) 60 (2.36)
20 (66) 65 (2.56)
55 (2.17)
25 (82) 67 (2.64)
30 (98) 70 (2.76)
15 (49) 70 (2.76)
20 (66) 75 (2.95)
65 (2.56)
25 (82) 79 (3.11)
30 (98) 82 (3.23)
Tab. 6 Calculating the inside diameter for air pipes

If the calculated supplementary length x is between

two values listed in the above table, choose the next
largest supplementary length.
If pipes are used instead of air hoses, the standard
diameter of the next wider inch pipe must be se-
lected after dL has been determined.
Typical calculation using the table above (metric
values):

D Distance between installation site of the air sup-

ply unit and the printing press: l = 20 m.
D Number of tube bends in the air pipe: n = 3.

D Diameter of the cabinet connecting socket:

dS = 40 mm.
D The following applies:
x = l + (n x 1 metre)
= 20 m + (3 x 1 metre)
= 23 m
D With a supplementary length x = 25 m, the
above table details the diameter of the air pipe
as follows:
dL = 48 mm

A.6.23
Installation of the air supply

Typical calculation using the table above (ANSI

values):

D Distance between the installation site of the air

supply unit and the printing press: l = 66 ft.
D Number of tube bends in the air pipe: n = 3.

D Diameter of the cabinet connecting socket:

dS = 1.57 in.
D The following applies:
x = l + (n x 3.3 ft)
= 66 ft + (3 x 3.3 ft)
= 76 ft
D With a supplementary length of x = 82 ft the
above table details the diameter of the air pipe
as follows: dL = 1.89 in

Air pipe requirements

D For temperature and pressure stability: see

Chapter ”Suction and Blast Air Supply (Low
Pressure)”, section ”Typical temperatures of
suction and blast air during the operation of the
printing press”.
D Resistant to pressure and temperature at the
maximum occurring air temperatures (see also
the following Note).
D Smooth inner wall to reduce the flow resistance.
If necessary, utilization of suitable pipes.
D Lengths of air pipes as short as possible.
D Installation as straight as possible.
D Chemical resistance against common solvents
and cleaners.
D Avoid using thin-walled air pipes. Background:
The compression of the air produces sound
waves that are propagated via the pipe walls.
D Bending radius for the installation:
More than five times the inside diameter of the
air pipe.
D Maintaining the inner diameter also with 90o
tube bends. The air pipes must not be kinked.
D Because of increased temperatures during op-
eration, air pipes must not be installed in cable
conduits next to electrical cables.

Note
Very often, manufacturers of air hoses
state temperature and pressure stability
independently of each other.
It is necessary, that air pipes are at the
same time temperature- and pressure-
resistant at the occurring maximum tem-
peratures.

A.6.24
 Installation of the air supply

For SM 102 only:

With some compressors, the air that flows back after

the compressor is switched off may damage the unit
(the unit rotates backward). To avoid this, a corre-
sponding non-return flap must be installed at the S6
pressure socket of the corresponding AirStar cabi-
nets. This flap is not contained in the scope of deliv-
ery from Heidelberg.

A.6.25
 Installation of the air supply

7 Air supply via central air supply systems

UTKSC9064007001000000

7.1 General information

Some print shops use central air supply systems with

one or several central compressor stations. These
systems supply compressed air to one or several
compressed-air supply networks.
For reasons of uniform and manageable mainte-
nance, the customer often wants the printing press to
be connected to such a central compressed-air sup-
ply system.
The air supply for the printing press must be pro-
vided in two different air pressures:

D Compressed-air supply (performance features

according to Chapter ”Compressed-air supply
and compressed-air conditioning”);
D Suction and blast air supply (performance fea-
tures according to Chapter ”Suction and blast
air supply”).

Note
You are strongly advised not to produce
blast air via an expansion process of the
compressed air. This would mean great
investment costs and also high energy
costs.

A.6.26
 Installation of the air supply

7.2 Compressed-air supply (high pressure)

Compressed air requirement

When the compressed-air is provided by a central

compressed-air supply system, the following mini-
mum requirements must be met.

Press Feeding point Operating pressure Minimum volumetric

model [barrel.] ([psirel.]) flow at 7 barrel.
[l/min] ([cu in/min])
CD 102-1 + L
CD 102-1 + LX
CD 102-2
CD 102-2 + LX
CD 102-2 + LYLX 200 (12200)
CD 102-3
CD 102-3 + L
CD 102-3 + LX
CD 102-3 + LYLX
CD 102-4
CD 102-4 + L
CD 102-4 + LX
CD 102-4 + LYLX
Feeder at operator’s side
CD 102-5 7 ... 10 (102 ... 145)
(O.S.)
CD 102-5 + L
CD 102-5 + LX
CD 102-5 + LYLX
CD 102-6
300 (18300)
CD 102-6 + L
CD 102-6 + LX
CD 102-6 + LYLX
CD 102-7
CD 102-7 + L
CD 102-7 + LX
CD 102-8
CD 102-8 + L
CD 102-8 + LX
Tab. 7 Compressed-air consumption

A.6.27
Installation of the air supply

Implementation of the compressed air connec-

tion

D A special compressed-air connecting hose (fi-

brous hose) of the following technical specifica-
tions comes with the Heidelberg printing press
versions without a compressor station.
D Inside diameter:
13 mm (0.51 in)
D Outside diameter:
17.6 mm (0.69 in)
D Length: 11 m (36.1 ft)
D Minimum bending radius:
100 mm (3.94 in)
D Operating temperature:
0 oC ... +40 oC (+32 oF ... +104 oF)

The compressed-air hose provided must be con-

nected in a suitable form to the fixed compressed-air
supply pipe that is installed in the pressroom. A
screwed connection is recommended.

D The compressed-air hose must be laid such

that it is easily accessible for service and repair
work. We do not recommend an installation in
supply ducts (underfloor ducts).
The compressed-air hose can be installed next
to current-carrying cables.
D The compressed-air hose must adequately be
connected to the printing press at the drive
side D.S., between feeder and printing unit 1.
D The pressure control valve at the printing press
is factory-set and may not be adjusted!
D The compressed air must feature the following
properties:
D Air intake temperature:
min. 0 oC (32 oF);
max. 40 oC (104 oF);
As a rule, the air intake temperature
should be at least 5 oC (9 oF) below the
ambient temperature. However, it must not
be lower than the minimum suction tem-
perature.
D Maximum oil content of the air:
1 mg/m3 (per standard cubic meter atmo-
spheric air).
D Maximum water content of the air:
5.9 g/m3 at 7 bar (102 psi) gauge pressure
(corresponds to a dew point at
+3 oC (+37 oF)).
D Solid content of the air:
Particle size max. 5 mm
Particle number density max. 5 mg/m3.

A.6.28
 Installation of the air supply

Guarding and protective measures

A pressure switch on the printing press monitors the

input pressure. It recognizes if the air pressure drops
below 6 bars (87 psi) for more than 5 seconds. In
this case, there will be a fault message on presses
with CPTronic or CP 2000 control system.

Checking the compressed air connection

Once the compressed air connection has been

installed, it must be checked for leaks (listening
check). This must be done at a time at which com-
pressed air is not consumed and/or no noises disturb
the verification.

Repair work

Warning – Danger if repair work is

not carried out properly!
Repair work must never be carried out
on pneumatic systems which are under
pressure.
This can lead to serious injuries.
Therefore, repair work may only be
carried out if the entire installation or
the respective part of the system has
been depressurized.

In the case of leakage, compressed-air hoses must

not be repaired along the walls.
In this case, a spare line must be ordered from Hei-
delberg-Service and be installed.

A.6.29
Installation of the air supply

7.3 Suction and blast air supply (low pressure)

Blast air required at the central air distributor

To enable the overall blast air volume requirements

to be calculated, the allocations of the AirStar cabi-
nets to the machine versions are listed here.

Press AirStar version for machines without AirStar version for machines with in-
model intermediate floor drying process termediate floor drying process
CD 102-1 + L(X) AirStar LGK/WGK C4 AirStar LGK/WGK C4
CD 102-2 AirStar LGK/WGK C3 AirStar LGK/WGK C3
CD 102-2 + L(X) AirStar LGK/WGK C4 AirStar LGK/WGK C4
CD 102-2 + LYLX AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-3 AirStar LGK/WGK C3 AirStar LGK/WGK C3
CD 102-3 + L(X) AirStar LGK/WGK C4 AirStar LGK/WGK C4
CD 102-3 + LYLX AirStar LGK/WGK C5 AirStar LGK/WGK C6
CD 102-4 AirStar LGK/WGK C3 AirStar LGK/WGK C3
CD 102-4 + L(X) AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-4 + LYLX AirStar LGK/WGK C6 AirStar LGK/WGK C6
CD 102-5 AirStar LGK/WGK C4 AirStar LGK/WGK C4
CD 102-5 + L(X) AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-5 + LYLX AirStar LGK/WGK C6 AirStar LGK/WGK C6
CD 102-6 AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-6 + L(X) AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-6 + LYLX AirStar LGK/WGK C6 AirStar LGK/WGK C7
CD 102-7 AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-7 + L(X) AirStar LGK/WGK C6 AirStar LGK/WGK C6
CD 102-8 AirStar LGK/WGK C5 AirStar LGK/WGK C5
CD 102-8 + L(X) AirStar LGK/WGK C6 AirStar LGK/WGK C6
CD 102-9 AirStar LGK/WGK C6 AirStar LGK/WGK C6
Tab. 8 Allocation AirStar version to machine version
D The standard volume flow for each individual
connecting socket of the air supply unit is listed
in this Chapter under the heading ”Typical oper-
ating conditions of the press for the configura-
tion of a central air supply”.

A.6.30
 Installation of the air supply

Suction and blast air required at feeder and deliv-

ery

Press model Feeding Consumer Supply through

point connection socket no.
Suction nozzles on the suction head
S4
Sheet catcher
Feeder Governor foot at the suction head S6

CD 102-1 + L ... Forwarding flap

CD 102-8 + LX Lateral, diagonal and rear edge blowers S5
Lateral sheet separation blowers
Delivery Sheet brake above the yellow filter
S7
Sheet catcher
Tab. 9 Suction and blast air consumption on feeder and delivery
D The standard volume flow for each individual
connecting socket of the air supply unit is listed
in this Chapter under the heading ”Typical oper-
ating conditions of the press for the configura-
tion of a central air supply”.
D The standard volumetric flow refers to the air
values under standard condition:
D Ambient pressure:
p0 = 1013 mbar (14.7 psi);
D Ambient temperature:
T0 = 20 oC (68 oF);
D Air density: òL = 1.20 kg/m3

D Definition of absolute pressure pabs.:

pabs. = p0 + prel.
D Definition of relative pressure prel.:
prel. = pabs. – p0

Typical operating states of the printing press for

the layout of a central air supply

Depending on the adjustment of suction and blast air

consumers in the press, there are different operating
conditions. Two typical operating conditions are
shown in the table below.

A.6.31
Installation of the air supply

Alternative Inside diame- Typical operating condition Typical operating condition End pres-
supply con- ter A B sure
nection or air hose [barabs.]
Standard Absolute Standard Absolute
socket no. [mm] ([in]) ([psiabs.])
volume flow pressure volume flow pressure
[m3/h] [barabs.] [m3/h] [barabs.]
([cu ft/h]) ([psiabs.]) ([cu ft/h]) ([psiabs.])
S1 65 (2.56) 205 (7240) 1.20 (17.4) – – 1.26 (18.3)
S2 65 (2.56) 205 (7240) 1.20 (17.4) – – 1.26 (18.3)
S3 65 (2.56) 103 (3640) 1.20 (17.4) – – 1.26 (18.3)
S4 32 (1.26) 12 (420) 0.41 (6.0) 22 (780) 0.6 (8.8) 0.33 (4.8)
S5 40 (1.57) 100 (3530) 1.43 (27.0) 110 (3890) 1.4 (20.5) 1.46 (21.2)
S6 40 (1.57) 50 (1770) 1.86 (27.0) 60 (2120) 1.6 (23.4) 2.01 (29.2)
S7 55 (2.17) 60 (2120) 0.56 (8.1) 120 (4240) 0.8 (11.8) 0.46 (6.7)
S8 65 (2.56) 205 (7240) 1.20 (17.4) – 1.26 (18.3)
S9 65 (2.56) 205 (7240) 1.20 (17.4) – 1.26 (18.3)
S10 65 (2.56) 205 (7240) 1.20 (17.4) – 1.26 (18.3)
S11 65 (2.56) 205 (7240) 1.20 (17.4) – 1.26 (18.3)
Tab. 10 Typical operating conditions of the press for the configuration of a central air supply
D The values for standard volume flow and abso-
lute pressure for S1 to S3 and S8 to S11 for the
”typical operating condition B” are not listed
since the air is supplied to a joint manifold in
which the pressure is kept constant.
D The connection sockets S1 to S11 are de-
scribed in the Chapter ”Process Air Supply for
the Printing Process”.
D The standard volume flow for the individual
press versions with reference to the main sup-
ply are detailed in this Chapter under the head-
ing ”Blast air consumption on the central air dis-
tributor” and ”Suction and blast air consumption
on feeder and delivery” on the two previous
pages.

Typical temperature states of suction and blast

air during the operation of the printing press

The selection of suitable air supply lines must be

made according to the columns ”Maximum process
air temperature at 40 oC (104 oF) ambient tempera-
ture” and ”End pressure”.

A.6.32
 Installation of the air supply

Alternative Inside diame- Temperature rise DT of the Max. process air tempera- End pres-
supply con- ter of air hose process air by ture at 40 oC (104 oF) ambi- sure
nection [mm] ([in]) compression or ent temperature [barabs.]
socket no. air intake [oC] ([oF]) [oC] ([oF]) ([psiabs.])
S1 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
S2 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
S3 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
S4 32 (1.26) 20 (36) 40 (104) 0.33 (4.8)
S5 40 (1.57) 65 (117) 105 (221) 1.46 (21.2)
S6 40 (1.57) 40 (72) 80 (176) 2.01 (29.2)
S7 55 (2.17) 20 (36) 60 (140) 0.46 (6.7)
S8 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
S9 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
S10 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
S11 65 (2.56) 40 (72) 80 (176) 1.26 (18.3)
Tab. 11 Typical temperatures of suction and blast air during the operation of the printing press
Note
The maximum occurring process air
temperature is measured at the connec-
tion socket of the air supply cabinet.

D The connection sockets S1 to S11 are de-

scribed in the Chapter ”Process Air Supply for
the Printing Process”.
D Process air is the suction air and the blast air
for the printing process.
D If the temperature in the pressroom is below
40 oC (104 oF), air pipes with a lower tempera-
ture stability can be used. The temperature sta-
bility can be calculated using the ambient tem-
perature and the ”Temperature rise of the
process air” values from the table above.
D Example:
D Typical pressroom temperature with air-
conditioning: 25 oC (77 oF);
D Connecting socket: S5;
D Temperature rise DT on S5:
65 oC (117 oF);
D Maximum process air temperature:
25 oC + 65 oC = 90 oC
or
77 oF + 117 oF = 194 oF

A.6.33
 Installation of the air supply

8 Installing the exhaust air cleaning cabinet

UTKSC9064008000000000

8.1 General information

The exhaust air cleaning cabinet CleanStar com-

bines the exhaust air streams from the individual
suction points in the delivery of the printing press,
and filters the exhaust air that is loaded with spray
powder. The cleaned air is blown out of the top of the
CleanStar. Optionally, it can be led from the press-
room into the open air via an exhaust-air hood and a
connected pipe system.
The CleanStar is switched on via the central control
box ZSG. It is triggered via the printing press control
station.
Swivel doors make the inside of the exhaust air
cleaning cabinet accessible from the front and from
the rear.

8.2 Installing the exhaust air cleaning cabinet

Depending on the printing press version, one or two

exhaust air cleaning cabinets are required:

D Machines with standard delivery: 1 exhaust air

cleaning cabinet.
D Machines with extended delivery: 2 exhaust air
cleaning cabinets.

The exhaust air cleaning cabinets are installed next

to the dryer cabinet. There are two hose connections
(Ø 160 mm) for each cabinet; the hose pipes run at
the D.S. from the bottom into the delivery. The maxi-
mum hose length is 6 m.

A.6.34
 Installation of the air supply

8.3 Air throughput in the exhaust air cleaning cabinet

GR SG9064400000000000
Intake of powder-loaded air
4
2 Electrical connection
3 Clean air outlet
3 4 Exhaust-air hood (option)

The powder-loaded exhaust air is first cleaned in the

intake air room. Coarse contamination (such as pa-
per chips) are separated here. Next, the air passes a
prefilter and a filter cartridge where fine dust particles
separated.
2 Finally, the clean air is blown out of the clean air
room via the top of the CleanStar.
In the standard version, the clean air is blown directly
into the pressroom. Optionally, an exhaust-air hood
can be used. Depending on the length of the exhaust
pipe, additional fans may be required in the exhaust
pipe.

Fig. 10 CleanStar exhaust air cleaning cabinet

8.4 Suction points of the CleanStar unit

GR SG9064000000000000

Depending on the machine version, the exhaust air

is sucked from the delivery at several points.
2
Standard delivery

D The ”Foil suction” (Fig. 11/1) sucks the powder-

3 loaded air that emerges downwards towards
the exhaust air cleaning cabinet (Fig. 11/2).
D ”Rear edge suction” (Fig. 11/3) removes the
powder-loaded air through an integrated suction
duct at the rear edge of the pile.

1 Extended delivery

D In addition to the suction points in the standard

delivery, air is sucked at D.S. and O.S. from a
suction tube behind the last slide-in dryer. This
Fig. 11 extraction requires a second exhaust air clean-
ing cabinet.

With a new filter, the maximum air flow volume per

exhaust air cleaning cabinet is approximately
2400 m3/h.

A.6.35
Installation of the air supply

A.6.36
 Chapter overview

Installation of the dampening solution supply

1 Installation of the dampening solution supply . . . . . . . . . . . . . . . . . . . . A.7.3

1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.7.3
1.2 Dampening solution supply via central dampening solution supply systems . . . . . A.7.3

A.7.1
Chapter overview

A.7.2
 Installation of the dampening solution supply

1 Installation of the dampening solution supply

UTKSC9064200001000000

1.1 General information

Warning – Danger when installation

work is not carried out correctly!
Planning and any other work that con-
cern the dampening solution supply of
the printing press must be initiated by
the user or the management of the
printshop, and may only be carried out
by qualified experts.
Relevant national provisions must also
be observed!

D Heidelberg printing presses are always pre-

pared for the connection to a central dampening
solution supply (building mains).
D This Chapter must also be made available to
the appointed experts for planning the neces-
sary installation work.

1.2 Dampening solution supply via central dampening solution supply systems

Type and layout of the dampening solution sup-

ply system

D Connecting the printing press to a central

dampening solution supply system (building
mains) requires a dampening solution inlet tem-
perature of 8 oC ... 10 oC (46 oF ... 50 oF) to be
maintained.
D The temperature of the dampening solution in
the press must not rise by more than 1 oC
(1.8 oF).
D Never use distilled or demineralized water as
dampening solution.
D The link to a central dampening solution supply
system requires special water treatment. The
standard values of the water quality are detailed
in the Chapter ”Water supply and conditioning”.
D The removal of the dampening solution requires
a suitable removal system to be planned and
installed. Dampening solution which is no lon-
ger usable must never be disposed of via the
sewage system.

A.7.3
Installation of the dampening solution supply

Requirements on fixed dampening solution inlet

and return lines

D The user must select the dampening solution

supply lines such that they are suitable for the
occurring operating conditions and able to with-
stand external influence. The dampening solu-
tion supply line should be made from high-
grade steel, galvanized steel, or PVC. We
recommend not to use copper lines or copper-
plated lines.

Layout of the dampening solution connection

D To avoid a pollution of the fresh water with

dampening solution, suitable check valves (pipe
dividers) should be installed between the fresh
water connection and the dampening solution
preparation system.
D The fixed dampening solution supply and return
pipes must adequately be grounded against
static charge.
D The user must provide a flexible hose of the
following properties that is to be laid between
the fixed dampening solution supply and return
lines and the printing press:
D Inside diameter of the dampening solution
supply line:
25 mm (1 in)
D Inside diameter of the dampening solution
return line:
32 mm (1.26 in)
D Minimum bending radius:
100 mm (3.94 in)
D Maximum operating pressure:
6 bars (87 psi)
D Operating temperature:
8 oC ... 20 oC (46 oF ... 68 oF)
D Material: PVC fibrous hose, for example.

D Between the fixed dampening solution supply

line and the flexible dampening solution supply
hose, a coarse filter and a stop-cock should be
installed.
D Always lay the hoses separately from the other
supply lines (power, air, etc.) to the printing
press.
D Use a suitable hose clamp for fixing the hose to
the dampening solution connecting socket of
the printing press.
D Thoroughly rinse the dampening solution supply
and return pipes after they have been installed.

A.7.4
Installation of the dampening solution supply

Testing the dampening solution connection

D After the dampening solution connections have

been established, the tightness of the dampen-
ing solution supply and return lines and of all
hose couplings must be tested (visual inspec-
tion).

A.7.5
Installation of the dampening solution supply

A.7.6
 Chapter overview

Installation of the dryer units

1 Mains connection of the IR dryer to the three-phase mains . . . . . . . . A.8.3

1.1 Supplementary general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.3
1.2 Overview of the Standard Connections to power supply . . . . . . . . . . . . . . . . . . . . . . . A.8.4
1.3 Standard mains connection, versions A1 to A5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.5
1.4 Cross-sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.9

2 Air-cooled dryer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.11

2.1 Drying air for the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.11
2.2 Process air extraction from the drying process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.13
2.3 Intermediate floor drying process as pre-drying (only with CD 102) . . . . . . . . . . . . . A.8.13

3 Cooling Water Circuit of the Water-Cooled Guide Plate . . . . . . . . . . . A.8.14

3.1 Cooling Water Circuit of the Water-Cooled Guide Plate . . . . . . . . . . . . . . . . . . . . . . . A.8.14

4 UV Drying Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.15

4.1 Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.15
4.2 Technical Pre-Installation by Heidelberger Druckmaschinen AG . . . . . . . . . . . . . . . . A.8.15
4.3 Intermediate Floor Drying Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.15
4.4 Requirements on the UV Dryer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8.16
4.5 Clarification of Technical Aspects by the Manufacturer of the UV Dryers . . . . . . . . A.8.16

A.8.1
Chapter overview

A.8.2
 Installation of the dryer units

1 Mains connection of the IR dryer to the three-phase mains

UTKSC9064401001000000

1.1 Supplementary general notes

Warning – Electrical shock when

touching voltage-carrying parts!
Any electrical installation work may
only be carried out by qualified experts
and when the mains is switched off.
The mains connection must be
installed according to the relevant
specifications in DIN EN 60204 and/or
IEC 204.
The Chapters ”Basic Regulations for
Mains Connections” and ”Basic Rec-
ommendations and Information for
Mains Connections” must be observed
when the IR dryer connection to the
power mains is prepared.
Relevant national provisions must also
be observed!

In addition to the requirements and recommenda-

tions of the Chapters ”Basic Regulations for Mains
Connections” and ”Basic Recommendations and In-
formation for Mains Connections”, the following
notes must be observed:

D The IR dryer requires a separate three-phase

mains connection (independent of the printing
press).
D All slide-in dryers in the press are supplied with
power via the dryer control cabinet.
D In addition, the dryer control cabinet contains all
air supply units that are required for the drying
process, and a cooling unit for the sheet guide
in the delivery (water cooling).
D The IR dryer is equipped with a half-wave con-
trol which is located in the dryer cabinet.
The following question must be clarified with the
local public utility:
D If more than one printing press is operated
in the print shop: Is it necessary to install a
desynchronising system?

D The dryer can be connected to the printing

press without any additional EMC measures.

A.8.3
Installation of the dryer units

1.2 Overview of the Standard Connections to power supply

Nominal voltages IR dryer version with mains connection variant

and frequencies of
the
three-phase mains
DryStar Ink DryStar Coating DryStar Combination
AC 200 V 50 Hz Version A1 Version A1 Version A1
60 Hz Version A2 Version A2 Version A2
AC 208 V 50 Hz Version A1 Version A1 Version A1
60 Hz Version A2 Version A2 Version A2
AC 220 V 50 Hz Version A1 Version A1 Version A1
60 Hz Version A2 Version A2 Version A2
AC 230 V 60 Hz Version A2 Version A2 Version A2
AC 240 V 60 Hz Version A2 Version A2 Version A2
AC 350 V 50 Hz Version A1 Version A1 Version A1
AC 380 V 50 Hz Version A3 Version A3 Version A3
60 Hz Version A4 Version A4 Version A4
AC 400 V 50 Hz Version A3 Version A3 Version A3
AC 415 V 50 Hz Version A3 Version A3 Version A3
AC 440 V 50 Hz Version A1 Version A1 Version A1
60 Hz Version A2 Version A2 Version A2
AC 480 V 60 Hz Version A5 Version A5 Version A5
AC 600 V 60 Hz Version A2 Version A2 Version A2
Tab. 1 Overview of standard mains connections
D Please contact Heidelberg Service to agree the
mains connection if the table above does not
permit any allocation to be made.
D The operating voltage of the dryer cabinet is
AC 400 V.
D For a mains frequency of 60 Hz, Heidelberger
Druckmaschinen AG always supplies an addi-
tional matching transformer (including connect-
ing cables) that may only be installed by
Heidelberg Service.
In order to enable the units with a frequency-de-
pendent working point (e.g. air blowers) to be
used, the matching transformer raises the volt-
age from AC 400 V to AC 480 V.

Description of the mains connection versions A1

to A5:

See Chapter ”Standard Mains Connection, Versions

A1 to A5”.

A.8.4
 Installation of the dryer units

Example taken from the opposite table

For a printing press, the ”DryStar Ink” IR dryer ver-

sion was ordered.
The local voltage of the three-phase mains is as-
sumed to be AC 350 V, the mains frequency is
50 Hz.
Row ”AC 350 V/50 Hz” and column ”DryStar ink”
show:
Mains connection version A1.

1.3 Standard mains connection, versions A1 to A5

Connection diagram

GR SG9044403000001000
Responsibility of Heidelberg service Responsibility of customer

Fig. 1 Layout of the mains connection according to versions A1 to A5

1 Mains
2 Fuses
3 Supply cables
4 Dryer cabinet with mains connection area
5 Series or matching transformer
6 Cables between mains connection area and
series transformer (feeder cable length: 5 m;
return cable length: 5 m; cables included in the
delivery)

Note
With versions A1 to A5, the mains is al-
ways connected to the series terminals
of the dryer cabinet. Connecting the
mains is within the user’s responsibility.

A.8.5
Installation of the dryer units

Standard mains connection, version A1

Valid for the following electrical ratings and dryer

models:

D AC 200 V/50 Hz, all dryer versions

D AC 208 V/50 Hz, all dryer versions
D AC 220 V/50 Hz, all dryer versions
D AC 350 V/50 Hz, all dryer versions
D AC 440 V/50 Hz, all dryer versions

GR SG9044404000001000
Power Mains connection area
supply system (dryer cabinet)

PE
Series transformer

3 AC 400 V/
Back–up fuses 50 Hz
L1
L2
L3

Responsibility of customer Responsibility of Heidelberg service

Fig. 2 Wiring diagram for mains connection version A1

Standard mains connection, version A2

Valid for the following electrical ratings and dryer

models:

D AC 200 V/60 Hz, all dryer versions

D AC 208 V/60 Hz, all dryer versions
D AC 220 V/60 Hz, all dryer versions
D AC 230 V/60 Hz, all dryer versions
D AC 240 V/60 Hz, all dryer versions
D AC 440 V/60 Hz, all dryer versions
D AC 600 V/60 Hz, all dryer versions

A.8.6
 Installation of the dryer units

GR SG9044405000001000
Power Mains connection area
supply system (dryer cabinet)

PE
Series transformer
3 AC 480 V/
60 Hz

Back–up fuses
L1
L2
L3

3 AC 400 V/
60 Hz

Responsibility of customer Responsibility of Heidelberg service

Fig. 3 Wiring diagram for mains connection version A2

Standard mains connection, version A3

Valid for the following electrical ratings and dryer

models:

D AC 380 V/50 Hz, all dryer versions

D AC 400 V/50 Hz, all dryer versions
D AC 415 V/50 Hz, all dryer versions

GR SG9044406000001000
Power Mains connection area
supply system (dryer cabinet)

PE
Back–up fuses
L1
L2
L3

Responsibility of customer Responsibility of Heidelberg service

Fig. 4 Wiring diagram for mains connection version A3

A.8.7
Installation of the dryer units

Standard mains connection, version A4

Valid for the following electrical ratings and dryer

models:

D AC 380 V/60 Hz, all dryer versions

GR SG9044407000001000
Power Mains connection area Matching transformer
supply system (dryer cabinet)
3 AC 480 V/
60 Hz

PE
Back–up fuses
L1
L2
L3

Responsibility of customer Responsibility of Heidelberg service

Fig. 5 Wiring diagram for mains connection version A4

Standard mains connection, version A5

Valid for the following electrical ratings and dryer

models:

D AC 480 V/60 Hz, all dryer versions

A.8.8
 Installation of the dryer units

GR SG9044409000001000
Power Mains connection area
supply system (dryer cabinet)
3 AC 480 V/
60 Hz

PE
Series transformer

Back–up fuses
L1
L2
L3

3 AC 400 V/
60 Hz

Responsibility of customer Responsibility of Heidelberg service

Fig. 6 Wiring diagram for mains connection version A5

1.4 Cross-sections of the conductor terminals

Warning – Danger if the following

safety instructions are not observed!

D The matching transformer may only be used for

the power supply of the dryer cabinet and the
electrical consumers that are connected to it
and intended for this use by Heidelberg.
D Don’t connect any additional consumers like, for
example, non-Heidelberg units to the series
transformer.
D Only one current conductor must be connected
per terminal. Terminal connections must be car-
ried out in a way that they do not work lose dur-
ing operation.
D With respect to the requirements to the power
lines and type and test of the mains connection,
the rules from the Chapter ”Basic Regulations
for Mains Connections” apply.

Cross-sections of the conductor terminals [mm2] ([sq in])

DryStar ink DryStar coating DryStar combination
IR dryer cabinet 70 (0.108) 70 (0.108) 150 (0.232)
Connection transformer
primary 70 (0.108) 70 (0.108) 200 – 240 V: 240 (0.372)

A.8.9
Installation of the dryer units

Cross-sections of the conductor terminals [mm2] ([sq in])

DryStar ink DryStar coating DryStar combination
350 V:150 (0.232)
380 – 600 V: 70 (0.108)
secondary 70 (0.108) 70 (0.108) 70 (0.108)
Tab. 2 Cross-sections of the conductor terminals
Conductor terminals and possible cable cross-
sections

The cross-sections of the conductor terminals in the

matching transformer and in the IR dryer cabinet per-
mit the following conductor cross-sections of
stranded wires to be used:

Cross section of the terminal Possible cable cross-section Possible cable cross-section
[mm2] ([sq in]) in the IR dryer cabinet in the matching transformer
[mm2] ([sq in]) [mm2] ([sq in])
70 (0.108) 10 ... 95 10 ... 95
(0.015 ... 0.147) (0.015 ... 0.147)
150 (0.232) 35 ... 185 35 ... 185
(0.054 ... 0.286) (0.054 ... 0.286)
240 (0.372) – 70 ... 240
(0.108 ... 0.372)
Tab. 3 Conductor terminals and possible cable cross-sections
Note
Conductor terminal for the protective
earth (PE) conductor:
eyelet terminal, diameter = 8.5 mm
(0.33 in) (M8 thread).

A.8.10
 Installation of the dryer units

2 Air-cooled dryer cabinet

UTKSC9064402001000000

2.1 Drying air for the printing process

Assignments of the connection sockets of the

air-cooled dryer cabinets

GR SG9044408000002000
S14
S5 S13
S2 S12
S4 S11
S3
S1 S10
S9 S8
S7 S2
S6
S5 S1
Fig. 7 Assignment of the connection sockets of the air-cooled dryer cabinets

Note
The numbering of the connection sock-
ets is valid across all dryer cabinets.

Connection Version
socket no.
DryStar Ink DryStar Coating DryStar Combination
S1 * *
S2 * * *
S3 * *
S4 * *
S5 * * *
S6 *
S7 *
S8 *
S9 *
S10 *

A.8.11
Installation of the dryer units

Connection Version
socket no.
DryStar Ink DryStar Coating DryStar Combination
S11 o

S12 *
S13 *
S14 *
Tab. 4 Assignment of the connection sockets of the dryer cabinets
* Connection socket exists and is used
o Connection socket exists and is not used

Connection Outside diameter Consumer Function

socket no. of socket [mm] ([in])
S1 100 (3.94) Coating dryer 1 Blast air/hot air
S2 80 (3.15) Ink dryer Blast air/IR radiators
Coating dryer 1 Blast air/IR radiators
100 (3.94) Coating dryer 1 + 2 Blast air/IR radiators
S3 19.05 (3/4 ” ) Sheet guide plate Cooling water return flow
for ink dryer
Sheet guide plate Cooling water return flow
for coating dryer 1
S4 19.05 (3/4 ” ) Sheet guide plate Cooling water supply
for ink dryer
Sheet guide plate Cooling water supply
for coating dryer 1
S5 125 (4.92) Ink dryer Suction air
Coating dryer 1 Suction air
S6 19.05 (3/4 ” ) Sheet guide plate Cooling water return flow
for coating dryer 1
S7 19.05 (3/4 ” ) Sheet guide plate Cooling water supply
for coating dryer 1
S8 19.05 (3/4 ” ) Sheet guide plate Cooling water supply
for coating dryer 2
S9 19.05 (3/4 ” ) Sheet guide plate Cooling water return flow
for coating dryer 2
S10 100 (3.94) Coating dryer 2 Blast air/hot air
S11 80 (3.15) not assigned –
S12 125 (4.92) Coating dryer 2 Suction air
S13 100 (3.94) Cold air unit Blast air/cold air
S14 125 (4.92) Cold air unit Suction air/cold air
Tab. 5 Assignment of the connection sockets of the dryer cabinets

A.8.12
 Installation of the dryer units

2.2 Process air extraction from the drying process

During the ink or varnish drying process, the hot air

can be exhausted from the drying process and be
removed via the exhaust-air hood of the dryer cabi-
net.
The following configurations for air suction exist:

D SM/CD 102 with ink or varnish dryer and stan-

dard delivery: one Dietz blower (M33);
D SM/CD 102 with ink or varnish dryer and ex-
tended delivery: two Dietz blowers (M33 and
M33a);

The technical specifications for the Dietz blower are:

D Air jet pressure (= inlet pressure): 1000 Pa

D Volume flow rate: 1080 m3/h (38140 cu ft/h)

2.3 Intermediate floor drying process as pre-drying (only with CD 102)

GR SC9064411000000000

The intermediate floor drying process as pre-drying

runs in the area of the transfer cylinder between
printing unit and coating unit. Its purpose is to accel-
erate the drying of inks.
The inter-unit dryer as pre-dryer is only available as
an IR dryer (Fig. 8). It is installed under the printing
unit footboard between the last printing unit and the
first coating unit, and is triggered by the dryer cabi-
net. No further dryer cabinet is required if an inter-
unit dryer is used for pre-drying.
The installed electrical power of the dryer causes an
increased heat radiation between the last printing
unit and the coating unit.

Fig. 8 IR slide-in unit intermediate floor drying

process

A.8.13
 Installation of the dryer units

3 Cooling Water Circuit of the Water-Cooled Guide Plate

UTKSC9064403000000000

3.1 Cooling Water Circuit of the Water-Cooled Guide Plate

The printing press can be prepared for the installa-

tion of an IR dryer ex factory. The delivery is then
equipped with a water-cooled guide plate whose
cooling circuit is lead through the dryer cabinet.
The water-cooled guide plate has the following tech-
nical specifications:

D Outside diameter of the cooling water connect-

ing flange:
20 mm (0.79 in);
D Water pressure:
max. 1.5 bars (21 psi).

A.8.14
 Installation of the dryer units

4 UV Drying Process
UTKSC9064404000000000

4.1 Warning

Warning – Danger when installation

work is not carried out correctly!
Planning and any other work that con-
cern the installation of UV drying
equipment in the printing press must
be initiated by the user, and may only
be carried out by qualified experts.
Therefore Heidelberger Druckmaschi-
nen AG accepts no warranty or liability
for personal injury, press damage, or
any defects that are caused by attach-
ing or installing non-HDM devices.
Especially EN 60 204, part 1 and
IEC 204, part 1 must be observed.
Relevant national provisions must also
be observed!

4.2 Technical Pre-Installation by Heidelberger Druckmaschinen AG

Upon special request, certain Heidelberg printing

machines can be prepared in the factory for the
installation of UV dryers.
Also a retrofit to prepare the press for the installation
of a UV dryer is possible. This retrofit may only be
performed by Heidelberg Service.

4.3 Intermediate Floor Drying Process

GR SC9064410000000000

The intermediate floor drying process runs in the

area of the transfer cylinder or (with the perfector) in
the area of the storage drum. Its purpose is to accel-
erate the drying of inks and varnishes.
Intermediate floor drying requires special dryers
which are not part of the Heidelberg range of prod-
ucts.
Depending on the installed electrical power of the
dryers, there is an increased heat emission between
the printing units above the transfer cylinder.
To prevent overheating of the printing press and of
the sheets in the event of an unforeseen interruption
(e.g. emergency stop), the manufacturer of the UV
dryers must take appropriate technical measures
that exclude machine damage owing to overheating.
For example, it is possible to equip the UV radiators
with an automatic water-cooled shutter mechanism.
Fig. 9 Place of installation of the intermediate
floor dryer components

A.8.15
Installation of the dryer units

4.4 Requirements on the UV Dryer System

The following guidance value must be observed

when an UV dryer is installed:

D Maximum temperature in the area of the sensor

of the sheet travel monitor: 70 °C (158 °F);

Furthermore, UV dryers that comply with the

following characteristic values have proved success-
ful in practice:

D Application of CMC radiators (Cold Mirror Con-

vex; cold-light mirror);
D Maximum aperture of the radiator: 45 mm
(1.77 in);
D Max. electrical power per radiator, referring to a
press speed of 5,000 impressions per
hour: 120 W;
D Maximum exhaust-air temperature:
60 °C (140 °F);

Note

The supplier of the UV dryer must initiate the produc-

tion of the required radiation protection plates.

4.5 Clarification of Technical Aspects by the Manufacturer of the UV Dryers

The following technical matters must be verified by

the supplier prior to the installation of UV dryers:

D Calculation of the air flow rate in the cooling

system of the UV dryers.
D Dimensioning and installation of suction con-
duits, hoses and blowers for exhaust-air re-
moval.
D Verifying the application of heat exchangers for
heat recovery from the exhaust air.
D Catalysis of the ozone content in the exhaust
air.

A.8.16
 Chapter overview

Installing the CPTronic and CPC units

1 Power connection of the CPC units to the AC mains (lighting mains, one phase)
A.9.3
1.1 Power connection of the CPC units to the AC mains (lighting mains, one phase) . A.9.3

2 Overview of standard mains connections . . . . . . . . . . . . . . . . . . . . . . . . A.9.5

2.1 Overview of standard mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.5

3 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.7

3.1 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.9.7

A.9.1
Chapter overview

A.9.2
 Installing the CPTronic and CPC units

1 Power connection of the CPC units to the AC mains (lighting mains, one phase)
UTKSC9064801001000000

1.1 Power connection of the CPC units to the AC mains (lighting mains, one phase)

Warning – Electrical shock when

touching voltage-carrying parts!
Any electrical installation work may
only be carried out by qualified experts
and when the mains is switched off.
The mains connection must be
installed according to the relevant
specifications in DIN EN 60204 and/or
IEC 204.
The connection elements must be able
to withstand the occurring electrical,
thermal, and mechanical stress. Rele-
vant national provisions must also be
observed!

For the type of power supply of the respective

CP2000, CPTronic and CPC devices refer to the
following table:

Designation of the Power supply via Connection made by

CPTronic and CPC
Central CPC 1-04 CP 2000- separate Heidelberg qualified
devices
control control Center mains con- Service personnel
cabinet console nection
ZSG (AC, one
phase)
CP 2000-Center * *
CPTronic * *
central control console
CPC 1-04 * *
control console
Standard daylight lamp * *
for CPC 1-04
Standard daylight lamp * *
for CP 2000
QualityControl * *
QualityProof * *
ImageControl * *
Plate Image Reader * *
AutoRegister * * *
Data Control * *
(machine terminal)
Tab. 1 Power connection of the CPTronic and CPC units to the AC mains (lighting mains, one phase)

A.9.3
Installing the CPTronic and CPC units

Note
You may have to replace the connector
of the mains cable provided for a CPC
unit that is fed via a separate one-phase
AC mains connection with a different
connector that is compatible with the lo-
cal requirements.This plug is not deliv-
ered with the press.

A.9.4
 Installing the CPTronic and CPC units

2 Overview of standard mains connections

UTKSC9064802001000000

2.1 Overview of standard mains connections

The appointed experts must match the CPC units

listed below to the supply voltage that exists at the
printing press installation site. The following nominal
voltages and frequencies are possible:

Nominal voltages QualityControl ImageControl Plate Image DataControl

and frequencies of Reader
the AC system
AC 100 V 50 Hz * *
60 Hz * *
AC 110 V 50 Hz * * * *
60 Hz * * * *
AC 115 V 50 Hz * *
60 Hz * *
AC 120 V 50 Hz * *
60 Hz * *
AC 125 V 50 Hz * *
60 Hz * *
AC 145 V 50 Hz *
60 Hz *
AC 160 V 50 Hz *
60 Hz *
AC 200 V 50 Hz * *
60 Hz * *
AC 220 V 50 Hz * * *
60 Hz * * *
AC 230 V 50 Hz * * *
60 Hz * * *
AC 240 V 50 Hz *
60 Hz *
AC 250 V 50 Hz * *
60 Hz * *
Tab. 2 Overview of standard mains connections
* Mains connection possible
D Please contact Heidelberg Service to agree the
mains connection if the table above does not
permit any clear allocation to be made for a
CPC unit.

A.9.5
Installing the CPTronic and CPC units

D The mains connection must be connected by

the skilled personnel appointed by the print
shop user.

A.9.6
 Installing the CPTronic and CPC units

3 Connection diagram
UTKSC9064803001000000

3.1 Connection diagram

GR SG9044800000001000
Responsibility
of customer

Responsibility of
Heidelberg service

Fig. 1 Layout of the mains connection for different CPC devices. Separate AC connections must be
provided for QualityControl, Plate Image Reader, DataControl, and PC.

1 CPTronic (central control console)

2 CPC 1-04 (control console)
3 QualityControl
4 Plate image reader (preferably installed in the
prepress area)
5 PC for the installation of ”Plate image reader
online kit” and ”Prepress interface” as well as
their connection to the local network (LAN).
6 DataControl (machine terminal)

A.9.7
Installing the CPTronic and CPC units

GR SG9044801000000000
Responsibility
of customer

Responsibility of
Heidelberg service

Fig. 2 Layout of the mains connection for different CPC devices. Separate AC connections must be
provided for ImageControl, Plate Image Reader, DataControl, and PC.

1 CP2000 centre
2 ImageControl
3 Plate image reader (preferably installed in the
prepress area)
4 PC for the installation of ”Plate image reader
online kit” and ”Prepress interface” as well as
their connection to the local network (LAN).

A.9.8
 Chapter overview

Electronic interfaces

1 Interface adapter STA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.3

1.1 Structure and Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.3
1.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.5
1.3 Installation Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.6
1.4 Terminal Strip STA-X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.6
1.5 Plug Connector STA-X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.7

2 Interface Input Module SEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.8

2.1 Structure and Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.8
2.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.8
2.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.9
2.4 Input Signals at the SEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.10

3 Interface Output Module SAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.13

3.1 Structure and Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.13
3.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.14
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.14
3.4 Output signals at the SAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.16

4 Single-Fault Fail-Safe Extension Module EEM . . . . . . . . . . . . . . . . . . . . A.10.19

4.1 Task and Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.19
4.2 Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.19
4.3 Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.20

5 Press cycle position switch 1S65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.21

5.1 Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.21
5.2 Installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.10.21

A.10.1
Chapter overview

A.10.2
 Electronic interfaces

1 Interface adapter STA

UTKSC9065200000000000

1.1 Structure and Task

The interface adapter STA provides electrical isola-

tion to the signal lines between the central control
cabinet and the additional equipment. The electrical
isolation of signal lines serves to protect the
CPTronic control system. The following additional
equipment can be connected to the interface
adapter:
IR dryer, UV dryer, sheeter, tape inserter, production
recorder, external powder spray device.
The interface adapter contains an interface input mo-
dule SEM, an interface output module SAM, the ter-
minal strip STA-X1, and the plug connector STA-X2.

Interface input module SEM

Electrical isolation of input signals is provided on the

interface input module by means of an optocoupler.

Interface output module SAM

Electrical isolation of output signals is provided on

the interface output module by means of a relay.

Terminal strip STA-X1

An AC 230V and the press cycle signal of the 1S65

position switch for additional equipment are provided
at the terminal strip STA-X1.

Plug connector STA-X2

The ”press cycle” position switch 1S65 is connected

to the plug connector STA-X2.
In case of malfunctions, error messages are given
via the press displays MID and the control console
display ZID (in the production display and in the fault
display).

A.10.3
Electronic interfaces

GR SG9045201000000000
Fig. 1 Interface adapter STA

1 Interface output module SAM

2 Interface input module SEM
3 Interface adapter enclosure
4 Terminal strip STA-X1
5 Plug connector STA-X2 for position switch
”press cycle” 1S65
6 Line to central control cabinet
7 Position switch ”press cycle” 1S65

A.10.4
 Electronic interfaces

1.2 Block Diagram

GR SG9045200001000000
Additional equip-
ment

STA STA-X1

SAM SEM

STA-X2

FAM/EVM FEM/EVM

EAK

REK2 ESK

CPTronic control

Printing press
É 1S65

MID

Control console dis-

play ZID
or
Fault displays +
Display on the CP messages of external
2000 equipment
control station

Fig. 2 Signal flow

A.10.5
Electronic interfaces

1.3 Installation Location

GR SG9045202000000000
The STA is located on the outside of the backplane
of the central control cabinet. The position switch
”press cycle” 1S65 is located in front of the first print-
ing unit on O.S.

Fig. 3 Interface adapter STA on the backplane

of the central control cabinet ZSG

1.4 Terminal Strip STA-X1

GR SG9045218000000000
Position switch
”press cycle” 1S65
PE PE
1
52 52 Press cycle
2
53 53 NO contact
3
54 54
4 Press cycle
55 55
NC contact
N2 N2
STA-X2
220 220

Power supply
Central (control)
control cabinet Terminal strip STA-X1
ZSG

Fig. 4 Terminal assignment of the terminal strip STA-X1

A.10.6
 Electronic interfaces

1.5 Plug Connector STA-X2

GR SG9045203000000000
Pin Function
1 Normally open contact,
switching capacity AC 230 V, 1 A
2 Normally open contact,
switching capacity AC 230 V, 1 A
3 Normally closed contact,
switching capacity AC 230 V, 1 A
2 1
4 Normally closed contact,
switching capacity AC 230 V, 1 A
3 4 Tab. 1 Plug connector STA-X2, switch side

Fig. 5 Plug connector STA-X2, switch side

A.10.7
 Electronic interfaces

2 Interface Input Module SEM

UTKSC9065201000000000

2.1 Structure and Task

GR SG9045204000000000
The SEM’s task is the isolation between the inputs to
the CPTronic or CP 2000 control system and the
additional equipment.
AC
211 21V On the SEM, an auxiliary voltage of DC 12 V is gen-
DC erated out of AC 21 V. This voltage is picked up by
N4 12V
10 the external device and switched back. On the SEM,
+1
11 this voltage is passed on to an optocoupler. The lat-
DC 24 V
ter switches DC 24 V via the FEM/EVM to the EAK to
E1 10 the ESK and from there to the REK2.
12

E2 10
13

E3 10
14

E4 10
15

E5 10
16

E6 10
17

E7 10
18

E8
X1 X2

Fig. 6 Structure of the SEM module

2.2 Block Diagram

GR SG9045205000000000

AC
21V
DC
AC 21V
12V

EAK ESK
DC 24V

REK2

external equip- SEM FEM / EVM

ment

Fig. 7 SEM circuit diagram

A.10.8
 Electronic interfaces

2.3 Connections

GR SG9045206000000000
E8

E7

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
E6
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
18

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
10 E8

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
17
E7

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
10 E6
16

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
E5
10
E4

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
E5 15
E3

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
10 E2

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
14 E1
10 +1

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
13
N4

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
E4 10 211

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
12

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
10

11

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
10

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
E3

ÉÉÉÉÉÉÉÉÉÉÉÉÉ
ÉÉÉÉÉÉÉÉÉÉÉÉÉ
E2 ÉÉÉÉÉÉÉÉÉÉÉÉÉ

E1

Fig. 8 Additional equipment on the SEM

1 Terminal strip: SEM-X2;

connections of additional equipment
2 Terminal strip: SEM-X1;
connections to central control cabinet ZSG

The cables of the additional equipment are con-

nected on the terminal strip SEM-X2 of the interface
input module SEM.

A.10.9
Electronic interfaces

Connection to ter- Input Additional equipment

minal
10 and 11 E1 Emergency stop
10 and 12 E2 UV dryer in operation
10 and 13 E3 Malfunction on UV dryer
10 and 14 E4 Sheeter operational
10 and 15 E5 Malfunction at sheeter
10 and 16 E6 Dryer blocking after washing
10 and 17 E7 UV dryer with shutter
10 and 18 E8 not assigned
Tab. 2 Additional equipment on the SEM
Note

The corresponding jumper must be removed when

an additional unit is connected to
– the terminals 10 and 11
– the terminals 10 and 12
– the terminals 10 and 16.

2.4 Input Signals at the SEM

UV dryer with shutter

This signal tells the electronic control system that all

installed UV dryer units have been equipped with
shutters.

Dryer blocking after washing

After the completion of an automatic washup proce-

dure, the signal ”dryer on/off” (SAM) is disabled for
approx. 180 seconds.
During this time the position code 20 is displayed in
the fault display of MID and ZID (production display).

Note

After completion of an automatic washup procedure,

a UV dryer may only be put back to operation after
180 seconds.

Malfunction at sheeter

A malfunction occurred at the sheeter. The position

code 14 is displayed in the fault display of MID and
ZID (production display).

A.10.10
 Electronic interfaces

Sheeter operational

The signal causes a shutdown of the feeder pile con-

trol. The feeder pile can no longer be moved. The
paper supply occurs via the sheeter.

Malfunction at dryer

A malfunction occurred at the dryer. The printing

press is brought to a ”controlled” stop, i.e. the current
press state is taken into consideration (”Operation”,
”Paper run” and ”Production”).
The position code 20 is displayed in the fault display
of MID and ZID (production display).
UV dryer in operation

Monitoring the gripper bars with a UV dryer without

shutter.
The ”in-operation” message of the UV dryer is
needed to monitor the gripper bars in the delivery. If
the gripper bars are positioned in the area of the UV
radiators during a press stop, optical and acoustic
warning signals are given. In the control console dis-
play, the symbol ”gripper bars positioned in radiator
area” appears in the production display and under
the type of error ”entire press/warning”. At the same
time, a warning signal is given every second. If the
gripper bars are in this area for longer than 1 minute,
the electronic control system disables the signal
”dryer on/off” (SAM).
Locking of the washup device:
The signal ”UV dryer in operation” is required in addi-
tion to lock the washup devices in the printing units.
If the signal ”UV dryer in operation” is present, an
automatic washup procedure is not possible. If the
signal ”UV dryer in operation” is no longer present,
the waiting period of 180 seconds starts. In the ZID
under the command ”WASHUP”, the message ”dryer
waiting time” is displayed with the current waiting
time.

Note

The operation of the UV dryer must be stopped for at

least 180 seconds before an automatic washup pro-
cedure is allowed to be started.

Emergency stop

The emergency stop signal brings the press to the

quickest possible standstill.

A.10.11
Electronic interfaces

The position code 15 appears in the fault display of

MID and ZID (production display). On the ZID under
the type of error ”entire press/press not ready to run”,
the symbol ”Emergency stop” appears.

A.10.12
 Electronic interfaces

3 Interface Output Module SAM

UTKSC9065202000000000

3.1 Structure and Task

GR SG9045207000000000
The SAM’s task is the isolation between the outputs
to the CPTronic or CP 2000 control system and the
+1 20 additional equipment.
DC 24 V 21
22 By means of an EAK output to earth, a relay on the
23 SAM is switched. In this way it is possible to execute
A1
24 switching operations in external devices. Two
25 switches each are connected in parallel.
26
A2 27 With the normally open contacts of the relays,
28 AC 230 V, 1 A can be switched directly.
29
30
A3 31
32
33
34
A4 35
36
37
38
A5 39
40
41
42
A6 43
44
45
46
A7 47
48
49
50
A8 51
52
53
54
A9 55
56
57
58
A10 59
X1 X2

Fig. 9 Design SAM

A.10.13
Electronic interfaces

3.2 Block Diagram

GR SG9045208000000000
REK2 DC
24V
AC 230V

ESK EAK

Emer-
gency
stop

FAM / EVM SAM external equip-

ment
Fig. 10 Block diagram – interface output module SAM

3.3 Connections

Warning – Danger if the following

safety instructions are not ob-
served!
If the following safety instructions are
not obeyed, direct danger for man and
machine can arise.

D To ensure an undisturbed function of the press

control system, the additional equipment that is
to be connected must contain adequate interfer-
ence suppression measures.
D For safety reasons, the signals ”radiators ON/
OFF” and ”paper in printing unit 1 at production”
must be linked appropriately with the signal ”op-
eration” by the dryer manufacturer.
D For safety reasons, washup devices and UV
dryers must not be operated at the same time
on the press.
D Likewise, the system must manually be halted
for an adequate waiting time in order to allow all
vapours to escape.

A.10.14
 Electronic interfaces

GR SG9045209000000000
Terminal strip: SAM-X1;
connections to central control cabinet ZSG
20
21
2 Relay
22 3 Terminal strip: SAM-X2;
23 connections of additional equipment
24
25 The cables of the additional equipment are con-
26 nected to the terminal strip SAM-X2 or the interface
27 output module SAM.
28
29
30
+1 31
A1
32
A2 33
34
A3
35
A4
36
A5 37
38
A6 39
A7 40
A8 41
42
A9
43
A10
44
Res 45
46
47
48
49
50
51
52
53
54
55
56
57
58
59

Fig. 11 Interface output module SAM

Connection to terminal Additional equipment

20 and 21 Run
22 and 23 Run
24 and 25 Dryer on/off (e.g.: IR dryer or UV dryer)
26 and 27 Dryer on/off (e.g.: IR dryer or UV dryer)
28 and 29 Radiator on/off (e.g.: IR dryer or UV dryer)
30 and 31 Radiator on/off (e.g.: IR dryer or UV dryer)
32 and 33 Paper in printing unit 1 at production (e.g.: UV dryer)

A.10.15
Electronic interfaces

Connection to terminal Additional equipment

34 and 35 Paper in printing unit 1 at production (e.g.: UV dryer)
36 and 37 Emergency stop (e.g.: sheeter)
38 and 39 Emergency stop (e.g.: sheeter)
40 and 41 Printed sheets in the delivery (e.g.: tape inserter)
42 and 43 Printed sheets in the delivery (e.g.: tape inserter)
44 and 45 Feeder on/off (e.g.: HSQ)
46 and 47 Feeder on/off (e.g.: HSQ)
48 and 49 Powder spray unit on/off
50 and 51 Powder spray unit on/off
52 and 53 Reserve
54 and 55 Reserve
56 and 57 Main drive emergency stop
58 and 59 Main drive emergency stop
Tab. 3 Interface output module SAM
Note

Maximum contact load: AC 230 V/1 A

3.4 Output signals at the SAM

Warning – Danger if the following

safety instructions are not ob-
served!
If the following safety instructions are
not obeyed, direct danger for man and
machine can arise.

D In the UV dryer connection, the ”Radiator ON/

OFF” and ”Paper in printing unit 1 during pro-
duction” must be interconnected in a suitable
way with the ”RUN” signal.
D For reasons of safety, wash-up devices and dry-
ers must never be operated at the same time.
The UV dryer must be stopped for a waiting
time of 180 seconds before and after a washing
process using a washup device.

A.10.16
 Electronic interfaces

Run

Control signal for all additional equipment.

The signal is present when the printing press is in
”operation” (press runs at minimum speed
3,000 iph).

Dryer/Off

Control signal, e.g. for IR and UV dryer. The signal is

enabled if

D the dryer has been preselected on the control

console and if the following guards are closed:
cylinder guards between the printing units and
printing unit/delivery protection grids;
D there is still paper in the press after a press
stop and the printing press goes back to ”opera-
tion”.

The signal is disabled if

D an emergency function has been triggered

(press standstill only by means of ”emergency
stop”, cylinder guard between the printing units
and printing unit/delivery protection grid);
D an automatic washup procedure has been initi-
ated;
D there is still paper in the press in the case of a
press standstill (not with UV dryer with shutter);
D the gripper bars in the delivery are positioned
for more than 1 minute in the radiator area of
the UV dryer (only with UV dryer without shut-
ter).
D less than 180 seconds have passed after basic
initialization.

Radiator on/off

Control signal, e.g. for IR and UV dryer.

The signal is present if printed sheets pass through
the dryer section in the delivery.
In case of an emergency stop function during pro-
duction, the signal shuts down. When ”operation” is
restarted, the signal is present again until all sheets
have been transported to the delivery.
The signal can be enabled or disabled via the func-
tion ”Dryer On/Off” on the actual value display.

A.10.17
Electronic interfaces

Paper in printing unit 1 during production

Control signal e.g. for inter-unit dryer. The signal is

present when the sheets pass the first printing unit
during ”production”.
Emergency stop (of the press)

Control signal for the additional equipment which

should be shut off when the ”emergency stop switch”
has been actuated on the printing press.
The signal is present as long as no ”emergency stop
switch” has been actuated.

Printed sheets in the delivery

Control signal e.g. for tape inserter.

Prerequisite:
The job counter has been switched on.
It is triggered when printed sheets arrive in the deliv-
ery.

Feeder on/off

Control signal e.g. for sheeter.

The control signal is present as long as the feeder is
engaged.

Powder spray device On

Control signal for external powder spray devices.

Prerequisite:
The powder spray device has been preselected on
the control console.
The signal is present as long as printed sheets leave
the last printing unit and arrive at the delivery.

Main drive emergency stop

Additional (redundant) control signal for additional

equipment which is to be shut off in case of an
”emergency stop” of the printing press.
The signal is present as long as the press control
system does not enable the ”emergency stop” signal
to the main drive.

A.10.18
 Electronic interfaces

4 Single-Fault Fail-Safe Extension Module EEM

UTKSC9065203000000000

4.1 Task and Function

GR SG9045210000000000
Connector X1;
Connection to the computer back panel RER2
2 Connector X2;
Ground and connection to the SAM

In an isolated and open-circuit-monitored way, the

EEM switches the ”main drive emergency stop” sig-
nal from the REK2. This second signal transmission
path (as opposed to the signal ”emergency stop” via
EAK to SAM) ensures a single-fault fail-safe struc-
ture.
In the event of an open circuit or when the ”main
drive emergency stop” signal from an SEK is active,
the corresponding relay on the SAM trips.

Fig. 12 Single-fault fail-safe extension module

EEM

4.2 Block Diagram

GR SG9045211000000000
REK2 RER2 EEM
SAM
X1 X2

A10

Fig. 13 Block diagram EEM

A.10.19
Electronic interfaces

4.3 Connector

GR SG9045212000000000
1 3 Pin Function
1 Connection to earth
(when using two SEKs for >
8 PUs, otherwise not connected)
2 Connection to earth
(when using one SEK for <=
Fig. 14 Connector X2 8 PUs, otherwise not connected)
3 Relay when
emergency stop/non-emergency stop
(ground)
and when
emergency stop high-impedance (no
ground)
Tab. 4 Plug connector X2

A.10.20
 Electronic interfaces

5 Press cycle position switch 1S65

UTKSC9065204001000000

5.1 Installation location

GR SG9045213000000000
The ”press cycle” position switch 1S65 is located in
the middle between D.S. and O.S., underneath the
feed table. It is connected to the interface adapter
STA.

Fig. 15 Printing press, operator’s side (O.S.)

feeder

5.2 Installation and removal

1 Set the press to 000.0o +/– 4o press angle.

GR SG9045214000001000

2 Switch off the main switch 15Q66.

3 Remove the defective position switch 1S65.
Install the new position switch 1S65.
4 When you install the position switch, align it
such that the NC and NO contacts are actu-
ated.
Fig. 16 Positioning
GR SG9045215000000000

1S65

21 22

13 14

Fig. 17 Contacts of the position switch 1S65

A.10.21
Electronic interfaces

GR SG9045216000000000
Adjust the position switch so that the remaining
actuator travel (to the stop of the position
switch) is 2 mm when the switch is actuated.

6 Tighten the fixing bolts of the position switch.

2mm 1S65

Fig. 18 Adjustment of the position switch

7
GR SG9045217000000000

Switch on the main switch 15Q66.

8 Check in inching mode whether both contacts
000.0° ... 080.0° of the position switch 1S65 are actuated for the
(SM 102, CD 102) duration of 000.0o ... 080.0o (display on the
21 22
MID).
21/22 = 0
13/14 = 1
13 14

Fig. 19 Contacts of the position switch 1S65

A.10.22
 Chapter overview

Annex

1 Particular Conversions and Multiples ........................... A.11.3

1.1 Particular Conversions and Multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.3

2 Water Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.4

2.1 Water Hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.4

3 Conversion of Fractions into Decimals . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.5

3.1 Conversion of Fractions into Decimals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.5

4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.7
4.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11.7

A.11.1
Chapter overview

A.11.2
 Annex

1 Particular Conversions and Multiples

UTKSC9065401000000000

1.1 Particular Conversions and Multiples

Conversion for units of length

1 ft = 12 in
1 yard = 3 ft = 36 in

Conversion for units of volume

1 litre = 1 dm3
1 litre = 0.26417 US gal
1 litre = 0.21997 UK gal
1 US gal = 231.0 cu in = 3.785 dm3
1 UK gal = 277.4 cu in = 4.546 dm3
1 cu ft = 1728 cu in

Conversion for units of mass

1 lbs = 16 oz (avoirdupois) = 453.6 g

1 oz (avoirdupois) = 28.35 g

Conversion for units of pressure

1 bar = 10 N/cm2
1 Pa = 1 N/m2

Conversion for units of temperature

Conversion oCelsius to oFahrenheit:

1.8 x n oC + 32
Conversion oFahrenheit to oCelsius:
(n oF – 32) / 1.8
Conversion for units of energy

1 W = 3.413 Btu/h (British thermal units per hour)

1 kW = 3413 Btu/h
1 kW = 0.94806 Btu/s
(British thermal units per second)
1 Btu/h = 0.29307 W
1 Btu/s = 1.05506 kW

A.11.3
 Annex

2 Water Hardness
UTKSC9065402000000000

2.1 Water Hardness

The water hardness is a criterion for water quality. It

is defined by the content of calcium ions and magne-
sium ions in the water.
In Germany it is normally specified in ”odH” (degrees
German hardness). Internationally, the water hard-
ness is specified as a substance concentration in
”mmol/l“ (millimol per litre).
1 odH corresponds to a calcium oxide content (CaO)
of 10 mg/l (corresponding to 0.178 mmol/l).
The following table gives an overview of the various
hardness grades:

Type of Hardness Hardness CaO-

water grade [odH] content
[mg/l]
soft I 0 ... 7.9 0 ... 79
medium- II 8 ... 14.9 80 ... 149
hard
hard III 15 ... 21.9 150 ... 219
very hard IV 22 ... 27.9 220 ... 279
28 ... 34.9 280 ... 349
35 ... 40 350 ... 400
Tab. 1 Water hardness
Conversion of units of water hardness

German water hardness:

1 odH corresponds to 10 mg CaO per litre of water
American water hardness:
1 oaH corresponds to 1 grain per US gal
(1 grain = 0.0648 g CaO)
English water hardness:
1 oeH corresponds to 1 grain per UK gal
(1 grain = 0.0648 g CaO)
French water hardness:
1 ofH corresponds to 10 mg CaCO3 per litre of water

Correspondence
Unit odH oaH oeH ofH

Factor 1 1.04 1.25 1.79

Tab. 2 Correspondence

A.11.4
 Annex

3 Conversion of Fractions into Decimals

UTKSC9065403000000000

3.1 Conversion of Fractions into Decimals

Conversion of linear values into

from
Fraction [in] Decimal [in] Decimal [mm]
1/ 0.0156 0.3969
64
1/ 0.0313 0.7938
32
3/ 0.0469 1.1906
64
1/ 0.0625 1.5875
16
5/ 0.0781 1.9844
64
3/ 0.0938 2.3813
32
7/ 0.1094 2.7781
64
1/ 0.1250 3.1750
8
9/ 0.1406 3.5719
64
5/ 0.1563 3.9688
32
11/ 0.1719 4.3656
64
3/ 0.1875 4.7625
16
13/ 0.2031 5.1594
64
7/ 0.2188 5.5563
32
15/ 0.2344 5.9531
64
1/ 0.2500 6.3500
4
17/ 0.2656 6.7469
64
9/ 0.2813 7.1438
32
19/ 0.2969 7.5406
64
5/ 0.3125 7.9375
16
21/ 0.3281 8.3344
64
11/ 0.3438 8.7313
32
23/ 0.3594 9.1281
64
3/ 0.3750 9.5250
8
25/ 0.3906 9.9219
64
13/ 0.4063 10.3188
32
27/ 0.4219 10.7156
64
7/ 0.4375 11.1125
16
29/ 0.4531 11.5094
64
15/ 0.4688 11.9063
32
31/ 0.4844 12.3031
64
1/ 0.5000 12.7000
2

A.11.5
Annex

Conversion of linear values into

from
Fraction [in] Decimal [in] Decimal [mm]
33/ 0.5156 13.0969
64
17/ 0.5313 13.4938
32
35/ 0.5469 13.8906
64
9/ 0.5625 14.2875
16
37/ 0.5781 14.6844
64
19/ 0.5938 15.0813
32
39/ 0.6094 15.4781
64
5/ 0.6250 15.8750
8
41/ 0.6406 16.2719
64
21/ 0.6563 16.6688
32
43/ 0.6719 17.0656
64
11/ 0.6875 17.4625
16
45/ 0.7031 17.8594
64
23/ 0.7188 18.2563
32
47/ 0.7344 18.6531
64
3/ 0.7500 19.0500
4
49/ 0.7656 19.4469
64
25/ 0.7813 19.8438
32
51/ 0.7969 20.2406
64
13/ 0.8125 20.6375
16
53/ 0.8281 21.0344
64
27/ 0.8438 21.4313
32
55/ 0.8594 21.8281
64
7/ 0.8750 22.2250
8
57/ 0.8906 22.6219
64
29/ 0.9063 23.0188
32
59/ 0.9219 23.4156
64
15/ 0.9375 23.8125
16
61/ 0.9531 24.2094
64
31/ 0.9688 24.6063
32
63/ 0.9844 25.0031
64

1 1.0000 25.4000
Tab. 3 Conversion of fractions into decimals

A.11.6
 Annex

4 Definitions
UTKSC9065404000000000

4.1 Definitions

D.S.

Abbreviation for drive side.

O.S.

Abbreviation for operator’s side.

Chromo paper

Mostly woodpulp paper, one-sided coated, which has

good properties regarding embossing, coating and
bronzing in offset printing.
Used for the production of labels, covering paper,
etc.

Chromo cardboard

Same properties as chromo paper.

Used for the production of display packages, picture
postcards etc.

EMC

Abbreviation for ”electromagnetic compatibility”.

Surface pressure

Surface pressure stands for the maximum pressure

exerted on a contact surface.

Grammage

Paper weight which is normally measured in ”gram

per square meter” (gsm).
Combination device

A combination device is a dampening solution supply

system which accommodates both the central damp-
ening solution supply and the inking unit temperature
control.

PE

Abbreviation for ”protective earth”.

A.11.7
Annex

Pictograph

Icon with internationally fixed meaning.

Example for a pictograph with warning:

Warning – Danger when the safety

instructions are not observed!

A.11.8
 Index

B Index

A C
Air pipes Ceilings in buildings, A.2.3
Determining the diameter at a length > 10 m (>33 Central compressed-air supply, A.6.27
ft), A.6.22 Checking the compressed air connection, A.6.29
Requirements, A.6.24 Guarding and protective measures, A.6.29
Air supply Implementation of the compressed air connection ,
via central air supply systems, A.6.26 A.6.28
Air supply cabinet Repair work , A.6.29
Air cooling of the air-cooled units, A.6.10 Central control box ZSG
Air throughput of the air-cooled unit, A.6.8 Cross-sections of the conductor terminals, A.5.21
Air throughput of the water-cooled unit, A.6.15 Central dampening solution supply systems
air-cooled, A.6.8 Dampening solution supply via, A.7.3
Calculating the air pipe diameter, ANSI values, Central suction and blast air supply, A.6.30
A.6.24 Typical operating states for the layout , A.6.31
Calculating the air pipe diameter, metric values, Typical temperature states of suction and blast air,
A.6.23 A.6.32
Calculating the pressure drop, metric values, Chromo
A.6.20 cardboard, A.11.7
Calculating the pressure drops, ANSI values, paper, A.11.7
A.6.21 Combination device, A.11.7
Determining the air pipe diameter, A.6.22 Compressed air
Installation, A.6.18 Conditioning, A.2.7
Installation site requirements, A.6.18 Required from central air supply systems, A.6.27
Minimum distances at the installation location, Supply, A.2.7
A.6.18 Compressed-air supply
Pressure drop when using exhaust-air hoods in see also Central compressed-air supply, A.6.27
the air-cooled air supply cabinet, A.6.19 Compressor, A.6.3
Process air removal from the printing process with Conductor terminals
air-cooled unit, A.6.13, A.6.15 Cross-section of the terminals at the series
Suction and blast air generation, A.6.5 transformer, A.5.21
Technical specifications of the process air supply, Cross-section of the terminals in the ZSG, A.5.21
A.6.12 Conversion
Waste air removal of the air-cooled unit, A.6.10 for units of energy, A.11.3
water-cooled unit, A.6.14 for units of length, A.11.3
Air supply systems for units of mass, A.11.3
Central, A.6.26 for units of pressure, A.11.3
Air throughput for units of temperature, A.11.3
of the air-cooled air supply cabinet, A.6.8 for units of volume, A.11.3
of the pneumatic compressor, A.6.4 of fractions into decimals, A.11.5
of the water-cooled air supply cabinet, A.6.15 of units of water hardness, A.11.4
physical, A.11.3

B
D
Blast air
Supply, A.2.8, A.6.30 Dampening solution connection
Supply , A.6.31 Layout, A.7.4
Breaks in operation, A.1.9 Testing, A.7.5
Building activities Dampening solution supply
in the pressroom, A.2.3 Installation , A.7.3
Building structures, A.2.3 Layout of a supply mains , A.7.3
via central dampening solution supply systems,
A.7.3
Dampening solution supply lines

B.1
Index

Requirements , A.7.4 on the printing press, A.5.7

Definitions, A.11.7
Disposal conduits, A.2.3
Door openings F
to pass with the machines , A.2.4
Dryer cabinet Floor coverings, A.2.3
Air-cooled, A.8.11 Floors, A.2.3
Assignments of the connection sockets of the Foot steps
air-cooled unit, A.8.11 for the elevated printing press, A.3.22
Cooling water circuit of the water-cooled guide
plate, A.8.14
Cross-sections of the conductor terminals at the G
matching transformer, A.8.9
Glossary, A.11.7
Drying air for the printing process, A.8.11
Grammage, A.11.7
Mains connection variants A1 to A4, A.8.5
Guard
Mains connection variants A1 to A5, A.5.14
Elevated printing press, A.3.28
Process air extraction from the drying process,
Guide plate
A.8.13
see also Water-cooled guide plate, A.8.14

E H
Electrical installation
Heidelberg Service
General information, A.5.3
for printshop planning, A.2.9
Printing press, A.5.3
Electrical power supply, A.2.6
Electromagnetic compatibility, A.11.7
Elevated printing press I
Bottom plates, A.3.13 Inside walls, A.2.4
Calculating the weight of the motor mounting Intended use, A.1.11
base, A.3.18 Interface adapter, A.10.3
Catwalks, A.3.20 Block diagram , A.10.5
Design of catwalks and platforms, A.3.23 Installation location, A.10.6
Design of foot steps and stairs, A.3.22 Plug connector STA-X2, A.10.7
Design of railings, A.3.25 Structure and task, A.10.3
General information, A.3.21 Terminal strip STA-X1, A.10.6
Guarding measures, A.3.28 Interface input module, A.10.8
Installation of foundation strip segments, A.3.10 Block diagram, A.10.8
Installation of the motor mounting base, A.3.19 Connections, A.10.9
Making foundation strips, A.3.8 Input signals, A.10.10
Motor mounting base for the elevated unit, A.3.15 Structure and task, A.10.8
Motor mounting base with elevation by 300 Interface output module, A.10.13
mm/500 mm, A.3.16 Block diagram, A.10.14
Motor mounting base with elevation by 700 Connections, A.10.14
mm/900 mm, A.3.17 Output signals, A.10.16
Necessary additional equipment, A.3.5 Structure and task, A.10.13
Overview of applicable standards, A.3.20 Intermediate floor drying process, A.8.15
Platforms, A.3.20 IR dryer
Possible heights, A.3.5 Connection diagram, A.8.5
Prerequisites, A.3.4 Mains connection, A.8.3
Purpose, A.3.4 Overview of the standard connections to power
Railings, A.3.20 supply, A.8.4
Stairs , A.3.20
Warning, A.3.20
Weight calculation of the foundation strips, A.3.7
EMC, A.11.7
L
EMC measures Liability, A.1.12

B.2
 Index

M Press cycle position switch, A.10.21

Installation and removal, A.10.21
Mains connection, A.2.6 Installation location, A.10.21
Dimensioning, A.5.6 Printing press
Layout, A.5.9 – Attaching or installing non-Heidelberg devices,
Load characteristics and harmonics , A.5.11 A.1.6
Necessary fusing and protective measures , A.5.6 – Delivery and installation, A.1.5
of the CPC units, A.9.3 – Disassembling (demounting), A.1.10
of the IR dryer, A.8.3 – Installation and modification, A.1.6
Overview, A.5.13 – Operation, A.1.7
Power cable requirements, A.5.8 – Operational malfunctions, A.1.9
Recommendations and rips, A.5.10 – Unloading and internal transport, A.1.5
Supplementary notes to the IR dryer mains Basic regulations for mains connections, A.5.6
connection, A.8.3 Connection to the three-phase mains, A.5.12
Test, A.5.9 Electrical installation , A.5.3
Tolerances, A.5.8 EMC measures , A.5.7
Versions B1 to B2, A.5.18 Foundation strips for the elevated unit, A.3.6
Maintenance work, A.1.10 Motor mounting base for the elevated unit, A.3.15
Malfunctions, A.1.9 Technical specifications of the electrical
Motor mounting base equipment, A.5.4
Weight calculation, A.3.18 Printshop Planning, A.2.9
Multiples Process air supply
physical, A.11.3 of the air-cooled air supply cabinet, A.6.11
of the water-cooled air supply cabinet, A.6.15
Protective earth, A.11.7
N
Network
Servers, A.4.14
R
Versions, A.4.3 Railing
Non-Heidelberg devices for the elevated unit, A.3.25
– Attaching or installing, A.1.6 Rating plate
Notes for the electrical equipment of the printing press,
First degree, A.1.3 A.5.5
Second degree, A.1.4 Location of the rating plates, A.5.4
Third degree, A.1.5 Rating plate of the central control box (ZSG),
A.5.4
Repairs, A.1.10
O Room air conditioning , A.2.4
Room height, A.2.3
Outside walls, A.2.4

S
P
Safety devices
PE, A.11.7 – Failure of safety devices, A.1.9
Pictograph, A.11.8 Safety instructions
Pneumatic compressor, A.6.3 Explanation, A.1.3
Overall air throughput, A.6.4 Series transformer
Pneumatic compressor station Cross-sections of the conductor terminals, A.5.21
Installation, A.6.16 Single-fault fail-safe extension module EEM, A.10.19
Installation site requirements, A.6.17 Block diagram, A.10.19
Minimum distances at the installation location, Connector, A.10.20
A.6.16 Task and function, A.10.19
Power supplies, A.2.6 Space required
Power supply , A.2.6 in the pressroom, A.2.3
Power supply system Stairs
Requirements , A.5.6 for the elevated printing press, A.3.22

B.3
Index

Storage
– of press subassemblies, A.1.5
Suction air
Supply, A.2.8, A.6.31
Suction and blast air
Required from central air supply systems, A.6.30
Suction and blast air
Generation by the air supply cabinet, A.6.5
Required from central air supply systems, A.6.31
Suction and blast air supply
also refer to Central suction and blast air supply,
A.6.30
Supply lines, A.2.3, A.2.6
Surface pressure, A.11.7

U
Use
– see Intended use, A.1.11
UV drying process, A.8.15
Clarification of technical aspects, A.8.16
Requirements, A.8.16
Technical Pre-installation, A.8.15
Warning, A.8.15

V
Ventilation
Pressroom, A.2.4

W
Warranty, A.1.12
Waste air removal
of the air-cooled air supply cabinet, A.6.10
Water conditioning, A.2.6
Water hardness, A.11.4
Division into hardness grades, A.11.4
Water supply, A.2.6
Water-cooled guide plate
Cooling water circuit, A.8.14
Workflow
Hardware requirements, A.4.3

B.4