HEIDELBERG DryStar 2000 CAN User manual

DryStar 2000 CAN
SM/CD 102
SM 74
Betriebsanleitung
Instruction manual
Instructions d’utilisation
Manual de instrucciones
Edition: 01.2004 SC7.170.9004/01

DryStar 2000 CAN
SM/CD 102
SM 74
Instruction manual

Copyright clause
Printed in the Federal Republic of Germany.
Reprints, even of extracts hereof, are only per-
mitted if the source is quoted.
The main components, devices, arrangements, as
well as the software, control and instrumentation
equipment on all of our machines are protected
both domestically and abroad by patent applica-
tions, design registrations or copyright.
Copyright by
HEIDELBERGER DRUCKMASCHINEN AG
Kurfürsten-Anlage 52 60
69115 Heidelberg
Federal Republic of Germany
Heidelberger Druckmaschinen Aktiengesellschaft

Table of contents
3
1 Foreword 6.........................................................................
1.1 This instruction manual... 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Formatting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Abbreviations 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety 8.............................................................................
2.1 Basic Safety Requirements 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Organization of safety instructions 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Operation, maintenance and troubleshooting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Handling cleaning agents, solvents, inks and varnishes 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Handling anti-freezing agents 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Handling hot air / IR dryer slide-in units 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Handling with compressed air 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Proper Use 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Terms of guarantee 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 General information about the drying process 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Description 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Function 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Versions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 DryStar 2000 CAN, air-cooled 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 DryStar 2000 CAN, water-cooled 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Variants 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 DryStar 2000 CAN SM 74 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 DryStar 2000 CAN SM 74 L 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 DryStar 2000 CAN SM 74 LX 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 DryStar 2000 CAN SM/CD 102 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 DryStar 2000 CAN SM/CD 102 L 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.6 DryStar 2000 CAN CD 102 L + ZT 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.7 DryStar 2000 CAN SM/CD 102 LX 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.8 DryStar 2000 CAN CD 102 LX + ZT 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.9 DryStar 2000 CAN SM/CD 102 with UV dryer 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Maincomponents 30..................................................................
5.1 Dryer cabinet 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Dryer slide-in unit 1 (IR) 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 DryStar 2000 CAN SM 74 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 DryStar 2000 CAN SM/CD 102 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Dryer slide-in units 1 and 2 (IR + hot air) 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 For variants of the DryStar 2000 CAN SM 74 L/LX 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 For variants of the DryStar 2000 CAN SM/CD 102 L/LX 34. . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Dryer slide-in unit 3 (cooling air) 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 DryStar 2000 CAN SM 74 LX 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 For variants of the DryStar 2000 CAN SM/CD 102 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Interdeck dryer (IR) 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents
4
6 Operation 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Controls 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Switching on the DryStar 2000 CAN 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Switching off the DryStar 2000 CAN 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 CP2000 Center 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Before you start a print job... 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Recommended setting values 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.1 DryStar 2000 CAN without coating drying 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.2 DryStar 2000 CAN with coating drying 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Maintenance schedule 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Dryer cabinet 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Cleaning the air filters 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 Replacing the air filter 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.3 Cleaning the heat exchanger 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.4 Cleaning the protective grid 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.5 Checking the air and water supply 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.6 Checking the cooling water pressure and refilling the cooling water 55. . . . . . . . . . . . . . . .
7.2.7 Checking/changing the anti-freezing agent 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Dryerslide-inunits 59..................................................................
7.3.1 Removing the dryer slide-in unit 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.2 Cleaning the IR radiators and reflectors 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3.3 Cleaning the air nozzles
(only for SM/CD 102 printing presses with coating system) 62. . . . . . . . . . . . . . . . . . . . . . .
7.3.4 Cleaning the honeycomb element
(only for SM/CD 102 printing presses with coating system) 63. . . . . . . . . . . . . . . . . . . . . . .
7.4 Interdeck dryer (optional) 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Removing the IR module 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Cleaning the IR radiators and reflectors 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.3 Cleaning the air nozzles 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.4 Cleaning the honeycomb element 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.5 Removing the suction module 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.6 Cleaning the suction module 70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Cleaning the pile surface temperature sensor 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Troubleshooting 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Fault messages on the CP 2000 Center 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Fault messages (Vendor State Register) 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents
5
9 Specifications 81.....................................................................
9.1 Converting from Celsius to Fahrenheit 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Dryer cabinet 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.1 Dimensions 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2.2 General data 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Cooling water volumes 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1 DryStar 2000 CAN, air-cooled 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2 DryStar 2000 CAN, water-cooled 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Exhaust air hood (optional) 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Dryer slide-in unit 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.1 IR, IR + hot air and cooling air 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5.2 Interdeck dryer 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 Ventilation data 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.1 DryStar 2000 CAN SM 74 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.2 DryStar 2000 CAN SM/CD 102 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 Cooling circuit (DryStar 2000 CAN, water-cooled only) 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 Ambientconditions 92..................................................................
9.9 Maximum short circuit current 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Spare parts list 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Index 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foreword
6
1 Foreword
1.1 This instruction manual...
...supports you in the operation, maintenance
and troubleshooting of your DryStar 2000 CAN.
The information in this manual applies to the
following DryStar 2000 CAN variants:
DSM 74
DSM 74 L
DSM 74 LX
DSM/CD 102
DSM/CD 102 L
DCD 102 L + ZT
DSM/CD 102 LX
DCD 102 LX + ZT
DSM 102/CD 102 with UV dryer
1.2 Formatting
Numbers used to identify components in figures or
in legends are displayed as follows:
1(text)
2(text)
3(text)
Operational steps are displayed as follows:
1. (text)
2. (text)
3. (text)

Foreword
7
1.3 Abbreviations
Fig. Figure
AC Alternating current
A.S. Drive side
B.S. Operator’s side
CAN Controller Area Network
DC Direct current
IR Infrared
LED Light emitting diode
UV Ultraviolet
ZT Interdeck dryer

Safety
8
2 Safety
2.1 Basic safety requirements
Personnel in charge of assembling, operating and
maintaining the unit and its components must have
read and understood this manual, in particular the
Safety chapter.
In-house training programs that take the technical
qualifications of the relevant person into consider-
ation may be provided if necessary.
2.2 Organization of safety instructions
This manual has three categories of instructions,
which are explained in the following.
Each category is assigned a symbol (pictogram) with
a specific meaning to clarify individual instructions.
Pictograms may also appear on stickers affixed to
the unit.

Safety
9
Level 1 safety instruction (caution)
This safety instruction draws attention to situations
that could present a particular danger.
Failure to heed warnings can result in serious injury.
In extreme cases, this can result in a life-threatening
situation.
Failure to heed warnings can also result in damage
to machines and additional equipment.
Associated pictograms with signal words:
Warning -- <danger from electrical
current>
Warning -- <general danger>
Warning -- explosive substances!
Warning -- hot surface!
Warning -- revolving chain gripper
systems!
Example:
Warning -- explosive substances!
Flammable vapours form when the IR radiators
are cleaned using a cleaner containing solvents.
This may cause an explosion if the dryer is acti-
vated immediately afterwards.
Please ensure adequate ventilation to allow the
vapours formed from the cleaning agent to dissi-
pate fully before the dryer is switched on again.

Safety
10
Level 2 safety instruction (warning)
This safety instruction draws attention to situations
that could present a particular danger.
Failure to heed warnings can result in damage to
machines and additional equipment.
Associated pictogram with signal word:
Caution -- <brief description of the
danger>
Example:
Caution -- IR radiators are pressure sen-
sitive and easily soiled.
IR radiators can be irreparably damaged by
even slight application of pressure.
Please be particularly careful when performing
any work on the IR radiators.
Dirt and grease deposits on the IR radiators
can cause irreparable damage. Please wear
protective gloves for all work on the IR radia-
tors.
Level 3 safety instruction (general note)
This note offers additional information and tips
on operating the unit.
Associated pictogram with signal word:
"Note
Example:
"Note
An incorrectly installed air filter reduces the
circulation of air.

Safety
11
2.3 Operation, maintenance and troubleshooting
DPlease refrain from all methods or procedures
which:
Dendanger the health and safety of the user
or third parties,
Dare detrimental to this or other units,
Dimpair the safety of the unit or its ability
to function,
Ddo not comply with the safety instructions.
DAll work on the unit such as operation, mainte-
nance and troubleshooting may only be per-
formed by persons who are familiar with this
manual, have been instructed about potential
dangers and who possess the necessary quali-
fications.
DAlways check the printing press safety devices
before beginning work. Never remove or shut
down safety devices.
DCheck safety devices daily for proper function.
Immediately report faults or defects to
Heidelberg Service.
DMaintenance work poses an increased risk of
injury. Therefore, be sure to comply with the
special safety instructions in the “Maintenance”
chapter and perform maintenance work with
extreme caution and attention.
DNever clean, perform maintenance work,
change settings or troubleshoot while the
printing press is running.
DObserve the instructions on the care and main-
tenance of the unit. Additional danger can result
from a poorly or insufficiently maintained unit.
DPlease observe the regulations in the operating
and maintenance manuals of your printing
press.

Safety
12
DSwitch off the machine/system (printing press
main switch to “OFF”) when carrying out all
service work (cleaning, maintenance, settings,
troubleshooting). Secure the machine/system
against unintentional reactivation.
DHave electrical equipment repaired by the
authorized Heidelberg service only.
DAppropriate supports and protection must
be used to avoid dangerous situations when
assembling and disassembling heavy parts or
components.
DWear appropriate protective clothing when
performing all maintenance work.

Safety
13
2.4 Handling cleaning agents, solvents, inks and varnishes
Cleaning agents, solvents, inks and varnishes can
be combustible, explosive, corrosive, poisonous or
volatile. Observe the following instructions:
DProvide appropriate ventilation in the room.
DAvoid any possible sources of ignition.
DObserve explosion prevention measures.
DNo smoking, drinking or eating when working
with these materials.
DWear protective gloves.
DComply with the relevant accident prevention
regulations, safety regulations and manufactur-
er’s data sheets.
DUse only cleaning agents with a flash point of
at least 55 C.
DWhen using dryers, use only inks and varnishes
that do not constitute an explosion hazard as
they are heated in the dryer.
DDo not heat inks and varnishes above their
flash point.
DStore all cleaning agents, solvents, inks and
varnishes in appropriate and properly marked
containers.
DStore these materials in closed containers.
DRemove any leaking materials immediately and
in the correct manner.
DAll waste must be disposed of consistent with
existing regulations.
DDo not allow fumes from cleaning agents and
solvents to enter areas where air intake open-
ings are present.

Safety
14
2.5 Handling anti-freezing agents
Anti-freezing agents can contain dangerous sub-
stances such as ethylene glycol, which are particu-
larly hazardous to your health if swallowed. Observe
the following instructions:
DHandle anti-freezing agents carefully to avoid
contact with the skin and eyes.
DWear impermeable gloves if your skin could
come into contact with anti-freezing agents for
repeated or longer periods or time. In addition,
wear safety goggles to protect your eyes.
DWhen handling anti-freezing agents make
sure the room you are working in is properly
ventilated.
DStore anti-freezing agents in tightly sealed and
appropriately labelled containers in a well-
ventilated area. Do not place containers of
anti-freezing agent in direct sunlight.
DAvoid polluting the soil, groundwater and nat-
ural bodies of water.
DInstall a nonreturn valve at the drinking water
supply/cooling circuit transfer location to avoid
polluting the drinking with used cooling water.
DBuild a dike with earth around anti-freezing
agent as it exits and cover it with absorbant
material. Pour the mixture into containers or
plastic bags and prepare it for disposal.
DDispose of anti-freezing agents at an approved
reprocessor or authorized incineration plant.
DAnti-freezing agent containers must be com-
pletely emptied of any residue before being
disposed of.
DPay particular attention to the specifications
and instructions on the safety data sheet of
the anti-freezing agent used.

Safety
15
2.6 Handling hot air/IR dryer slide-in units
DHot dryer slide-in units (hot air/IR) pose a risk
of burns. Always let the dryer slide-in units cool
down for a long period of time before touching
them.
DIR radiation damages the eyes. Avoid looking
directly into the IR radiators.
DIR radiators are pressure-sensitive. The pinch-
type ducts at the ends are particularly sensitive.
Therefore, take extreme caution when handling
the IR radiators.
DIR radiators are sensitive to dirt. Grease and
sweat from the hands burn into the quartz pipes
and shorten their lifetime. Always wear clean
gloves when handling IR radiators.
DIf, however, the IR radiator becomes dirty, wipe
it with a soft, lint-free cloth. The front side of the
IR radiators can be cleaned with a cloth that
has been lightly soaked in alcohol. Alcohol must
not be used to clean the gold-plated back of
the IR radiator.

Safety
16
2.7 Working with compressed air
DWhen cleaning using compressed air, bear in
mind that loose dust and powder particles are
picked up by the air and can cause injury to the
eyes and can damage the respiratory system.
Always wear protective glasses and a dust
mask when cleaning using compressed air.
DCompressed air can cause serious injury. Never
direct a stream of compressed air at a person.
DCompressed air can cause irreparable damage
to sensors. Therefore, do not blast the sensors
with compressed air.
2.8 Proper use
The unit is intended solely for use as outlined in
chapter 4 “Description” and only with the supplied
and approved components.
Using the unit for purposes other than those
mentioned is considered contrary to proper use.
The manufacturer cannot be held liable for any
damage resulting from such use. The risk of such
misuse lies entirely with the user.
2.9 Terms of warranty
The manufacturer’s warranty becomes null and void
in the following cases:
DImproper use.
DFailure to comply with these instructions.
DEmploying under-qualified personnel.
DUsing spare parts not issued by Heidelberger
Druckmaschinen AG.
DUnauthorized changes to the unit and its com-
ponents which were supplied by Heidelberger
Druckmaschinen AG.

General information about the drying process
17
3 General information about the drying process
Drying process
Both inks and coatings are used for offset printing.
Inks and coatings both dry in a different way. Offset
ink dries, to a greater extent, through the chemical
process of oxidation, and to a lesser extent, through
the absorption of mineral oils by the print material.
The coatings used are dispersion coatings, which
dry through the physical process of the evaporation
of the water content.
The drying process must be adapted accordingly.
IR radiation is used to dry printing inks. The use of
IR radiation has advantages in terms of production
and is an efficient technique. This process allows IR
offset inks and conventional offset inks to be dried.
The process of hot air drying in conjunction with IR
radiation and circulating air is used for drying coatings.
IR radiators
An IR dryer slide-in unit contains a maximum of five
IR radiators. Its output can be manually or automati-
cally set. The IR radiators are cooled by blow air.
The air for cooling the radiators is still applied after
the IR radiators have been switched off to dissipate
the remaining heat generated by the IR radiators
(run-out time). The output of the IR radiators is
reduced to a harmless level to prevent the system
from overheating if the cooling air system fails
during operation.
Other sheet sizes can also be selected for the IR
dryer slide-in unit, thus saving energy.

General information about the drying process
18
Coating dryer
The dryer slide-in unit of a coating dryer contains the
IR radiators and other additional hot air nozzles. Hot
air is blown out of these nozzles and onto the coating
layer. The hot air heats the varnish and evaporates
the water content of the varnish. The hot air also
carries the air that is filled with water vapour away
from the print sheet. The hot air is supplied by an
additional blower which blows air through a heating
element. The heating output is infinitely variable. An
excess temperature switch prevents the temperature
in the heating element from exceeding the specified
limit.
Extended delivery
The extended delivery, unlike the conventional high-
pile delivery, allows a maximum of four dryer slide-in
units of different designs to be used. Therefore, the
extended delivery of the DryStar Combination is
equipped with a second IR dryer slide-in unit in addi-
tion to the normal configuration with hot air for even
faster drying and a circulating blower to increase
ventilation. This area of increased ventilation above
the print sheet is absolutely necessary for processing
dispersion varnishes with a high water content if you
want to achieve maximum drying capacity. An addi-
tional fan row in the sheet ascent reduces the odour
emissions (SM 74). Additional suction devices in the
delivery ensure the constant removal of the air filled
with water vapours and odorous substances from the
delivery.
Pile surface temperature
The pile surface temperature is a measure for the
drying state of the ink or varnish. It is recorded
using the pile surface temperature sensor. Certain
set points for the pile surface temperature must be
defined, depending on the grammage of the print
material, the quantity of ink or varnish and the
desired gloss effect.
The pile surface temperature is controlled at a
temperature between +/ 2C. Fine adjustments
up or down are permitted. This allows the drying
conditions to be optimally adapted to the process.

Description
19
4 Description
4.1 Function
The DryStar 2000 CAN is an accessory for
Heidelberger Druckmaschinen AG printing
presses that supports the drying process of printed/
coated sheets.
4.2 Versions
Two versions of the DryStar 2000 CAN are available:
DDryStar 2000 CAN, air-cooled
DDryStar 2000 CAN, water-cooled
4.2.1 DryStar 2000 CAN, air-cooled
The DryStar 2000 CAN air-cooled version releases
the waste heat of the sheet guide plate into the air
via an air/water heat exchanger. The heated air
should not be blown into the pressroom, but should
be directed through an optional exhaust air hood
and an exhaust air duct that must be installed
additionally.
4.2.2 DryStar 2000 CAN, water-cooled
The DryStar 2000 CAN water-cooled version con-
veys the waste heat to an external cooling circuit via
a water/water heat exchanger. The re-circulated heat
can be used for auxiliary purposes. The exhaust air
filled with odorous substances can escape by means
of an optional exhaust air hood and an exhaust air
duct that must be installed additionally.
4.3 Operation
The DryStar 2000 CAN is operated using the printing
press CP2000 Center.