HEIDELBERG DryStar 2000 User manual

DryStar 2000
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 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety 7.............................................................................
2.1 Basic safety requirements 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Organization of safety instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Operation, maintenance and troubleshooting 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Handling cleaning agents, solvents, inks and varnishes 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Handling anti-freezing agents 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Handling hot air/IR dryer slide-in units 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Working with compressed air 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Proper use 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Terms of warranty 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 General information about the drying process 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Description 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Function 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Versions 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 DryStar 2000 air-cooled version 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 DryStar 2000 water-cooled version 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Operation 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Variants 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.1 DryStar 2000 SM 74 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 DryStar 2000 SM 74 L 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 DryStar 2000 SM 74 LX 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 DryStar 2000 SM/CD 102 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 DryStar 2000 SM/CD 102 L 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.6 DryStar 2000 CD 102 L + ZT 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.7 DryStar 2000 SM/CD 102 LX 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.8 DryStar 2000 CD 102 LX + ZT 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.9 DryStar 2000 SM/CD 102 with UV dryer 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Maincomponents 29..................................................................
5.1 Dryer cabinet 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Dryer slide-in unit 1 (IR) 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 DryStar 2000 SM 74 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 DryStar 2000 SM/CD 102 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Dryer slide-in units 1 and 2 (IR + hot air) 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.1 For variants of the DryStar 2000 SM 74 L/LX 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3.2 For variants of the DryStar 2000 SM/CD 102 L/LX 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Dryer slide-in unit 3 (cold air) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.1 DryStar 2000 SM 74 LX 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4.2 For variants of the DryStar 2000 SM/CD 102 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Interdeck dryer (IR) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents
4
6 Operation 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Controls 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Dryer cabinet control panel 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.1 Meaning of the LEDs for status and fault displays 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.2 Input and selector keys 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Switching on the DryStar 2000 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Switching off the DryStar 2000 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Before you start a print job... 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6 Recommended setting values 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.1 DryStar 2000 without coating drying 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.6.2 DryStar 2000 with coating drying 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Menu displays 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Overview of the menu displays 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Main menu 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.1 Opening the main menu 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2.2 Additional functions in the main menu 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Selecting the sheet size 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Pile surface temperature control 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.1 Manual operating mode 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4.2 Automatic operating mode 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Actualvaluesmenu 59.................................................................
7.6 Operational, fault and maintenance messages menu 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.1 Operational message 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.2 Fault messages 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.3 Maintenance messages 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6.4 Opening the Fault messages menu 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7 Service menu 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.1 I/O display menu 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.2 Language selection menu 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.3 Keycode menu 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.4 Control parameters menu 69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.5 IR balance menu (only for printing presses with extended delivery) 70. . . . . . . . . . . . . . . .
7.7.6 Hot air balance menu (only for printing presses with extended delivery) 71. . . . . . . . . . . .
7.7.7 Preheating/blasting menu 72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7.8 IR radiator operating hours menu 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8 Information menu 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9 Interdeck dryer menu 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.1 Adjusting the IR output 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.9.2 IR radiator operating hours 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10 DryStar 2000 with UV drying 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.1 Printing presses with standard delivery 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.10.2 Printing presses with extended delivery 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of contents
5
8 Maintenance 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Maintenance schedule 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Dryer cabinet 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.1 Cleaning the air filter 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.2 Replacing the air filter 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.3 Cleaning the heat exchanger 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.4 Cleaning the protective grid 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.5 Checking the air and water supply 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2.6 Checking the cooling water pressure and refilling the cooling water 91. . . . . . . . . . . . . . . .
8.2.7 Checking/changing the anti-freezing agent 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Dryerslide-inunits 95..................................................................
8.3.1 Removing the dryer slide-in unit 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.2 Cleaning the IR radiators and reflectors 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3.3 Cleaning the air nozzles (only for SM/CD 102 printing presses with coating system) 98.
8.3.4 Cleaning the honeycomb element (only for SM/CD 102 printing presses with coating
system) 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Interdeck dryer (optional) 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.1 Removing the IR module 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.2 Cleaning the IR radiators and reflectors 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.3 Cleaning the air nozzles 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.4 Cleaning the honeycomb element 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.5 Removing the suction module 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4.6 Cleaning the suction module 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Cleaning the pile surface temperature sensor 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Troubleshooting 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Specifications 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.1 Converting from Celsius to Fahrenheit 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Dryer cabinet 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 Dimensions 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 General data 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Cooling water quantities 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 DryStar 2000, air-cooled 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 DryStar 2000, water-cooled 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Exhaust air hood (optional) 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Dryer slide-in unit 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5.1 IR, IR + hot air and cold air 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5.2 Interdeck dryer 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Ventilation data 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6.1 DryStar 2000 SM 74 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6.2 DryStar 2000 SM/CD 102 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7 Cooling circuit (only for the DryStar 2000 water-cooled version) 126. . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8 Ambient conditions 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.9 Maximum short circuit current 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11 Spare parts list 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 Index 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foreword
6
1 Foreword
1.1 This instruction manual...
...supports you in the operation, maintenance and
troubleshooting of your DryStar 2000.
The information in this manual applies to the follow-
ing DryStar 2000 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)
1.3 Abbreviations
Fig. Figure
A.S. Drive side
B.S. Operator’s side
IR Infrared
LED Light emitting diode
PLC Programmable controller
STA Interface adapter
UV Ultraviolet

Safety
7
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
section on safety.
If necessary, in-house instruction should be provi-
ded, taking into account the technical qualification
of the personnel concerned.
2.2 Organization of safety instructions
This manual has three categories of instructions,
which are explained below.
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
8
Safety instruction category 1 (warning)
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 the machine and additional equipment.
Associated pictograms with signal words:
Warning -- <general danger>
Warning -- explosive substances!
Warning -- hot surface!
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
9
Safety instruction category 2 (caution)
This safety instruction draws attention to situations
that could present a particular danger.
Failure to heed warnings can result in damage to the
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
radiators.
Instruction category 3 (general note)
This note offers additional information and tips on
the use of the unit.
Associated pictogram with signal word:
"Note
Example:
"Note
An incorrectly installed air filter reduces air
circulation.

Safety
10
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 the unit or others,
Dimpair the safety and functionality of the
unit,
Ddo not comply with the safety instructions.
DAll work on the unit such as operation, mainte-
nance and troubleshooting may only be perfor-
med by persons who are familiar with this man-
ual, have been instructed about potential
dangers and who possess the necessary
qualifications.
DAlways check the unit safety devices before
beginning work. Never remove or shut down
safety devices.
DCheck safety devices daily for proper function.
Immediately report malfunctions 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 chapter
“Maintenance” 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 Instruc-
tion Manual/Maintenance Instructions of your
printing press.

Safety
11
DSwitch off the machine/system (printing press
main switch to “OFF”) when servicing (cleaning,
maintenance, settings, troubleshooting). Secure
the machine/system against unintentional reac-
tivation.
DHave electrical equipment serviced by autho-
rized 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
12
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 notes:
DProvide appropriate ventilation in the room.
DAvoid sources of ignition.
DObserve explosion prevention measures.
DNo smoking, drinking or eating when working
with these materials.
DWear protective gloves.
DComply with all accident prevention regulations,
safety regulations and manufacturer’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 paints and varnishes above their
flash point.
DStore all cleaning agents, solvents, inks and
varnishes in the 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.
DFumes from cleaning agents and solvents may
not enter areas where air intake openings are
present.

Safety
13
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 when swallowed.
Observe the following notes:
DHandle anti-freezing agents carefully to avoid
contact with the skin and eyes.
DWear impermeable gloves if your skin could
come into contact for repeated or longer
periods or time. In addition, wear safety
goggles to protect your eyes.
DMake sure the room you are working in is
properly ventilated when handling anti-freezing
agents.
DStore anti-freezing agent in tightly sealed
and appropriately labeled containers in a well-
ventilated area. Do not place containers of
anti-freezing agent in direct sunlight.
DAvoid polluting the soil, groundwater and
natural 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 a recognized
reprocessor or authorized incineration plant.
DAnti-freezing agent containers must be
completely emptied of any residue before
being disposed of.
DPay particular attention to the specifications
and notes on the safety data sheet of the
anti-freezing agent used.

Safety
14
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
for a long period of time before handling 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 dealing
with 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 radiators become dirty, wipe
then with a soft, lint-free cloth. The front side
of the IR radiators can be cleaned with a cloth
lightly soaked with alcohol. Alcohol may not
be used to clean the gold-plated back of the
IR radiators.

Safety
15
2.7 Working with compressed air
DWhen cleaning with compressed air, bear in
mind that loose dust and powder particles are
carried away and can cause injury to the eyes
as well as damage the respiratory system. Al-
ways wear protective glasses and a dust mask
when cleaning with compressed air.
DCompressed air can cause serious injury. Never
direct a stream of compressed air at a person.
DThe application of compressed air can result in
damage to sensor engineering. Never clean
sensors with high energy compressed air.
2.8 Proper use
The unit may only be used for the purpose described
in chapter 4 “Description” in connection with the sup-
plied and authorized components.
Using the unit for purposes other than those men-
tioned is considered contrary to the 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 this manual.
DOperation by insufficiently qualified personnel.
DUsing spare parts not issued by Heidelberger
Druckmaschinen AG.
DUnilateral changes to the unit and its compo-
nents which were supplied by Heidelberger
Druckmaschinen AG.

General information about the drying process
16
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 automat-
ically 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
17
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
18
4 Description
4.1 Function
The DryStar 2000 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 are available:
DDryStar 2000 air-cooled version
DDryStar 2000 water-cooled version
4.2.1 DryStar 2000 air-cooled version
The DryStar 2000 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 press room, 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 water-cooled version
The DryStar 2000 water-cooled version conveys the
waste heat to an external cooling circuit via a water/
water heat exchanger. The recirculated 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 is operated from the operating
console of the printing press delivery and on the
control panel of the dryer cabinet.

Description
19
4.4 Variants
4.4.1 DryStar 2000 SM 74
1
2
Fig. 1 Printing press with DryStar 2000 SM 74
The DryStar 2000 SM 74 is an accessory of the
Speedmaster SM 74 (standard delivery without
coating unit). It comprises the following main
components:
1Dryer cabinet
2Dryer slide-in unit 1 (IR)

Description
20
4.4.2 DryStar 2000 SM 74 L
1
2
Fig. 2 Printing press with DryStar 2000 SM 74 L
DryStar 2000 SM 74 L is an accessory of the Speed-
master SM 74 L (standard delivery with coating unit).
It comprises the following main components:
1Dryer cabinet
2Dryer slide-in unit 1 (IR + hot air)