KBA-GRAFITEC KBA PERFORMA 74 Manual

KBA PERFORMA 74
People & Print
Basic Technical Information of the Printing Machine

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Basic Technical Information of the Printing Machine PERFORMA 74
Contents
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Equipment and systems of the KBA Performa 74 sheet-fed offset machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Description of KBA Performa 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Technical description of machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Technical description of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Standard and optional equipment of KBA Performa 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4. Transport and installation of machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. Technical parameters of the KBA Performa 74 machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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Basic Technical Information of the Printing Machine PERFORMA 74
The KBA Performa 74 sheet-fed offset machines represent a machine type line for the printing of sheets of up to 520 x 740 mm.
The assortment of the KBA Performa 74 machines allows the customer to choose from numerous variants of manufacturing and equipment.
Thanks to their universal nature, the KBA Performa 74 machines find their applications in small, medium, as well as large printing shops
producing a broad range of printing material, including the most demanding fine art reproduction works .
The machines work on an offset print principle; i.e. a positive image from a printing plate is accepted blanket of the blanket cylinder from
which it is transferred onto a sheet carried by a double diameter cylinder over all printing units.
The excellent register parameters of the machine ensure quality printing of multi-colour printing matters on all suitable kinds of paper.
The activation of printing pressures, inking unit control, engagement of ink rollers, as well as other functions are controlled by an electronic
programmable system (PLC).
All components comply with international safety regulations. The machines bear a CE mark.
Two-color offset machines KBA Performa 74
- KBA Performa 74-2 with a high-pile delivery (without a perfecting unit)
Four-color offset machines KBA Performa 74
- KBA Performa 74-4 with a high-pile delivery (without a perfecting unit)
Five-color offset machines KBA Performa 74
- KBA Performa 74-5 with a high-pile delivery (without a perfecting unit)
Six-color offset machines KBA Performa 74
- KBA Performa 74-6 with a high-pile delivery (without a perfecting unit)
1. Introduction

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Basic Technical Information of the Printing Machine PERFORMA 74
A Machine control
B Printing unit
C Machine drive
D Feeder
E Feeder head
F Ionization
G Conveyor
H Front lay
I Pregripper
J Dampening equipment
K Dampening aggregate
L Inking unit
M Plate cylinders
N Blanket cylinders
O Impression cylinders
P Transfer cylinders
Q Delivery
R Infra red drying
S Powder spray unit
T Sheet guide through the machine
U Central lubrication
V Air distribution
X Automatic inking unit washer
Y Automatic offset blanket washer
Z GrafiControl
2. Equipment and systems of the KBA Performa 74
sheet-fed offset machines

A
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Basic Technical Information of the Printing Machine PERFORMA 74

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Basic Technical Information of the Printing Machine PERFORMA 74
3.1 Technical description of machines
3.1.1 Machine control
The machine is controlled mainly by a central touch screen located on the rotary bracket on the delivery. From this place, most impor-
tant machine functions can be controlled. Other control elements are located on the control panels of the printing units and the feeder.
These controls ensure the direct regulation of functions on a respective machine part. The control panels are a part of machine coverage
and are easy to access for operators. Their front wall with buttons is covered with a foil keyboard that makes panel maintenance
and cleaning substantially easy.
3.1.2 Operator’s safety
The machine is equipped with covers with positive protection. The machine stops automatically
after tilting away the covers or safety spacers. The iching switches enable inching only from
a place that has been preselected. Mechanically blocked STOP buttons are always situated with-
in the operator’s reach. The lockable main switch accidental machine startup by an unauthori-
zed person. The convergent areas of the impression cylinders are protected by swinging safety
spacers that stop the machine even if its deflection is only minimal. Safety braking is ensured
by an energetically independent brake in connection with a relay safety module to guarantee
this function in compliance with CSN EN 60204-1. All safety elements meet the requirements
of the strictest safety regulations.
3.1.3 Printing units
The assembled side frames of the printing units, feeder and delivery create independent wholes. The possibility of their mutual connec-
tion and disconnection between the individual printing units is ensured.
3.1.4 Machine drive
A machine drive is executed on all printing cylinders and inking unit rollers by means of helical gears located on the out-
side of the non-operated side frame with automatic central lubrication. The main electric engine uses a gear drive and pro-
pels and a belt drive to propel the transfer cylinder on the respective printing unit (in the middle of the machine, de-
pending on the number of the printing units) and co-engaging gears to propel the other printing units. The main electric
engine is fitted with own energetically independent brake that brakes the machine in the event that a safety chain has been activated.
EU safety standard
3. Description of KBA Performa 74 sheet-fed offset machines

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Basic Technical Information of the Printing Machine PERFORMA 74
3.1.5 Feeder
The feeder ensures the proper loading of sheets into the machine. Its most important part is the
feeder head (further described in the text below). The working height of the pile is controlled
by a feeder head caliper; it is adjusted by means of the height setting of the whole feeder head.
A feeder trolley is the same as a delivery trolley.
Their mutual changeability makes paper handling easier for the operators. The maximal height of the paper stack inside the feeder can be
unloaded on the high-pile delivery table. Depending on the square weight of the printed paper, the operators can choose from two modes of
the automatic lifting of the feeder table. This selection is completed on the touch screen in the delivery. The KBA Performa 74 machines can
also be equipped with a non-stop feeder.
3.1.6 Nonstop feeder
The non-stop feeder enables continuous paper loading without necessity to stop the machine after removing all the sheets from the main
feeder table. The machine is equipped with an auxiliary grate with an independent drive that carries the rest of the stack towards the feeder
head while the machine operator can add sheets to the stack and add the stack to the loaded one.
The grate is made of rods that are inserted into the grooves in the transport trolley. The grate is carried on two girders driven over chains by
an electric engine.
3.1.7 Feeder head
The feeder head is fitted with two systems of suckers – i.e. with 4 picking-up suckers and
2 forwarding suckers. The picking-up suckers can be tilted to the side. This can achieve
the side tightening of sheets with thinner papers as well as increase feeding capacity.
Feeder trolley
Non-stop feeder
Feeder trolley for non-stop feeder
Height adjustment of the transport suction cups
Feeder head

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Basic Technical Information of the Printing Machine PERFORMA 74
The height of forwarding suckers can be adjusted while the machine is engaged in operation.
The rotary valve that controls the pressure and vacuum mode of air distribution can be easily
removed from the feeder head body and cleaned of collected paper dust. The working height
of the table depends on the height adjustment of the whole feeder head. The feeder head
is easily and quickly adjusted according to paper size by means of a sliding screw. The caliper
(shoe) can be adjusted easily and is fitted with a contactless position sensor that ensures reli-
able regulation of feeder table lifting within the entire range of printing speed. The excessive
movement of the feeder head caliper into a paper stack can be set off by adjusting the stack’s
height against the suction cups of the feeder head. This procedure is completed while the ma-
chine is running, using a rotary control element on the feeder head.
3.1.8 Ionization
This device eliminates the static charge produced by paper. It also enhances sheet transfer reliability.
The application of the ionization is suitable especially with thin and recycled paper.
The equipment consists of two rods with high voltage contacts (one rod in the feeder and one in the
delivery), and two nozzles blowing ionized air to the stack from the feeder head. Feeding is provided
by a mains supply on the feeder.
The equipment is activated on the feeder control panel.
3.1.9 Conveyor
The conveyor transports sheets from the feeder onto the machine front lays. This vacuum con-
veyor is equipped with own air source.
Its drive reduces the speed of transported paper when incidenting the front lays, thus dimi-
nishing the possible deformation of the front paper edge. Above suction tapes, there is a tilt-
away girder on which two transport pulleys or rotary brushes are fixed, both being supplied
with machine accessories. Double sheets are checked electronically by an ultrasonic sensor.
Table height adjustment with regard to suckers
Vacuum conveyor
Double sheet ultrasonic sensor
Ionization equipment

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Basic Technical Information of the Printing Machine PERFORMA 74
3.1.10 Double sheet control
This equipment indicates the loading of more than one sheet; the equipment does not require
any adjustments. In the event of wrong loading, the feeding comes to a stop and improperly
fed sheets are blocked on the feeding bar. There exists a certain small group of printed materi-
als that are wrongly analyzed by the sensor. These including, for instance, some of the recycled
papers and expanded thicker papers that contain air gaps. These gaps cause single sheets to be
identified as double sheets. If this is the case, the double sheet control system has to be turned
off and electromechanical equipment is applied instead.
Changing between the electromechanical and ultrasonic equipment is carried out on the touch screen on the machine delivery. If the electro-
mechanical equipment is not used, it is advised to use its ad element to disengage a reading pulley so that it does not have a negative impact
on loading. The conveyor can be easily tilted down.
3.1.11 Pressure pulleys on the conveyor for heavier paper
When feeding heavier types of paper it is advised to use special pressure wheels of more robust
structure. The wheels develop extra pressure by means of a spring. The size of the pressure can
be adjusted.
3.1.12 Front lay
Sheets are transported on a lower front lay that consists of a rod on which 8 stops are fixed. The rod with the stops can be slid – within a small
range – in the direction of the print, and its right and left parts can be deflected from each other. This allows for the balancing of smaller front
or diagonal deflections during register adjustment.
All front lay stops are fitted with a pulley that prevents sheet backs from damage while they move over the stops. Two front lay stops bear
optical sensors, unique optical barriers that control sheets on the front lays and identify skewed sheets. Working in close interaction with
sheet control on the front lays there are two pneumatic cylinders designed for the safe capturing and blocking of wrongly loaded sheets, thus
preventing them from reaching the 1st printing unit.
3.1.13 Side lay
The side jogging of loaded sheets is secured by two mechanical side lays – one side lay for one direction of side jogging. The adjustment
of both side lays is completed on the non-operated machine side by means of buttons. The side lays can also be adjusted while the machine
is running. The side lay can be equipped with a component ensuring the control of its function.
3.1.14 Side lay control device
Eeach of the two side lays is fitted with optical sensors at the side stop level; the sensors in-
dicate the complete loading of sheets. If a sheet has been loaded with its edge being about
0.3 mm (0,012”) from the end, an audio signal is initiated to warn the operator about the nec-
essary adjustments of the equipment. The equipment is not designed to measure or control
the accuracy of side jogging but to check whether the operator adjusted the side lay properly.
Double sheet electromechanical control
Pressure pulleys
Side lay control

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Basic Technical Information of the Printing Machine PERFORMA 74
3.1.15 Pregripper
The machine is equipped with a swinging pregripper that grips, while at rest, a jogged sheet, accelerates it continually until it reaches the
pre-selected machine’s speed, and then transport it to the grippers of the subsequent transfer cylinder.
The pregripper is fitted with a device for blocking pregripper grippers in an open position.
This device prevents the gripping of a wrongly loaded sheet by the pregripper grippers and its further transport into the machine.
3.1.16 Rubber rollers of the dampening systems and the inking unit
The dampening system and the inking unit are fitted with Böttcher rubber rollers. It is advised
to wash the rubber coated roller by means of respective Böttcher products or by product of
similar composition; a list of suitable detergents is given in the Operation Manual, chapter 32
– Washing Chemicals.
3.1.17 Dampening equipment
The dampening is four-roller, continual equipment with the forced circulation and cooling
of a cooling solution. All rollers are without any blanket. The forme rollers and the pan rollers
are manufactured with a rubber surface, the metering roller has a chromium-plated surface
and the bridge roller has a polyamide surface finish.
The engagement and disengagement of all dampening rollers is fully automatic according to
a machine mode and is controlled by a pneumatic system. The revolutions of the pan roller
are derived from regulated electromotors by means of control electronics. The fast dampening
buttons are located on the control panels. The control panels can also be used to change the
position of the bridge roller (possible interconnection of the dampening system with the inking unit forme roller).
The standard equipment of the machine includes a dampening solution chiller by TECHNOTRANS. The standard equipment of KBA Performa
74-2 includes a TECHNOTRANS unit, type alpha d10. The temperature of the dampening solution cannot be set on this type of unit;
the temperature is set by the manufacturer to +10°C (50°F), IPA dosing can be set within a range of 0 to 15 %.
The TECHNOTRANS type alpha d20 is standard equipment for KBA Performa 74-4 and 74-5 machines.
The TECHNOTRANS type alpha d30 is standard equipment for KBA Performa 74-6 machines.
The temperature of the dampening solution can be set from +8 to +15 °C (46 to 59°F), its recommended set value is above +10 °C (50°F);
IPA dosing can be set within a range of 0 to 15 %.
KBA Performa 74-2 74-4 74-5 74-6
Technotrans unit alpha.d 10 alpha.d 20 alpha.d 30
Electric connection 1x230 V, 50 Hz [kW / A] 0.9 / 6.3 2.2 / 10.8 - / -
1x230 V, 60 Hz [kW / A] 1.1 / 6.5 2.2 / 11.4 - / -
3x400 V, 50 Hz [kW / A] - / - - / - 2.7 / 5.8
3x480 V, 60 Hz [kW / A] - / - - / - 3.3 / 6.2
Mains supply protection (supplied by the
customer)
[A] 10 16 16 10
Size -height x width x depth [mm] 942x470x567 1155x654x800
[inch] 37.1x18.5x22.3 45.5x25.7x31.5
Working weight kg 105 225
lb 231 496
Böttcher rubber rollers
Bare back dampening