technotrans manroland beta.d 40 User guide

- Original instruction manual -
Instruction Manual
beta.d-line
8095AENA999
90000030766-02 - EN
2011-05-02
technotrans AG
Robert-Linnemann-Straße 17
D-48336 Sassenberg
Phone 02583 / 301-1000
Fax 02583 / 301-1030
http://www.technotrans.de

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Copyright clause
Translation, transfer to third parties as well as any reproduction and
distribution are prohibited without our prior permission.
The main components, devices, arrangements, as well as software,
control and instrumentation equipment on all of our machines are
protected both at home and abroad by patent applications, design
registrations or copyright.
Copyright by
technotrans AG
Robert-Linnemann-Straße 17
D-48336 Sassenberg
Federal Republic of Germany
technotrans AG

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1 Contact Addresses.................................................................................................................................8
1.1 Service addresses............................................................................................................................ 8
1.2 Manufacturer's address.................................................................................................................... 9
2 Safety.....................................................................................................................................................10
2.1 General information regarding safety............................................................................................. 10
2.2 Safety of personnel ........................................................................................................................ 11
2.3 Intended use................................................................................................................................... 12
2.4 Terms of warranty .......................................................................................................................... 12
2.5 Installation site................................................................................................................................ 14
2.6 Safety instructions for transport ..................................................................................................... 15
2.6.1 Use of cranes............................................................................................................................. 15
2.7 Use of cleaning agents................................................................................................................... 16
2.8 Use of chemicals ............................................................................................................................ 17
2.9 Explosion protection ....................................................................................................................... 19
2.9.1 General information ................................................................................................................... 19
2.9.2 Qualification and training of personnel ...................................................................................... 19
2.9.3 Hazards resulting form non-compliance with the safety instructions......................................... 20
2.9.4 Explosion-proof equipment parts ............................................................................................... 20
2.9.5 Structural alterations .................................................................................................................. 20
2.9.6 Equipment parts......................................................................................................................... 21
2.9.7 Remaining hazards .................................................................................................................... 22
2.9.8 Information on maintenance and repair ..................................................................................... 22
2.10 Use of refrigeration units ................................................................................................................ 23
2.11 Safety instructions for set-up.......................................................................................................... 23
2.12 Safety instructions for maintenance ............................................................................................... 24
3 Description / Overview.........................................................................................................................25
3.1 General information........................................................................................................................ 25
3.2 Dampening solution circuit (D-circuit) ............................................................................................ 25
3.3 Options ........................................................................................................................................... 25
4 System Layout ......................................................................................................................................26
4.1 Overview......................................................................................................................................... 26
4.1.1 Refrigeration circuit (R-circuit) - air-cooled version.................................................................... 26
4.1.2 Refrigeration circuit (R-circuit) - glycol-cooled version .............................................................. 28
4.1.3 Dampening solution circuit (D-circuit) ........................................................................................ 30
4.1.4 Connections ............................................................................................................................... 32
4.1.5 Electrical components................................................................................................................ 34

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4.2 System schematic .......................................................................................................................... 36
4.2.1 Refrigeration circuit (R-circuit) - air-cooled version.................................................................... 36
4.2.2 Refrigeration circuit (R-circuit) - glycol-cooled version .............................................................. 38
4.2.3 Dampening solution circuit (D-circuit) ........................................................................................ 40
5 Components..........................................................................................................................................42
5.1 Filter system ................................................................................................................................... 42
5.2 Refrigeration unit ............................................................................................................................ 43
5.2.1 Refrigerant sight glass ............................................................................................................... 44
5.2.2 Refrigerant sight glass ............................................................................................................... 45
5.3 fluidos dampening solution doser................................................................................................... 46
5.4 Dampening solution doser, type digidos ........................................................................................ 47
5.5 Alcohol stabiliser ............................................................................................................................ 47
5.6 Conductivity measuring device ...................................................................................................... 48
5.7 pH measuring device...................................................................................................................... 48
5.8 Filter bag, type softflow .................................................................................................................. 49
5.9 Intermediate tank with float valve................................................................................................... 50
5.10 Touchscreen................................................................................................................................... 51
5.10.1 TP 5.7......................................................................................................................................... 51
5.11 Control unit ..................................................................................................................................... 52
5.11.1 multicom-IT ................................................................................................................................ 52
5.12 Basic electronic system.................................................................................................................. 54
5.12.1 TBC 50/51, TBD 50.................................................................................................................... 54
5.12.2 Interface card for basic electronic system (CAN SUB-print)...................................................... 56
5.12.3 TIOM-121 ................................................................................................................................... 57
5.12.4 Basic electronics TMM 50.......................................................................................................... 59
5.12.5 Interface card for basic electronic system (CAN SUB-print)...................................................... 61
5.13 Ex-(i) buffer amplifier (not on alcohol-free version)........................................................................ 62
6 Setting Up..............................................................................................................................................63
6.1 General information........................................................................................................................ 63
6.2 Overview......................................................................................................................................... 64
6.2.1 Air-cooled version ...................................................................................................................... 65
6.2.2 Glycol-cooled version................................................................................................................. 66
6.3 Installation ...................................................................................................................................... 67
6.4 Alcohol stabiliser ............................................................................................................................ 67
6.5 Dampening solution doser, type digidos ........................................................................................ 67
6.6 Fresh water connection .................................................................................................................. 68
6.7 Dampening solution circuit (D-circuit) ............................................................................................ 69
6.7.1 Connections ............................................................................................................................... 69
6.7.2 Containers.................................................................................................................................. 70

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6.7.3 Suction tubes ............................................................................................................................. 70
6.7.4 pH measuring device ................................................................................................................. 71
6.7.5 Return suction system ............................................................................................................... 72
6.8 Glycerine-filled pressure gauge ..................................................................................................... 74
6.9 External heat dissipation ................................................................................................................ 75
6.9.1 Chilling medium (glycol-cooled version only)............................................................................. 75
6.9.2 Waste air system (only air-cooled version)................................................................................ 76
6.10 Electrical connection ...................................................................................................................... 77
6.11 Disconnecting the unit .................................................................................................................... 78
6.11.1 Disassembly............................................................................................................................... 78
6.11.2 Recycling.................................................................................................................................... 78
7 Operation...............................................................................................................................................79
7.1 General information........................................................................................................................ 79
7.2 Adjustments.................................................................................................................................... 80
7.2.1 Dampening solution circuit (D-circuit) ........................................................................................ 82
7.2.2 Notes concerning the software .................................................................................................. 83
7.3 Control unit ..................................................................................................................................... 85
7.3.1 Selection and adjustment of values ........................................................................................... 85
7.3.2 Entering a password .................................................................................................................. 86
7.3.3 Loading the default settings ....................................................................................................... 87
7.3.4 Symbol description..................................................................................................................... 87
7.3.5 Program overview ...................................................................................................................... 90
7.3.6 Screen contents and descriptions.............................................................................................. 95
7.3.6.1 Screen overview................................................................................................................ 95
7.3.6.2 Screen: Functions ............................................................................................................. 95
7.3.6.3 Screen: Values .................................................................................................................. 99
7.3.6.4 Screen: Setup.................................................................................................................. 100
7.3.6.5 Screen: Process data ...................................................................................................... 116
7.3.6.6 Screen: Service ............................................................................................................... 119
7.3.6.7 Screen: Status................................................................................................................. 125
7.3.6.8 Screen: Language selection............................................................................................ 126
8 Maintenance........................................................................................................................................127
8.1 Overview....................................................................................................................................... 128
8.1.1 Air-cooled version .................................................................................................................... 129
8.1.2 Glycol-cooled version............................................................................................................... 131
8.2 Maintenance plan ......................................................................................................................... 133
8.2.1 General information ................................................................................................................. 133
8.2.2 Dampening solution circuit (D-circuit) ...................................................................................... 134
8.2.3 Refrigeration circuit .................................................................................................................. 136

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8.2.4 Control unit............................................................................................................................... 137
8.2.5 Intermediate tank ..................................................................................................................... 137
8.3 Dampening solution circuit (D-circuit) .......................................................................................... 138
8.3.1 Cleaning aid ............................................................................................................................. 139
8.3.2 Rinsing process ....................................................................................................................... 140
8.3.3 Conductivity probe, pH probe .................................................................................................. 143
8.3.4 pH calibration ........................................................................................................................... 144
8.3.5 Suction tubes ........................................................................................................................... 145
8.3.6 Replacing the filter bag ............................................................................................................ 146
8.4 Intermediate tank.......................................................................................................................... 147
8.5 Refrigeration unit .......................................................................................................................... 148
8.5.1 Refrigerant sight glass ............................................................................................................. 149
8.6 Control unit ................................................................................................................................... 150
8.6.1 Battery replacement................................................................................................................. 150
9 Troubleshooting .................................................................................................................................152
9.1 Electrical connection .................................................................................................................... 153
9.2 Control unit ................................................................................................................................... 154
9.3 Dampening solution circuit (D-circuit) .......................................................................................... 155
9.4 Refrigeration unit .......................................................................................................................... 158
10 Technical Data ....................................................................................................................................159
10.1 Dimensions................................................................................................................................... 159
10.2 Connections ................................................................................................................................. 160
10.3 Mechanical connection................................................................................................................. 161
10.4 Electrical connection .................................................................................................................... 162
10.4.1 General information ................................................................................................................. 162
10.4.2 Air-cooled version .................................................................................................................... 162
10.4.3 Glycol-cooled version............................................................................................................... 162
10.4.4 Residual-current-operated circuit-breaker ............................................................................... 163
10.5 Weights......................................................................................................................................... 164
10.5.1 Air-cooled version .................................................................................................................... 164
10.5.2 Glycol-cooled version............................................................................................................... 164
10.6 General information...................................................................................................................... 165
10.7 Dampening solution circuit (D-circuit) .......................................................................................... 166
10.8 Refrigerant circuit (R-circuit)......................................................................................................... 167
10.8.1 Air-cooled version .................................................................................................................... 167
10.8.2 Glycol-cooled version............................................................................................................... 168
10.8.3 Chilling medium consumption (glycol-cooled version only) ..................................................... 169
10.9 Options ......................................................................................................................................... 170

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11 Proof of inherent safety in accordance with DIN EN 60079-14......................................................172
11.1 Block diagram............................................................................................................................... 172
11.2 Electrical data............................................................................................................................... 172
11.3 Configuration of the electrical parameters ................................................................................... 173
11.4 Evaluation..................................................................................................................................... 173
11.5 Manufacturer’s declaration........................................................................................................... 174
12 Spare Parts..........................................................................................................................................175
13 Declaration of conformity..................................................................................................................176

Contact Addresses
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1 Contact Addresses
1.1 Service addresses
technotrans AG
Robert-Linnemann-Straße 17
48336 Sassenberg
Phone: [phone]
Fax: [phone]
Germany
technotrans AG
Porschestraße 1
86368 Gersthofen
Phone [phone]
Fax [phone]
Germany
technotrans graphics ltd.
Axis One, Brunel Way
Severalls Business Park
Colchester, Essex CO4 9QX
Phone: [phone]
Fax: [phone]
England
technotrans france sarl
ZAET “Les Haies“
Rue Albert Einstein
60740 Saint-Maximin cedex
Phone: [phone]
Fax: [phone]
France
technotrans España
Poligono Industrial Las Acacias
Calle de Portugal 54, nave 29
28840 Mejorada del Campo, Madrid
Phone: [phone]
Fax: [phone]
Spain
technotrans italia s.r.l.
Via Spallanzani, 18
20025 Legnano (Mi)
Phone: [phone]
Fax: [phone]
Italy
technotrans scandinavia AB
Rallarvägen 41
184 40 Åkersberga
Phone: [phone]
Fax: [phone]
Sweden
technotrans america inc.
1050 E Business Center Dr.
Mt. Prospect, Illinois 60056
Phone: [phone]
Fax: [phone]
USA
technotrans américa latina
Rua Barão de Melgaço 126
Real Parque
São Paulo -SP - CEP 05684-030
Phone: [phone]
Fax: [phone]
Brasil
technotrans Asia-Pacific limited, Japan branch
Room D, Oak Plaza 3F
2-10-6 Kanda-Awaji cho
Chiyoda-ku
101-0063 Tokyo
Phone: [phone]
Fax: [phone]
Japan
technotrans Asia-Pacific limited
Unit 16-19, 16/F
Tuen Mun Central Square
22 Hoi Wing Road, Tuen Mun
New Territories, Hong Kong
Phone: [phone]
Fax: [phone]
Hong Kong

Contact Addresses
9
technotrans printing equipment (Beijing) co. ltd.
Xincheng Industrial Park B1-4
No. 9 Kechuang Er Jie
Eastern Area BDA
Beijing 100 023
Phone: [phone]
Fax: [phone]
P.R. China
Shanghai Office
Unit 1007, Pine City Building
No. 777 Zhaojia Bang Road
Shanghai, 200032
Phone: [phone] /-9100
Fax: [phone]
P.R. China
technotrans technologies pte.ltd
190 MacPherson Road #04-06
Wisma Gulab
Singapore 348548
Phone: [phone]
Fax: [phone]
Singapore
technotrans technologies pte ltd
Unit 7 / 111 Lewis Road
Wantirna
Victoria 3152
Phone: [phone]
Fax: [phone]
Australia
technotrans Middle East FZ-LLC
Circular Building - Block D
International Media Production Zone
(IMPZ)
Second Floor - Office 208
P.O. Box 485010
Phone: [phone]
Fax: [phone]
Dubai, United Arab Emirates
technotrans india pvt ltd.
#24, Eden Plaza Second Floor
Mount Poonamallee High Road
Nandambakkam, Chennai 600 089
Tamil Nadu
Tel: [phone]
Fax: [phone]
India
1.2 Manufacturer's address
technotrans AG
Robert-Linnemann-Straße 17
48336 Sassenberg
Phone [phone]
Fax [phone]
Germany

Safety
10
2 Safety
2.1 General information regarding safety
Personnel in charge of carrying out work on the unit or system must have read and
understood this manual and in particular the section on safety.
If necessary, in-house instruction should be provided, taking into account the
technical qualifications of the personnel concerned.
The following symbols are used in this manual:
Warning – General danger
Warning – Electrical hazard!
Warning – Risk of explosion!
Caution – Danger of damage!
Note
Information or notes appear here.
Certain components have additional warning plates or labels to facilitate safer
operation. Plates or labels must not be covered or removed.
Observe all safety instructions. Observation of these instructions is in the interest of
personal safety.
The relevant accident prevention regulations as well as other generally recognised
regulations concerning workplace health and safety must be observed.

Safety
11
2.2 Safety of personnel
Avoid any working practice which:
• Endangers the health and safety of the user or third parties
• presents a danger to the unit or system or other property,
• impairs the safety or functionality of the unit or system,
• does not comply with the safety instructions.
Maintenance and service should be carried out only by suitably qualified persons
who are familiar with the unit and who have been informed as to potential hazards.
Warning – Danger to personnel
There is an increased risk of injury if the safety devices are put out of
operation. Never dismantle or put out of operation any safety device.
• Check the safety devices daily for correct operation.
• Malfunctions and defects concerning the safety devices must
be reported immediately to the after-sales service.
• The unit covers must be closed during system operation and
may be opened only to rectify malfunctions and for
maintenance work.
• Repairs to pipe systems and tanks may only be carried out
when the system is depressurised.
• When handling chemicals, observe the applicable safety data
sheets and corresponding disposal information from suppliers,
as well as any relevant local safety regulations. Wear
protective clothing!
Any safety devices removed for set-up, maintenance or repair purposes must be
refitted and checked immediately upon completion of maintenance and repair work
and their proper function must be checked.
In the above case, particular attention should be paid to general accident
prevention and safety regulations.

Safety
12
2.3 Intended use
The unit or the system is intended solely for the application outlined in the
“Description/Overview” section and only with the components supplied and
approved.
Using the unit for purposes other than those mentioned above is considered
contrary to the intended use. The manufacturer cannot be held liable for any
damage resulting from such use. The risk of such misuse lies entirely with the user.
2.4 Terms of warranty
The manufacturer is not liable for damage resulting from improper use, the failure
to observe this manual, the employment of insufficiently qualified personnel, or
unauthorised modifications. In these cases the manufacturer’s warranty is
rendered void.
Caution – Impairment of correct unit operation when using
incorrect spare parts!
When using components which have not been approved, correct
operation can no longer be guaranteed. Only use spare parts
approved by the after-sales service.
Caution – Loss of warranty claim!
The use of media (e.g. washing agents, additives, cleaning agents
etc.) that are not approved may result in damage to the unit or to the
system. The warranty claim will expire. The same shall apply when
different media are mixed.
Use only media approved by technotrans and the printing press
manufacturer.

Safety
13
Note
Removing type plates will make the warranty claim expire.
Fig. 1: Sealings
Sealings can be found at different positions on the unit or the system:
1 Sealing wax (example of application)
2 Metal sealings (example of application)
3 Sealing labels (example of application)
Note
The warranty claim will expire when sealings are broken high-
handedly.

Safety
14
2.5 Installation site
When selecting an installation site, observe the following instructions:
• Keep the specified escape routes clear.
• Ensure firm support and a horizontal position of the unit.
• Comply with the data stated in the “Technical Data” section concerning the
ambient temperature for operation, transport and storage when the unit is
completely empty.
• Ensure sufficient space for operating, maintaining and cleaning.
• If provided, keep the vents for incoming and outgoing air clear
Observe relevant technical and building regulations.
Hoses and electrical cables must be laid such that there is no danger of dripping
and that they are protected from damage.
When selecting an installation site, the applicable safety regulations and
manufacturer’s instructions concerning substances used for or located near the
machine must be observed.
When installing the units near traffic routes, separate the units from the traffic
routes by suitable structures.

Safety
15
2.6 Safety instructions for transport
Caution – Equipment damage
Danger of damage due to improper handling during transport.
• When transporting the unit, observe the instruction labels on
the unit (if installed).
• Use only appropriate lifting tools for transport.
• Transport the unit only when empty.
• Transport the unit only on a suitable and secured transport
pallet.
2.6.1 Use of cranes
Warning - Danger due to suspended goods!
Suspended goods may fall down.
Standing under suspended goods is prohibited.
Caution – Danger of damage during transport by crane!
Safe transport by crane cannot be guaranteed when using clevises
which have not been approved. Only use clevises approved by
technotrans. The clevises adapt to the pulling direction. Transverse
loads are avoided. technotrans part no.: 035.10.1012
Fig. 2: Use of cranes
Note
The permissible angle of inclination is 60° maximum. Particular
attention should be paid to accident prevention and safety
regulations. If necessary, remove the upper sheet or the lid sheet to
screw in the clevises.

Safety
16
2.7 Use of cleaning agents
No material, i.e. neither metals nor plastics can be certified to be completely
resistant to chemicals.
Due to the large number of available additives and cleaning agents the recipes of
which are subject to changes, the manufacturer will not assume any liability for
damage attributable to the influence of such substances.
Caution – Damage due to cleaning agents!
Cleaning agents may influence units and measuring devices, may
destroy materials and harm the environment.
Please observe the following points:
• Cleaning agents must not enter system circuits.
• Use cleaning agents in a well-aimed way and economically.
• Their on-time, especially on plastic parts and seals, has to be
limited to a minimum.
• Excess detergent has to be removed and parts have to be
wiped dry or, if possible, rinsed with clear water.
• Do not use any flammable cleaning agents (unless explicitly
specified by the manufacturer).
• Do not use any cleaning agents containing silicone or chorine
(unless explicitly specified by the manufacturer).
In case of doubt, the user should perform a test to see whether the detergents /
chemicals are compatible with the materials used. The necessary sample material
for these tests can be supplied by the manufacturer free of charge upon request.
The materials used for this product have been selected on the basis of several
years of field experience of these products worldwide. If the product is used as
intended and if the information provided in the "Safety" chapter is observed, this
product offers very good performance and a long service life.

Safety
17
2.8 Use of chemicals
Warning - Danger of explosion when handling flammable
liquids!
The operator must inform personnel as to the possible risk of
explosion whilst using flammable liquids (in this case isopropyl
alcohol), in accordance with the relevant regulations.
• Only use cleaning agents and solvents, additives, solvent-free
washing agents or coatings approved by the after-sales service
with a flash point of at least 55 °C (131 °F).
• Do not heat the substances above the flash point.
• Provide appropriate ventilation in the room.
• No open flames or sources of ignition.
• Observe the relevant explosion prevention measures.
• Immediately remove any leaking materials in a proper manner.
• Make sure that there are no open containers, spills or
impregnated rags.
Warning – Health hazard!
The use of chemicals can present a health hazard.
• When handling chemicals always put on protective gloves,
eyewear and clothing.
• Observe the applicable safety data sheets.
Caution – Danger of damage due to aggressive chemicals!
Aggressive chemicals can cause damage to components.
• Do not use any chemicals (e.g. for cleaning) which are
aggressive to components.
• Observe the relevant manufacturer‘s safety data sheets.

Safety
18
Warning – Explosion hazard due to improper use of alcohol!
Increased risk of explosion due to improper use of alcohol.
To ensure safe handling of alcohol, observe the safety data sheets,
the hazardous material regulations and the following points.
• The system owner must inform the operating personnel as to the possible
risk of explosion when handling flammable liquids (in this case isopropyl
alcohol), in accordance with the explosion prevention regulations.
• Store alcohol only in rooms complying with the hazardous material
regulations and with local regulations.
• There is an increased risk of explosion due to static discharge when there is
no equipotential bonding between the alcohol tank and the unit housing.
There must always be a conductive connection between the alcohol tank
and the unit housing (see Layout). Remove any traces of corrosion.
• Avoid electrostatic discharges by taking suitable measures (ESD protective
measures) (e.g. earthing of person, wearing of shoes with discharging
capability).
• All components fittings and lines containing IPA must be "permanently
technically tight" in the sense of the safety regulations. Check that the
connection hoses to the alcohol tank do not leak.
• Use only approved, conductive alcohol tanks for storing alcohol to cover
immediate requirements.
• Make sure that the alcohol tanks are set up in a tilt- and spill-proof way.
• Ensure that no flammable substances are stored in the vicinity of the alcohol
tanks.
• If alcohol should overflow or be spilled it must be prevented from entering
areas where ignition sources must be expected. Any alcohol has to be
diluted immediately with water and soaked up.

Safety
19
2.9 Explosion protection
2.9.1 General information
This section contains fundamental information for use in potentially explosive
locations. Observe this information when setting up, starting, operating and
maintaining the unit. The information must be available at the operating location of
the machine at any time.
The corresponding local, country-specific rules and regulations apply in addition to
this information.
Note
Since the unit or system has no own ignition source, it does not come
within the scope of regulation 94/9/EC (ATEX).
If the alcohol dosing system (if installed) is used as intended and if this instruction
manual and the required installation conditions (in particular the maximum
admissible ambient temperature) are observed, the formation of a hazardous
explosive atmosphere in the immediate vicinity of the tank is not expected, so that
it is not necessary to define a potentially explosive area in the sense of the
directive 1999/92/EC.
The inside of the alcohol tank is an area where – due to operating reasons – a
hazardous explosive atmosphere is constantly or frequently present in the form of a
mixture of air and flammable gases (zone "0" according to ATEX RL1999/92/EC).
2.9.2 Qualification and training of personnel
The personnel employed for setting up, starting, operating and maintaining the
system must have the corresponding qualifications for working in potentially
explosive areas.
The areas of responsibility and the supervision of the personnel must be defined
and ensured by the operator. If the personnel is not sufficiently trained, training
courses must be held and proven.

Safety
20
2.9.3 Hazards resulting form non-compliance with the safety instructions
The alcohol dosing system and the related equipment have been manufactured in
accordance with the state of the art and are operationally safe.
Warning – Hazards resulting from improper use!
Improper operation or misuse may lead to the following hazards:
• For the health and safety of the operator.
• For the unit or system or other property of the operator.
Use the alcohol dosing system and the related equipment only as
intended and only if they are in a perfectly safe state.
Non-compliance with these instruction may damage the equipment. Non-
compliance with the safety instructions excludes any damage claims.
2.9.4 Explosion-proof equipment parts
Explosion-proof equipment parts must be tested for proper installation by an
authorised person prior to the start-up of the equipment or after a repair. Observe
the EU (European Union) installation regulations as well as local, country-specific
regulations.
Please refer to the chapter "Proof of inherent safety".
2.9.5 Structural alterations
Alterations are prohibited without the written authorisation by technotrans.
If spare parts are sourced from third parties, it cannot be guaranteed that they are
designed and manufactured in compliance with the load and safety requirements.
Liability and warranty for damages resulting from the utilisation of non-original
spare parts are excluded.