Training Miraflex AM EQ.59468 OPus

Z WINDMLLER & HLSCHER
Flexoprint MIRAFLEX AM OP
Eq.59468 Training manual OP
Windmller & Hlscher KG | Postfach 1660 | 49516 Lengerich | Deutschland | Tel.: +49 5481 14-0 | Fax: +49 5481 14-2649
info@wuh-lengerich.de | www.wuh-lengerich.de
Copyright Windmller & Hlscher KG
Z WINDMLLER & HLSCHER Overall table of contents
Overall table of contents
1 Training instructions
1.1 Information on the training manual
1.2 Instructions for training
2 Safety
2.1 Machine data
2.1.1 Manufacturer's address and name plate
2.1.2 Technical specifications
2.2 Workplaces
2.2.1 Overview of the workstations
2.3 Safety devices: Description
2.3.1 Emergency-Stop
2.3.2 Eltainer
2.3.3 Winder
2.3.4 Printing unit
2.3.5 Drying system
2.3.6 Central warning device
3 Machine description
3.1 Machine overview
3.1.1 Overview of the entire machine
4 Control elements and screen pages

4.1 Arrangement of the operator panels
4.1.1 Arrangement of the control consoles
4.2 General control elements
4.2.1 General instructions for use of the control elements
4.2.2 Main switch on the Eltainer
4.2.3 EMERGENCY-STOP
4.2.4 Pre-alarm/Jog
4.2.5 Stop
4.2.6 Slow
4.2.7 Fast
4.3 Unwind
4.3.1 Operator panel +R10
4.4 Main operator panel
4.4.1 Overview Main operator panel +P59
4.4.2 Machine On
4.4.3 Production speed
4.5 Printing unit
13.07.2016 - Eq.59468 Training manual OP 1

Overall table of contents Z WINDMLLER & HLSCHER

4.5.3 Control elements on the color deck
4.5.4 Hand-held panel
4.6 Rear frame
4.7 Slitting assembly
4.8 Rewind
4.9 Procontrol
4.9.1 Procontrol
4.9.2 Procontrol Operation
4.9.3 Alarms
4.9.4 Procontrol screen pages
4.9.5 Job processing
4.9.6 Data backup
4.9.7 Cleaning the touchscreen
4.9.8 Operating the service pages
4.9.9 Internet Remote Service
4.10 Operator terminal - Winder
4.10.1 Winder operator terminal
5 Operation
5.1 Unwind
5.1.1 Design and function
5.1.2 Compressed-air supply line
5.1.3 Establishing the ready-for-operation status
5.1.4 Swiveling the turret manually
5.1.5 Loading a roll and operating the chucks
5.1.6 Switching the drive of the winding shaft on or off
5.1.7 Roll change
5.1.8 Web tension increase at the unwind
5.1.9 Lifting gear
5.2 Static removal
5.2.1 Static charge removal
5.3 Printing unit
5.3.1 Layout and function
5.3.2 Programs for deck in/deck out operations
5.3.3 Register adjustment
5.3.4 Nip roll in sleeve technology
5.3.5 Ink supply
5.3.6 Hinged cap bearing
5.3.7 Anilox roll sleeve change
2 13.07.2016 - Eq.59468 Training manual OP

5.3.8 Plate cylinder sleeve change

5.3.9 Sleeve change - Hybrid mandrel
5.3.10 Safety guards on the printing unit
5.3.11 Operating the roll up doors
5.4 Web guide control unit
5.4.1 Web guide control
5.5 Nip rolls
5.5.1 Operating the nip rolls
5.6 Easy-Set
5.6.1 Safety instructions
5.6.3 Automatic functional steps and messages
5.6.4 Material requirements and technical specifications
5.6.5 Requirements and operation
5.6.6 EASY-TOPO
5.6.7 EASY-SET S
5.6.8 Quick reference guide
5.7 Easy-Reg
5.7.1 How to operate EASY-REG S
5.8 Easy-View
5.8.1 Easy-View
5.9 Easy-Col
5.9.1 EASY-COL - Overview
5.9.2 Notes
5.9.3 Assignment screen page
5.9.4 Manual color correction
5.9.5 Color correction with leftover ink
5.9.6 Color corrections using the Lab/LCh color values
5.9.7 Color correction using a recipe
5.9.8 Color correction using the color chart
5.9.9 Color settings
5.9.10 Measuring the substrate to be printed
5.9.11 Defining the target color location
5.9.12 Measuring the actual color location
5.9.13 Making corrections
5.9.14 Metering by use of a platform weigher
5.9.15 Anilox roll calibration
5.9.16 Consumption screen page
5.9.17 Control elements on the ink weighing system
5.9.18 Attaching the ink weighing system to the pump and valve unit
5.9.19 Operating the ink weighing system
5.9.20 Checking and calibrating the ink weighing system

5.10 Drying system

5.10.1 Safety instructions for use of the drying system
5.10.3 Operating the drying system
5.10.4 Measuring stations
5.10.5 Calculation examples
5.10.6 Dryer rating plate
5.10.7 Flow diagram with solvent vapor concentration controller
5.11 Solvent analyzer
5.11.1 Solvent analyzer Setup
5.12.1 Safety information
5.12.3 Positioning of the cutting assembly
5.12.4 Setting the spreader roller
5.12.5 Changing the blades
5.12.6 Setting up the edge trim removal
5.12.7 Draw prior to the rewind
5.13 Rewind
5.13.1 Special function, bypassing the safety light grid
5.13.6 Inserting the core
5.13.8 Roll change
5.13.9 Nip roll and lay-on roller
5.13.10 Taper tension on the rewind
5.13.11 Lifting gear
5.13.12 Automatic chucks (option)
5.14 Inking system
5.14.1 Safety instructions for using the inking unit
5.14.3 Permitted solvents in the washing systems
5.14.4 Conductivity of fluids
5.14.5 Control elements on the pump and valve unit
5.14.6 Supply system for cleaning agents
5.14.7 Changeover when non-mixable inks are to be used
5.14.8 Control elements on the hand-held panel
5.14.9 Inking, wash-up and viscosity screen page
5.14.10 Starting inking, wash-up, preconditioning or pump out programs
5.14.11 Inking programs
5.14.12 Pump-out programs

5.14.13 Wash-up programs

5.14.14 Pre-conditioning programs
5.14.15 Error display on the hand-held panel
5.14.16 Cleaning the connectors
5.14.17 Pivoting and removing the doctor blade chamber
5.14.18 Layout and assignment of the drain boxes
5.14.19 Layout and arrangement of the doctor blade chambers
5.14.20 Profiled element on doctor blade chamber - Blade change
5.14.21 Doctor blade chamber profile - Changing the seal in the machine
5.14.22 Profiled element on the doctor blade chamber - Cleaning
5.14.23 Additional doctor blades
5.14.24 Fitting the additional doctor blade
5.14.25 Fitting/removing the clamping rail
5.14.26 Determining the doctor blade length
5.15 Viscosity control system
5.15.1 Viscosity controller and solvent pump
5.15.2 Viscosity control
5.15.3 Conversion
5.16 Production make-ready
5.16.1 Switching the machine to ready for operation
5.16.2 Selecting the winding direction
5.16.3 Threading up the web
5.16.4 Changing the web paths towards the web inspection unit
5.16.5 Instructions for the correct printing plate assembly
5.16.6 Web tension reference values
5.16.7 Roller covers
6 Maintenance
6.1 ATEX-relevant greasing points
6.1.1 Important information on 'ATEX-relevant greasing points'
6.1.2 ATEX-relevant greasing points on the printing unit
6.2 Cleaning
6.2.1 Rewind
6.2.2 Unwind
6.2.3 Unwinder
6.2.4 Rewind
6.2.5 Rewind
6.2.6 Printing unit
6.2.7 Printing unit
6.2.8 Printing unit
6.2.9 Printing unit
6.2.10 Printing unit
6.2.11 Overhead structure
6.2.12 Drying system

6.2.13 Drying
6.2.14 Rear frame
6.2.15 Film slitter
6.2.16 Film slitter
6.2.17 Procontrol
6.2.18 Eltainer
6.2.19 Easy-Col
6.2.20 Easy-Set
6.2.21 Easy-Reg

Z WINDMLLER & HLSCHER 1 Training instructions

1 Training instructions Z WINDMLLER & HLSCHER

1.1 Information on the training manual....................................................................................2
1.2 Instructions for training......................................................................................................3

X000060557
1.1 Information on the training manual

This training manual only serves as training material.
It contains information regarding the machine environment plus product-related settings and chro-
nological procedures.
In addition to the instruction manual provided with the machine, this training manual explains ma-
chine functions and working steps, and provides additional information for the machine operator.
You must read and abide by the safety instructions given in the provided instruction manual without
fail before you start work on the machine.
Consult the provided instruction manual during the entire training for information regarding the
machine's operating functions.
The chapter Instructions for training must be observed.

X000059714
1.2 Instructions for training

Copyright and ancillary copyright
All rights reserved. The training material, files / storage media and films / video cassettes are protected
by copyright law. Every utilization and/or distribution to third parties requires the prior written approval
of WINDMLLER & HLSCHER. This applies in particular to reproductions, modifications, micro-
filming, storage and processing in electronic systems as well as unlawful transfer and commercial
usage (e.g. through rental, presentation, etc.).
Disclaimer
The material included, files / data storage media and films / video cassettes have been created to the
best of our knowledge solely for training purposes. Their contents can differ, in particular with regard
to commissioned or equipment-related machine designs / documentation. As such, we cannot as-
sume any guarantee / liability that the training material and the associated training (including the
information conveyed verbally) is correct and free of errors. This applies, in particular, to technical
documentation for a specific machine type and/or for a machine with specific equipment. Damages
that occur as a result are always excluded.
Qualification of the training participants
The machinery and shift manager trainees must fulfill the physical and mental requirements for work-
ing with the machine. The maintenance trainees must possess qualified knowledge in the necessary
electronic and mechanical fields. The training assumes familiarity with the internationally applicable
standards, guidelines, regulations, etc. along with the national standards of the country in which the
equipment is operated. As such, these are not included in the scope of the training.
Safety instructions
The safety and accident prevention regulations applicable for the machine and the warnings included
in the instruction manual delivered with the machine must be read and complied with at all times.
Safety regulations
If the training takes place on the premises of WINDMLLER & HLSCHER then the training partic-
ipants must comply with the company's internal safety and accident prevention regulations, security
regulations and access rules. Photographs and video recordings are prohibited in the buildings.

X000059714

Z WINDMLLER & HLSCHER 2 Safety
2 Safety
2.1 Machine data

2.2 Workplaces
2.3.2 Eltainer
2.3.3 Winder
2.3.4 Printing unit
2.3.5 Drying system

2 Safety Z WINDMLLER & HLSCHER

Z WINDMLLER & HLSCHER 2 Safety | Machine data
2.1 Machine data

2.1.1 Manufacturer's address and name plate...........................................................................2
Manufacturer's address.................................................................................................2
Name plate....................................................................................................................2
2.1.2 Technical specifications....................................................................................................3

2 Safety | Machine data Z WINDMLLER & HLSCHER
X000221423

Manufacturer's address
WINDMLLER & HLSCHER KG

Mnsterstrae 50
D-49516 Lengerich
Phone: +49(0) 5481140
Telefax: +49(0) 5481142649
EMail: info@wuh-group.com
Internet: www.wuh-group.com
Name plate
NOTE
The details given on the name plate are important for ordering spare parts. Windmller & Hlscher
can only supply the correct spare part if the machine model and equipment number are known.
Windmller & Hlscher KG

Postfach 1660 - D49516 Lengerich
Masch.-Bez.
Masch.-Typ. 2
Equip.-Nr. 3
Baujahr 4
(1) Machine model (2) Machine type

(3) Equipment number (4) Year of construction

Z WINDMLLER & HLSCHER 2 Safety | Machine data
X000323556
Space required
Length See installation drawing
Width See installation drawing
Height See installation drawing
General specifications for the entire machine

Web width, max. mm 1,500
Printing width, max. mm 1,450
Print repeat range mm 387,350-800
Roll diameter, max. mm 1,000
Roll weight, max.(unwind and rewind) kg 1,470
Core inner diameter mm 76/152
Core outer diameter mm 85/180
Web tension range, unwind N 25-450
Web tension range at the rewind without slitter operation N 25-450
Web tension range at the rewind with slitter operation N 40-450
Web tension range, draws N 25-450
Machine speed, max. m/min 400
(The machine speed depends on job-specific and print-related
factors.)
Power supply
Connected load KVA 190
Cooling water requirements

Cooling water quantity required m3/h 1.5
(per chill roll)
Cooling water quantity required for the temperature control unit, m3/h 2.0
max.
Compressed air
Pressure kPa 600
(overpressure)
Turboclean, approx. m3/h 120
(with ink mixer integrated in the cover)
Solvent analyzers, approx. m3/h 12
during sleeve change, approx. m3/min 2.5
(for each sleeve change normally lasting less than one minute)

2 Safety | Machine data Z WINDMLLER & HLSCHER
X000323556
Drying system (gas-heated)

Make-up air volume - between-color, max. approx. m3/h 5,280
Make-up air volume - tunnel, max. approx. m3/h 7,200
Total exit air volume - between-color and tunnel m3/h 4,600/8,990
(reference temperature 20 degrees Celsius)
Exhaust air temperature, approx. C 66
Fresh-air volume - between-color, min. m3/h 2,690
Fresh-air volume - tunnel, min. m3/h 1.905
Additional fresh-air volume - between-color, max. m3/h 1,610
Additional fresh-air volume - tunnel, max. m3/h 2.780
Fresh-air temperature, approx. C 20
Heating capacity - between-color, approx. kj/h 180,000
(at max. make-up air volume, max. fresh-air volume and max.
temperature)
Heating capacity - tunnel, approx. kj/h 360,000
(at max. make-up air volume, max. fresh-air volume and max.
temperature)
Nozzle air exit temperature - between-color, max. C 100
(with heating switched off, ambient temperature plus) C 25-30
Nozzle air exit temperature - tunnel, max. C 120
(with heating switched off, ambient temperature plus) C 25-30
Nozzle air exit speed, between-color m/s 55(+/- 10%)
Air exit speed, tunnel m/s 45(+/- 10%)
Emission sound pressure level

Emission sound pressure level, max. dB (A) <80
Noise measurement in compliance with EN 13023 / DIN EN ISO 3746 / DIN EN
ISO 11204 at a distance of 1m from the machine surface at a height of 1.6m.
The emission sound pressure level guarantee is invalidated if additional units
are incorporated in the machine which do not form part of W&H's scope of sup-
ply.

Z WINDMLLER & HLSCHER 2 Safety | Workplaces
2.2 Workplaces
2.2.1 Overview of the workstations............................................................................................2

2 Safety | Workplaces Z WINDMLLER & HLSCHER
X000125942
CAUTION
Missing lighting
Potential hazards at the unwind and rewind workstations and the upper color decks due to poor
lighting.
Lamps should be provided at the superstructure to illuminate the printing section in the upper area
and the unwind and rewind workstations.
(1) Workstation Unwind (2) Workstation Main operator column PRO-

CONTROL
(3) Workstation Rewind

Z WINDMLLER & HLSCHER 2 Safety | Safety devices: Description

2.3.1 Emergency-Stop................................................................................................................2
2.3.2 Eltainer..............................................................................................................................3
Main switch....................................................................................................................3
Emergency trip wire.......................................................................................................4
2.3.3 Winder...............................................................................................................................5
Double light barrier with chain.......................................................................................5
Fixed guards locked in place on the winder...................................................................6
Fixed guards on the winder...........................................................................................6
2.3.4 Printing unit.......................................................................................................................7

Interlocking guards on the winder..................................................................................7
Fixed guards on the printing unit...................................................................................9
Guard chain at the catwalk..........................................................................................10
Emergency-Stop pushbutton at the printing unit..........................................................10
2.3.5 Drying system..................................................................................................................11

Schematic diagram showing the safety devices..........................................................11
Definitions....................................................................................................................13
Explosion pressure relief valves..................................................................................13
Gas warning device.....................................................................................................14
Equipotential bonding cables.......................................................................................14
Temperature sensors...................................................................................................15
Pressure transmitter....................................................................................................16
Safety functions...........................................................................................................17
2.3.6 Central warning device....................................................................................................18

2 Safety | Safety devices: Description Z WINDMLLER & HLSCHER
X000166484
When hitting the EMERGENCY-STOP button the machine stops and all of the machine movements
are slowed in a controlled manner.
DANGER
Risk of injury from the machine when starting
There is a risk for persons to get hurt if the machine is restarted before the potentially dangerous
situation has been cleared.
Eliminate all danger sources and make sure that no persons are present in the machine's protected
area before unlatching the button. Do not restart the machine unless the potentially dangerous sit-
uation has been cleared.
NOTE
There is a risk of damage when misusing the EMERGENCY-STOP button.
The machine will be exposed to great stress when actuating the Emergency-Stop pushbutton. Dam-
age to the machine may occur if the machine is usually switched off by use of the EMERGENCY-
STOP pushbutton although there is no threat of personal danger.
The EMERGENCY-STOP pushbutton must only be actuated if there is a threat of personal danger.
(-) EMERGENCY-STOP
Press the EMERGENCY-STOP pushbutton

whenever a dangerous situation arises.
The machine is brought to a standstill in a con-
trolled manner and depressurized. The push-
button is latched.
Clear the potentially dangerous situation.
Turn the pushbutton in the direction of the ar-
row or pull it out.
The pushbutton is unlatched.
The machine can now be restarted.

X000192430
2.3.2 Eltainer
Main switch
The main switch serves to switch the entire electrical power to the machine on or off. Components
still live after the main switch has been switched off are covered and provided with warning signs.
Power supply to the temperature control unit is switched off.
The main switch comprises an operating element attached outside the Eltainer and a power pack
mounted inside the Eltainer. The operating element is used to switch the electrically driven power
pack on or off.
(1) Operating element
Turn the switch in the operating element (1) to

ON to switch on power. Turn the switch back to
OFF to switch off power.
(1) Power pack
Use the operating element attached outside the

Eltainer to switch the power pack (1) inside the El-
tainer on or off.

X000192430
(1) Warning light
The flashing warning light (1) attached to the op-

erating element indicates the following states:
The emergency trip wire switch in the Eltainer
has tripped.
The uninterruptible power supply is not ready.
Emergency trip wire
Pulling the emergency trip wire
Pulling the emergency trip wire causes the main switch to be switched off immediately.
(1) Emergency trip wire

(2) Warning light
Pull the emergency trip wire (1).

The emergency trip wire is attached inside the
Eltainers in form of a ring.
The emergency trip wire switch is hit and the
warning light (2) flashes red.
Emergency trip wire switch Reset
(1) Reset button
DANGER
Risk of fatal injury from electrical current.
Persons may get hurt when switching the main
switch back on before the dangerous situation
has been eliminated. Do not switch the main
switch back on unless the dangerous situation
has been eliminated.
Press the Reset button(1).

The emergency trip wire switch is reset and the
pilot lamp goes dark.
Turn on the main switch.

X000192432
2.3.3 Winder
Double light barrier with chain
The winder is secured by a double light barrier with safety chain to prevent injuries caused by rotating
parts and circular knives from occurring. During production, the safety chain may only be opened to
permit operation of the roll loading and unloading systems at the winding station.
The plugged in chain is monitored by a limit switch. When the chain is unplugged, the lighted SAFETY
LIGHT GRID BLOCKED pushbutton in the operator panel of the winder flashes. All movement of the
cut-off assembly or the turret is blocked. The blocking of the rotary and traversing movements is
cleared by pushing the safety chain back in and by pressing the pushbutton.
(1) Chain 1
(2) Double light barrier
The chain (1) and the double light barrier (2) are
located on the front side of the winder.
When removing the chain while the turret is rotat-
ing or while the cut-off assembly is traversing, all
rotary and traversing movements are stopped im- 21
mediately. In production mode, the machine is
stopped in a minimum of time.
The double light barrier serves as crawl-under pro- Wic_0339
tection. When the safety chain is plugged in and
the turret and the cut-off assembly are moving, all
movement is stopped if the monitored range of the
double light barrier is entered. In production mode,
the machine is stopped in a minimum of time.

X000192432
Fixed guards locked in place on the winder
Guard doors
(1) Guard doors
Guard doors (1) are provided on the operator side

of the winder. Through the doors, access to the
winders is provided for repair and service work as
well as for threading the web.
The guard doors are monitored by a switch which
is kept shut electrically. If the machine is in the
production or jog mode, the doors are locked.
Locking is released only when the machine is at a
standstill and only then can the doors be opened.
When opening one of the guard doors the com-
pressed air supply to the respective winder is
switched off and the winder is completely bleeded.
The entire production process including jog mode
are disabled.
Fixed guards on the winder
Protective gratings and protective flaps
(1) Protective grating

(2) Protective flaps
These safety devices can only be opened by use

of appropriate tools. These safety devices must be
closed while the machine is running. Access to the
components behind is allowed for maintenance
only. Only authorized personnel may be allowed
access when the machine is at a standstill. The
machine must be secured against being switched
on inadvertently. Protective flaps each are provid-
ed on the drive and operator side on the front and
rear side of the winder.

X000288509
2.3.4 Printing unit

Interlocking guards on the winder
Sliding glass doors
The guard doors/optional roll up doors and sliding glass doors can only be opened when the color
decks on the respective side (color decks 1-4/1-5 or 5-8/6-10) are in their zero position or when the
anilox roll drives are switched off.
The doctor bars can only be moved when the guard doors/optional sliding glass doors on the re-
spective side (color decks 1-4/1-5 or 5-8/6-10) are closed.
Changes in the doctor blade pressure have an effect only when the guard doors/optional sliding glass
doors on the respective side (color decks 1-4/1-5 or 5-8/6-10) are closed
The doctor bar can only be swung on and off automatically during inking or purging when the guard
doors/optional roll up doors and sliding glass doors on the respective side (color decks 1-4/1-5 or
5-8/6-10) are closed.
(1) Sliding glass door
The sliding doors made of safety glass are located

on the front side of the printing unit. The color
decks can be accessed through them.
When in production mode, the doors are electri-
cally locked. The sliding doors cannot be opened.
If the sliding doors are open, the doctor bar cannot
be moved. Changes in the doctor blade pressure
have an effect only when the sliding doors are
closed.
If the sliding doors are open, you can only run the
machine at safe jog mode (less than 5 m/min.).
Safe jog mode can only be switched on by means
of the pendant control switch on the respective
side. The sliding door on the opposite side and all
further doors must be closed.
Closing the sliding door from inside is not possible.
The limit switch cannot be operated from inside.
The mechanical door stop must be operated from
outside to be able to close the door completely.

X000288509
Guard doors
The doctor bar can only be swung oi and out automatically during inking or purging when the guard
(1) Guard doors
The guard doors are located on the operator side

of the printing unit. Through the doors, access is
provided for the sleeve change.
When in production mode, the doors are electri-
cally locked. The sliding doors cannot be opened.
The guard doors provide emergency unblocking
and emergency unlocking mechanisms. An inad-
vertently trapped person can exit from the danger
area.
The emergency unlocking mechanism allows the
door to be opened from inside but not closed. The
machine can be stopped using the Emergency-
Stop buttons.
Roll up doors (optional)
The doctor bar can only be swung on and off automatically during inking or purging when the guard

X000288509
(1) Roll up doors
The roll up doors are located on the operator side

of the printing unit. Through the doors, access is
provided for the sleeve change.
It is impossible to open the roll up doors after the
machine has been started.
An accidentally trapped person can open the roll
up doors using an internal switch. The machine
can be stopped using the Emergency-Stop but-
tons.
If a power outage occurs, the roll up doors can be
opened by means of a crank. Open the roll up
doors only in the designated place and with the
appropriate climbing aids. Do not enter the catwalk
area behind the chain.
Fixed guards on the printing unit
Guard doors on the drive side
(1) Guard doors
The guard doors at the printing unit are located on

the drive side. They can only be opened by means
of tools and must be closed when the machine is
running.
Only service personnel are allowed to open the
guard doors if service work is to be done.
Never open the doors when the machine is run-
ning.

X000288509
Guard chain at the catwalk
Safety chain
(1) Safety chain
The end of the catwalk is blocked off by means of

a safety chain. The area behind the chain must
only be entered for doing repair and maintenance
work on the components behind.
If an insetter control is mounted the unit must only
be adjusted in the designated place and with the
suitable climbing aid. Do not enter the area behind
the chain.
Emergency-Stop pushbutton at the printing unit
Arrangement
(1) Emergency-Stop
Four Emergency-Stop pushbuttons are provided

behind the guard doors/roll up doors on the oper-
ator side.
(1) Emergency-Stop
An Emergency-Stop pushbutton (1) is integrated

in the operator panel adjacent to the sliding glass
door. This arrangement also applies for the oppo-
site color deck side.

X000258290
2.3.5 Drying system

Schematic diagram showing the safety devices
Pos. Designation Description

(1) Gas warning device for The gas warning device permanently measures the solvent
monitoring the dryer cir- concentration in the associated dryer. A warning alarm advis-
cuits es the operator of an increased solvent vapor concentration.
A main alarm causes the machine to be switched off. The
sensor is automatically checked for proper functioning.
(2) Gas warning device for reg- A solvent vapor concentration setpoint for the tunnel drying
ulating the solvent vapor and the between-color drying can be set at the central ' Pro-
concentration in the dryer control ' operator column.
circuits (option) The gas warning device continually measures the solvent
concentration in the associated dryer.
The required fresh-air supply is set up by regulating the addi-
tional fresh-air valves.

X000258290

(3) Gas warning device for The solvent vapor concentration in all relevant places of the
monitoring the printing area printing area on the operator and drive side, the drying tunnel
inlet and outlet section is monitored using the ring measuring
method. The following measures will be initiated if a defined
concentration at the measuring points is measured.
30% of the LEL = machine speed is decelerated. All active
color decks involved in printing move to the ' Print Off ' position.
40% of the LEL = ink supply and the anilox rolls are switched
off
(4) Flow monitor The make-up air flow rates for every dryer are permanently
monitored thus ensuring the recirculating air flow of the tech-
nical ventilation.
(5) Redundant exit air monitor- Used for continuous redundant exit air flow measurements for
ing every dryer. This ensures that sufficient fresh air is available.
(6) Redundant temperature Used for redundant drying temperature monitoring for each
monitoring dryer circuit. This ensures that the set drying temperature
cannot be exceeded.
Maximum temperature in the between-color drying = 100 C
Maximum temperature in the tunnel drying = 120 C
(7) Explosion relief flaps The tunnel drying is provided with explosion relief flaps which
must not be blocked by any objects.

X000258290
Definitions
Term Definition
GWD Gas warning device
LEL Lower explosive limit
Specifications accord- The gas-heated drying system is laid out for a solvent vapor concentra-
ing to AS1375 (Annex tion of max.25% LEL.
F6) This threshold limit value must not be exceeded. Danger of explosion!
Specifications accord- The gas-heated drying system is laid out for a solvent vapor concentra-
ing to NFPA86 tion of max.45% LEL.
This threshold limit value must not be exceeded. Danger of explosion!
DIN EN 1539 The flow-type heaters are suited for using gases and vapors in compli-
ance with explosion hazard subgroup IIB, ex temperature class T3 (flexo-
graphic printing) and explosion hazard subgroup IIB, ex temperature
class T2 (gravure printing).
The maximum permitted concentration level in flammable substances for
dryers limited to a defined solvent vapor concentration is subdivided in
operating zones according to DIN EN 1539.
Specifications accord- The drying system in operating zone 1 is laid out for a solvent concen-
ing to EN 1539 tration of max.40% LEL.
The drying system in operating zone 1 is laid out for a solvent concen-
tration of max.40% LEL.
The LEL depends on the solvents used and the maximum drying tem-
perature. This threshold limit value must not be exceeded. Danger of
explosion!
Operating zone 1 Refers to the operating zone in which the temperatures in any section of
the drying system that is liable to come into contact with flammable sub-
stances, exceed the threshold.
stances, are below the threshold.
Explosion pressure relief valves
(1) Explosion pressure relief valves
The explosion pressure relief valves (1) are pro-

vided at the tunnel drying. The valves must never
be blocked by objects. They are painted in yellow.
1
Tro_0266

X000258290
Gas warning device
For the mounting location of the gas warning device please refer to the electrical component ID or
the electrical circuit diagrams.
(1) Gas warning device C.I. section monitor-

ing
(2) Gas warning device Dryer circuit Be-
1
tween-color drying
(3) Gas warning device Drying circuit Be-
tween-color drying Solvent concentra-
tion control USA (option) 2
The gas warning device permanently measures

the solvent vapor concentration. Safety measures 3
will be initiated whenever necessary.
Tro_0243
Equipotential bonding cables
1 Equipotential bonding cables
Cables are secured to the dryer at different places

(green/yellow). These cables are used for creating
equipotential bonding between the specific com- 1
ponents.
These cables must never be removed or loosened.
A very high voltage level with severe potential dif-
ferences might result in the ignition of solvent-con-
taminated air if the connector is broken or be-
comes loose.
Tro_0245

X000258290
Temperature sensors
(1) Redundant temperature measurement

Between-color drying
(2) Redundant temperature measurement
Tunnel drying
Two temperature sensors (1) per drying circuit in

redundant design permanently measure the make-
up air temperature. If the measured temperatures
are different, safety measures will be initiated.

X000258290
Pressure transmitter
NOTE
For the mounting location please refer to the electrical component ID or the electrical circuit diagrams.

(1) Exit air controller Pressure measurement for maintaining the exit air flow rate.
(2) Redundant exit air monitor- The exit air flow rates for every dryer are continuously moni-
ing tored by flow monitors thus ensuring the recirculating air flow
of the technical ventilation.
(3) Flow monitor Tunnel drying The make-up air flow rates for every drying circuit are contin-
uously monitored by flow monitors thus ensuring the recircu-
lating air flow of the technical ventilation.
(4) Flow monitor Between-col- The make-up air flow rates for every drying circuit are contin-
or drying uously monitored by flow monitors thus ensuring the recircu-
lating air flow of the technical ventilation.
(5) Measuring station A measuring station is provided at the dryer. All measuring
points at this station must be closed by blind plugs to prevent
faulty measurements at the flow monitors/pressure transmit-
ters from occurring.

X000258290
Safety functions
The safety functions are constantly active and running in the background. Should a safety limit be
violated, measures will be taken immediately and the relevant error messages will be activated.
A solvent vapor analyzer continuously measures the solvent concentration in the drying air for every
drying circuit. Evaluation of the measurement and the introduction of any measures take place in the
W&H computer.
Three functions are constantly monitored:
The warning alarm
The main alarm
Checking the sensor for proper functioning
The warning alarm Definition

Warning alarm accord- The warning alarm is triggered when the solvent vapor concentration in
ing to DIN EN 1539 the dryers used in operating zone 1 (unprotected heaters) exceeds 35%
of the LEL.
The warning alarm is triggered when the solvent vapor concentration in
the dryers used in operating zone 2 (protected heaters) exceeds 55% of
the LEL.
The warning alarm indicates when the solvent concentration approaches
the maximum permissible threshold, it has no effect on running produc-
tion.
Warning alarm accord- The warning alarm is triggered when the solvent vapor concentration
ing to AS 1375 (Appen- exceeds 20% of the LEL.
dix F6) The warning alarm indicates when the solvent concentration approaches
tion.
Warning alarm to NFPA The warning alarm is triggered when the solvent vapor concentration
86 exceeds 40% of the LEL.
The warning alarm indicates when the solvent concentration approaches
tion.
The main alarm Definition

Main alarm according to The main alarm is triggered when the solvent vapor concentration in the
DIN EN 1539 driers used in operating zone 1 (unprotected heaters) exceeds 40% of
the LEL.
The main alarm is triggered when the solvent vapor concentration in the
driers used in operating zone 2 (protected heaters) exceeds 60% of the
LEL.
A main alarm causes the machine to be shut down immediately.
Main alarm according to The main alarm is triggered when the solvent vapor concentration ex-
AS 1375 (Appendix F6) ceeds 25% of the LEL.
Main alarm to NFPA 86 The main alarm is triggered when the solvent vapor concentration ex-
ceeds 45% of the LEL.

X000258290
NOTE
The machine speed slows down. All color decks involved return to the ' Print Off ' printing position.
Checking the sensor Definition

for proper functioning
Checking the sensor for The sensor is checked for proper functioning. This is ascertained through
proper functioning the signal 4...20 mA. A value less than 2.5 mA indicates that a fault has
occurred. An error in the check causes the machine to be shut down
immediately.
NOTE
The machine speed slows down. All color decks involved return to the ' Print Off ' printing position.
NOTE
The central warning device should be checked for proper functioning at regular intervals.
(1) Horn
The horn is a warning device. It warns you of ma-

chine movements and actions.

Z WINDMLLER & HLSCHER 3 Machine description
3 Machine description
3.1 Machine overview


3 Machine description | Machine overview Z WINDMLLER & HLSCHER
X000103362
The module overview shows the configuration of a MIRAFLEX flexographic printing press without
inline unit. The module overview may show modules which do not form part of the customer's ma-
chine.
EASY-SET S and EASY-REG D are pure software modules and not listed in the overview. The sen-
sors on the EASY-REG S module are attached to the individual color decks.

Z WINDMLLER & HLSCHER 3 Machine description | Machine overview
X000103362
Item Modules
1 Main operator column PROCONTROL
2 Unwind
3 Printing unit
4 TURBOCLEAN

3 Machine description | Machine overview Z WINDMLLER & HLSCHER
X000103362
Item Modules
5 Cleaning agent container
6 Drying system and superstructure
7 ELTAINER
8 Rewind
9 Web tension sensing system
10 Slitter
11 EASY-SET HD
12 Rear frame

Z WINDMLLER & HLSCHER 4 Control elements and screen pages
4 Control elements and screen pages

4.2.4 Pre-alarm/Jog
4.2.5 Stop
4.2.6 Slow
4.2.7 Fast
4.3 Unwind
4.4.2 Machine On
4.5 Printing unit
4.6 Rear frame
4.8 Rewind
4.9 Procontrol
4.9.1 Procontrol
4.9.3 Alarms
4.9.6 Data backup

4 Control elements and screen pages Z WINDMLLER & HLSCHER

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Arrangement of the
operator panels

4.1.1 Arrangement of the control consoles.................................................................................2
Control consoles Part 1.................................................................................................2
Control consoles Part 2.................................................................................................3

4 Control elements and screen pages | Arrangement of the
operator panels
X000125890

Control consoles Part 1
(1) Control console +R52 (2) Control elements for operating the roll up
door
(3) Control elements provided for a sleeve (4) Control console +R10 with operator ter-
change on color decks 1-4 (1-5) and for minal as an option
operating the roll up door
(5) Main control console +P59 (6) Control console +R93

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Arrangement of the
operator panels
X000125890
Control consoles Part 2
(1) Control elements provided for a sleeve (2) Control console +R51
change on color decks 5-8 (6-10) and for
operating the roll up door
(3) Pneumatic control elements for setting (4) Control console +R90 with operator ter-
up the nip rolls minal as an option

4 Control elements and screen pages | Arrangement of the
operator panels
X000125890

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | General control ele-
ments

4.2.1 General instructions for use of the control elements.........................................................2
General information.......................................................................................................2
Explanation of the status LEDs in the pushbuttons.......................................................2
4.2.2 Main switch on the Eltainer...............................................................................................3

Notes.............................................................................................................................3
Main switch:...................................................................................................................4
4.2.3 EMERGENCY-STOP........................................................................................................5
4.2.4 Pre-alarm/Jog....................................................................................................................5
Status of the LED in the Pre-alarm/Job pushbutton......................................................5
Pushbutton - Pre-alarm/Jog...........................................................................................6
4.2.5 Stop...................................................................................................................................6
LED status in the Stop pushbutton................................................................................6
Pushbutton Stop.........................................................................................................6
4.2.6 Slow...................................................................................................................................7
Status of the LED in the Slow pushbutton.....................................................................7
Pushbutton Slow.........................................................................................................7
4.2.7 Fast...................................................................................................................................7
Status of the LED in the Fast pushbutton......................................................................7
Pushbutton Fast..........................................................................................................8

4 Control elements and screen pages | General control ele-
ments
X000242746

General information
All of the modes require the control voltage to be switched on.

The control voltage can only be switched on at the main operator panel.
The operator panels are listed according to the machine's production flow direction.
A text in CAPITAL LETTERS refers to a pushbutton or a button.
The arrangement of the operator panels may vary according to the machine layout.
Explanation of the status LEDs in the pushbuttons
Certain pushbuttons provide status LEDs. The meaning of the status LEDs is described in the indi-
vidual operating steps.
LED in Status of the LED

the
push-
button
Flashing green:
Blinking green:
Flashing orange:
Blinking orange:
Flashing red:
Blinking red:

ments
X000036834

Notes
The mains switch is used to switch the entire electrical energy to the machine on or off. Parts of the
machine which are still live after the mains switch has been switched off are covered and provided
with warning signs.
The voltage supply to the temperature control unit will not be switched off.
DANGER
Risk of injury or even death caused by electric shock
When switching off the mains switch for service or repair work, it must be secured with a padlock to
prevent unauthorized persons switching it back on. The name of the person who switched off the
machine, the time and the approximate period that it will be switched off must be documented on a
sign that is clearly visible to everyone.
Only authorized persons are allowed to switch the mains switch back on.

ments
X000036834
Main switch:
The main switch comprises an operating element attached outside the Eltainer and a power pack
mounted inside the Eltainer. The operating element is used to switch the electrically driven power
pack on or off.
Operating element
Turn the switch in the operating element (1) to
ON to switch on power. Turn the switch back to
OFF to switch off power.
Power pack
Use the operating element attached outside the
Eltainer to switch the power pack (1) inside the El-
tainer on or off.
Warning light
The flashing warning light (1) attached to the op-
erating element indicates the following states:
The switch-on requirements have not been met.
The emergency trip wire switch in the Eltainer
has tripped.
The uninterruptible power supply is not ready.
The power supply shut-off time has not yet ex-
pired.

ments
X000242750
(1) Switch Emergency-Stop
Press the Emergency-Stop (1) pushbutton.

All machine modes are shut off within the short-
est time possible. As far as stationary compo-
nents are concerned, the control voltage is dis-
connected immediately. The power supply to 1
rotating parts is switched off in a delayed man-
ner in order to bring the related drives to a con-
trolled stop.
Turning the switch to the right:
Dw__1148
The Emergency-Stop pushbutton is unlatched
and the control voltage can be switched back
on.
4.2.4 Pre-alarm/Jog
Status of the LED in the Pre-alarm/Job pushbutton
LED in Status of the LED Description

the
push-
button
Blinking orange: The LED blinks orange when in pre-alarm mode.
Flashing orange: The LED flashes orange when the pre-alarm mode has ended.
Flashing green: Jog mode is started when pressing the PRE-ALARM/JOG push-
button once more. The LED in the PRE-ALARM/JOG pushbutton
and the LED in the MACHINE ON pushbutton flash green while
holding down the PRE-ALARM/JOG Pushbutton.

ments
X000259302
Pushbutton - Pre-alarm/Jog
(1) PRE-ALARM/JOG pushbutton
Press and hold down the PRE-ALARM/JOG

(1) pushbutton for at least one, at the most
three, seconds.
An acoustic startup warning is triggered.
1
Press and hold down the pushbutton again.
While holding down the pushbutton, the ma-
chine is rotates at the factory set jog speed.
When letting go of the button and pressing it
again within ten seconds, JOG mode is exe-
Dw__1150
cuted again without a prior acoustic startup
warning being triggered.
If the mode is interrupted for more than ten
seconds, the entire start up process must be
repeated.
4.2.5 Stop
LED status in the Stop pushbutton
LED in LED status Description

the
push-
button
Blinking orange: Stops the machine.
Pushbutton Stop
(1) STOP pushbutton
Press the STOP (1) pushbutton.

The machine is brought to a standstill and the
main drive is switched off.
1
Dw__1149

ments
X000259306
4.2.6 Slow
Status of the LED in the Slow pushbutton

the
push-
button
Flashing green: The LED in the SLOW pushbutton flashes green while holding down
the pushbutton.
Pushbutton Slow
(1) SLOW pushbutton
Press and hold down the SLOW (1) pushbut-

ton.
The machine slows down to its base speed
while holding down the pushbutton.
1
Dw__1151
4.2.7 Fast
Status of the LED in the Fast pushbutton

the
push-
button
Flashing green: The LED in the FAST pushbutton flashes green while holding down
the pushbutton.

ments
X000259308
Pushbutton Fast
(1) FAST pushbutton
Press and hold down the FAST (1) pushbutton.

The machine accelerates to its maximum
speed while holding down the pushbutton.
1
Dw__1152

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Unwind
4.3 Unwind
4.3.1 Operator panel +R10.........................................................................................................2

4 Control elements and screen pages | Unwind Z WINDMLLER & HLSCHER
X000261658
Depending on the machine design, control elements might be omitted.
1 2
3 4 5
6 7 8
9 10 11 12
13 14 15
16 17 18 19 20
21 22 23 24 25
Z AUTOMATION TECHNOLOGY
Wic_0413

(1) EMERGENCY-STOP Switches off the entire machine.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Unwind
X000261658

(2) COMPRESSED AIR SYS- Switches the compressed air supply to the winder on or off.
TEM ON/OFF
(3) WEB GUIDE CONTROL The sensor head of the web guide control system moves to-
SENSOR SETTING LEFT wards the operator side.
(4) DISPLAY Shows the actual value of the sensor head setting.
SENSOR SETTING wards the drive side.
RIGHT
(6) WINDING STATION 1 ON/ Switches winding station 1 on or off.
OFF
OFF
(8) LIFT TABLE UP The lift tables raises while holding down the button.
(9) ACKNOWLEDGE KEY The danger zone is enabled when actuating the pushbutton
SAFETY CHAIN while the chain is closed.
(10) SWING TURRET FOR- The turret approaches the next 180 degree position.
WARD
(11) SWING TURRET BACK The turret approaches the next 180 degree position in the op-
posite direction.
(12) LIFT TABLE DOWN The lift table lowers while holding down the button.
(13) MAKE READY/INITIATE Used for roll change make-ready for the rewind.
ROLL CHANGE
(14) CANCEL ROLL CHANGE Cancels the roll change for the rewind.
(15) INFLATE/DEFLATE The chuck is deflated or inflated.
CHUCK
(16) CHUCK WINDING STA- The roll clamped in place in winding station 1 is moved to the
TION 1 PARALLEL AD- left in parallel.
JUSTMENT LEFT
TION 1 PARALLEL AD- right in parallel.
JUSTMENT RIGHT
TION 2 PARALLEL AD- left in parallel.
JUSTMENT LEFT
TION 2 PARALLEL AD- right in parallel.
JUSTMENT RIGHT
(20) MOVE CHUCK APART The chucks are moved apart.
(21) PRE-ALARM/JOG Pre-alarm: An acoustic start up warning is triggered.
Jog: The machine is running at factory-set jog speed.
(22) MACHINE STOP Stops the machine.
(23) MACHINE SLOW Reduces the machine speed.
(24) MACHINE FAST Increases the machine speed.

4 Control elements and screen pages | Unwind Z WINDMLLER & HLSCHER
X000261658

(25) THREADING CHAIN Switches the threading chain motor on or off.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Main operator panel

4.4.1 Overview Main operator panel +P59.................................................................................2
4.4.2 Machine On.......................................................................................................................3

Status of the LED in the Machine On pushbutton..........................................................3
Pushbutton Machine On.............................................................................................3
4.4.3 Production speed..............................................................................................................3

Status of the LED in the Production speed pushbutton.................................................3
Pushbutton Production speed.....................................................................................4

4 Control elements and screen pages | Main operator panel Z WINDMLLER & HLSCHER
X000244024
1 2 3 4 5
6 7 8 9 10 11 12
Dw__1128

(1) EMERGENCY-STOP Switches off the entire machine.
(2) DRYING ON/OFF Used to switch on the selected drying mode at ' Procontrol '.
(3) PRINT ON/OFF All of the selected color decks move to the PRINT ON/OFF
position.
(4) ROLL CHANGE MAKE- Used for roll change make-ready for the rewind.
READY
(6) CONTROL VOLTAGE ON/ Switches the control voltage on or off.
OFF
(7) PRE-ALARM/JOG Pre-alarm: An acoustic startup warning is triggered.
Jog: The machine is running at factory-set jog speed.
(8) MACHINE ON The machine is started.
(9) MACHINE STOP The machine is brought to a standstill and the main drive is
switched off.
(10) MACHINE SLOW The machine slows down to base speed.
(11) MACHINE FAST The machine accelerates to its maximum speed.
(12) MACHINE PRODUCTION The machine accelerates to the speed entered into ' Procon-
SPEED trol '.
Pre-condition: The machine is running.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Main operator panel
X000259303
4.4.2 Machine On
Status of the LED in the Machine On pushbutton

the
push-
button
Flashing green: The machine is powered up.
Pushbutton Machine On
(1) MACHINE ON pushbutton
Press the MACHINE ON (1) pushbutton.

The machine starts when all requirements are
fulfilled.
1
Dw__1219

Status of the LED in the Production speed pushbutton

the
push-
button
Blinking green: The LED in the PRODUCTION SPEED pushbutton flashes green
until reaching the speed entered in Procontrol.

4 Control elements and screen pages | Main operator panel Z WINDMLLER & HLSCHER
X000259299
Pushbutton Production speed
(1) PRODUCTION SPEED pushbutton
Press the PRODUCTION SPEED (1) pushbut-

ton.
The machine accelerates to the speed entered
at Procontrol.
1
Dw__1220

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Printing unit
4.5 Printing unit

4.5.1 Operator panel +R51.........................................................................................................2
Overview........................................................................................................................2
Control element Doctor blade pressure.........................................................................3
Control element Doctor blade/anilox roll........................................................................4
Operator pendant connection socket.............................................................................5
4.5.2 Operator panel +R52.........................................................................................................6

Overview........................................................................................................................6
Control element Doctor blade pressure.........................................................................7
Control element Doctor blade/anilox roll........................................................................8
Connection socket Operator pendant............................................................................9
4.5.3 Control elements on the color deck.................................................................................10

Operator panels at color deck Part 1...........................................................................10
Operator panels at color deck Part 2...........................................................................11
4.5.4 Hand-held panel..............................................................................................................12

View of the operator pendant.......................................................................................12
Control elements..........................................................................................................13
Displays in the display field..........................................................................................18
Messages on the screen..............................................................................................23

4 Control elements and screen pages | Printing unit Z WINDMLLER & HLSCHER
X000250316

Overview
Depending on the machine layout, color decks 1-4 or 1-5 are operated by use of operator panel +R51.
1 2
Z WINDMLLER & HLSCHER Z AUTOMATION TECHNOLOGY
Dw__1155
(1) Emergency-Stop (2) Control element Doctor blade pressure

(3) Control element Doctor blade/anilox roll

X000250316
Control element Doctor blade pressure
1 2 3
Dw__1129

(1) REDUCE DOCTOR BLADE Reduces the doctor blade pressure in increments of 0.1
PRESSURE bar.
(2) Display Shows the actual doctor blade pressure.
(3) INCREASE DOCTOR BLADE Increases the doctor blade pressure in increments of 0.1
PRESSURE bar.

X000250316
Control element Doctor blade/anilox roll
1 2
Dw__1130

(1) DOCTOR BLADE ON/OFF Used to swing the doctor blade in or out
(2) ANILOX ROLL ON/OFF Switches the anilox roll on or off.

X000250316
Operator pendant connection socket
Dw__1160

(1) Connection socket The operator pendant for operating the color decks is
plugged into the connection socket.

X000242695

Overview
Depending on the machine layout, color decks 5-8 or 6-10 are operated by use of operator panel
+R52.
1 2
Z AUTOMATION TECHNOLOGY Z WINDMLLER & HLSCHER

Dw__1156
(1) Control element Doctor blade pressure (2) Emergency-Stop

(3) Control element Doctor blade/anilox roll

X000242695
Control element Doctor blade pressure
1 2 3
Dw__1158

(1) REDUCE DOCTOR BLADE Reduces the doctor blade pressure in increments of 0.1
PRESSURE bar.
(2) Display Shows the actual doctor blade pressure.
(3) INCREASE DOCTOR BLADE Increases the doctor blade pressure in increments of 0.1
PRESSURE bar.

X000242695
Control element Doctor blade/anilox roll
1 2
Dw__1157

(1) DOCTOR BLADE ON/OFF Swings the doctor blade in or out
(2) ANILOX ROLL ON/OFF Switches the anilox roll on or off.

X000242695
Connection socket Operator pendant
Dw__1161

(1) Connection socket The operator pendant for operating the color decks is
plugged into the connection socket.

X000293646

Operator panels at color deck Part 1
Every color deck has its own operator panel.

Color decks 1-4 (1-5):
1 2
Dw__1254

(1) PLATE CYLINDER MANDREL The plate cylinder mandrel is inflated with compressed
COMPRESSED AIR ON/OFF air or deflated.
EJECT THE PLATE CYLINDER The plate cylinder sleeve is being pressed out a few
SLEEVE centimeters.
(Hold down the button)
(2) ANILOX ROLL MANDREL COM- The anilox roll mandrel is inflated with compressed air
PRESSED AIR ON/OFF or deflated.
EJECT THE ANILOX ROLL The anilox roll sleeve is being pressed out a few centi-
SLEEVE meters.
(3) PLATE CYLINDER ADAPTOR The plate cylinder adapter is inflated with compressed

X000293646
Operator panels at color deck Part 2
Every color deck has its own operator panel.

Color decks 5-8 (6-10):
1 2
Dw__1253

(1) ANILOX ROLL MANDREL COM- The anilox roll mandrel is inflated with compressed air
PRESSED AIR ON/OFF or deflated.
EJECT THE ANILOX ROLL The anilox roll sleeve is being pressed out a few centi-
SLEEVE meters.
(2) PLATE CYLINDER MANDREL The plate cylinder mandrel is inflated with compressed
EJECT THE PLATE CYLINDER The plate cylinder sleeve is being pressed out a few
SLEEVE centimeters.
(3) PLATE CYLINDER ADAPTOR The plate cylinder adapter is inflated with compressed

X000103089

View of the operator pendant
Dw__0400
(1) Display field (2) Control elements

X000103089
Control elements
Selecting the control direction
As the operator pendants can be used on the web infeed and on the web outfeed side, the correct
side must be selected by pressing the PU1 or PU2 pushbutton. It is ensured that the operating modes
are carried out according to their correct use.
(1) PU1 WINDMLLER & HLSCHER
(2) PU2
PU1 TC
Press the PU1 pushbutton (1) if the operator
pendant is connected on the web infeed side.
Hold the pushbutton for at least three seconds. PU2 2 MENU
PU1 = Color deck side 1-4 (1-5)
Press the PU2 pushbutton (1) if the operator
pendant is connected on the web outfeed side. F1 F2 F3 F4
Hold down the pushbutton for at least three

seconds. ESC
Dw__0803
PU2 = Color deck side 5-8 (6-10)
Display-dependent pushbuttons
(1) F1 / F2 / F3 / F4 WINDMLLER & HLSCHER
Press the F1 / F2 / F3 / F4 keys.

The functions of the F1 / F2 / F3 / F4 keys de- PU1 TC
pend on the action to be carried out.
PU2 MENU
F1 F2 F3 F4
ESC
Dw__0402

X000103089
Canceling or confirming entries
(1) ESC
(2) ENTER PU1 TC
Press the ESC (1) button to cancel entries or PU2 MENU

to quit the page in the display field.
Press the ENTER (2) button to confirm entries 2
and to transfer them to the machine program. F1 F2 F3 F4
ESC
Dw__0801
Changing the display
(1) BACK
(2) FORWARD PU1 TC
(3) MENU
PU2 MENU
Press the BACK (1) button to get to the previos
display in the display field. 2
Press the FORWARD (2) button to get to the F1 F2 F3 F4
3
next display in the display field.
Press the BACK (1) and the MENU (3) button ESC
simultaneously in order to get a brighter display
field. Dw__0802
Press the FORWARD (2) and the MENU (3)

button simultaneously in order to get a darker
display field.
Color deck selection 1 - 10
(1) COLOR DECK SELECTION
Select the required color deck by pressing the

respective button in the COLOR DECK SE- 1 2 3 4 5
LECTION (1) block.
All of the settings carried out on the operator 6 7 8 9 10
pendant apply exclusively for the selected color
deck.
A B
Dw__0404

X000103089
Main drive control
(1) STOP
(2) SLOW
(3) FAST 1 2 3 4 5
Press the STOP (1) pushbutton. 27 3

6 8 9 10
The machine is brought to a standstill and the
main drive switched off.
Press and hold the FAST (2) pushbutton. A B
As long as the pushbutton is kept pressed the
machine accelerates until its maximum speed
is reached. Dw__0405
Press and hold the SLOW (3) pushbutton.

As long as the pushbutton is kept pressed the
machine decelerates until its base speed is
reached.
Register adjustment
(1) SIDELAY REGISTER ADJUSTMENT 3

(2) SIDELAY REGISTER ADJUSTMENT
(3) LONGITUDINAL REGISTER ADJUST-
MENT FORWARD 2
MENT BACK
4
Press the SIDELAY REGISTER (1) or (2)
pushbutton.
A sidelay register drive is used to move the se-
lected color deck towards the drive or operator Dw__0406
side. The adjustment direction depends on
which pre-selection has been made using the
PU1 or PU2 key.
Press the LONGITUDINAL REGISTER FOR-
WARD (3) pushbutton.
The printed image is moved in the direction of
web travel.
Press the LONGITUDINAL REGISTER BACK
(4) pushbutton.
The printed image is moved against the direc-
tion of web travel.

X000103089
Plate cylinder positioning
(1) PLATE CYLINDER FORWARD

(2) PLATE CYLINDER BACK
Press the PLATE CYLINDER FORWARD (1)

pushbutton. 2
The plate cylinder of the selected color deck is
moved towards the impression cylinder. Ad-
justment is made separately for the drive and
operator side. The allocation of the drive and
operator side depends on which pre-selection
has been made using the PU1 or PU2 key.
One keystroke causes the plate cylinder to Dw__0407
move by a given value.
Press the PLATE CYLINDER BACK (2) push-
button.
The plate cylinder of the selected color deck is
moved towards the anilox roll. Adjustment is
made separately for the drive and operator
side. The allocation of the drive and operator
side depends on which pre-selection has been
made using the PU1 or PU2 key.
One keystroke causes the plate cylinder to
move by a given value.

X000103089
Anilox roll adjustment
(1) ANILOX ROLL FORWARD

(2) ANILOX ROLL BACK
Press the ANILOX ROLL FORWARD (1) push-

button.
The anilox roll of the selected color deck is
moved towards the plate cylinder. Adjustment
is made separately for the drive and operator
side. The allocation of the drive and operator
side depends on which pre-selection has been
made using the PU1 or PU2 key. 2
One keystroke causes the anilox roll to move Dw__0408
by a given value.
Press the ANILOX ROLL BACK (2) pushbut-
ton.
The anilox roll of the selected color deck is
moved away from the plate cylinder. Adjust-
ment is made separately for the drive and op-
erator side. The allocation of the drive and op-
erator side depends on which pre-selection has
been made using the PU1 or PU2 key.
One keystroke causes the anilox roll to move
by a given value.
Print On / Off for the selected color deck
(1) PRINT OFF

(2) PRINT ON
Press the PRINT OFF (1) pushbutton.

The color deck selected in the operator pend-
ant moves in the Print Off position.
Press the PRINT ON (2) pushbutton.
The color deck selected in the operator pend-
ant moves in the Print On position. 2
Dw__0409

X000103089
Print On/Off all color decks
(1) PRINT OFF

(2) PRINT ON
Press the PRINT OFF (1) pushbutton.

All of the color decks selected in Procontrol
move to the Print Off position.
Press the PRINT ON (2) pushbutton.
All of the color decks selected in Procontrol
move to the Print On position. 2
Dw__0410
Displays in the display field
Selecting the display
(1) BACK WINDMLLER & HLSCHER
(2) FORWARD DRS OPS

PU1 TC
Press one of the BACK (1) or FORWARD (2) CD 1 PRINT OFF P M
pushbuttons until the selected display appears 00 PC 00
in the display field. PU2 00 AR 00 MENU
<-- P M -->
2
F1 F2 F3 F4
ESC
Dw__0804
Changing the doctor blade contact pressure
(1) INCREASE DOCTOR BLADE CON- WINDMLLER & HLSCHER

TACT PRESSURE
FW 7 Rakel
(2) REDUCE DOCTOR BLADE CONTACT
PU1 Anpressdruck TC
PRESSURE
1.2
Hold down the INCREASE DOCTOR BLADE PU2 MENU
CONTACT PRESSURE (1) or REDUCE DOC- +
TOR BLADE CONTACT PRESSURE pushbut-
ton until the desired contact pressure for the
F1 F2 F3 F4
doctror blade is reached.
1
ESC 2

X000103089
Moving the sensor heads of the web guide control
(1) F1 / F4 WINDMLLER & HLSCHER
(2) DS / OS display 2 DRS OPS

PU1 TC
Press the F1 (1) or F4 (1) key. CD 1 PRINT OFF P M
When pressing the keys, the sensor heads are 00 PC 00

00 AR 00
moved in the direction which is indicated in the PU2 MENU
display (2) above the key. The allocation of the <-- P M -->
drive side (DS) and the operator side (OS) de-
pends on which pre-selection has been made F1 F2 F3 F4
using the PU1 or PU2 key.
ESC
Dw__0411
Correction of the plate cylinder and the anilox roll
(1) SELECTED COLOR DECK display

(2) CORRECTION VALUES display DRS OPS
(3) PLATE CYLINDER FORWARD / BACK PU1 CD 1 PRINT ON P M TC
(4) ANILOX ROLL FORWARD / BACK 00 PC 00
2 00 AR 00
PU2 MENU
Select the desired color deck. <-- P M -->
The number of the color deck (1) is indicated in
the display field. F1 F2 F3 F4
Use the pushbuttons (3) to make corrections of
the plate cylinder separately for the drive and ESC
operator side.
The correction values (2) are indicated in the
display field separately for the drive and oper-
ator side.
3
Use the pushbuttons (4) to make corrections of
the anilox roll separately for the drive and op-
erator side.
The correction values (2) are indicated in the
display field separately for the drive and oper-
ator side. 4
Dw__0805

X000103089
Parallel correction of the plate cylinder or the anilox roll
(1) F2 KEY
(2) F3 KEY
(3) PARALLEL / MACRO display
(4) CORRECTION VALUES display
(5) PLATE CYLINDER FORWARD / BACK
(6) ANILOX ROLL FORWARD / BACK
Press the F2 (1) key.

A P (3) for parallel correction is displayed in the
display field. Corrections of the traverse paths
will now be carried ot simultaneously on the
drive and operator side. The traverse paths
(4) are being displayed in the display field for
the plate cylinder (PC) and the anilox roll (AR).
Press the F2 key again to switch off the parallel
correction mode.
A M (3) for a macro step is displayed in the dis-
play field. The traverse paths of the plate cyl-
inder or the anilox roll are greater than under
normal operating conditions when striking the
respective key once.
Press the F3 key again to switch off the macro
step mode.

X000103089
Correcting the sidelay and longitudinal register
(1) CONTROL DIRECTION display

(2) CORRECTION VALUES display
(3) DS / OS display
MENT
(5) SIDELAY REGISTER ADJUSTMENT
Select the desired color deck.

The number of the color deck is indicated in the
display field.
Use the pushbuttons (5) to make the correc-
tions of the sidelay register.
The arrows (1) determine the control direction.
The allocation of the drive side (DS) and the
operator side (OS) (3) depends on which pre-
selection has been made using the 3PU1 or
PU2 key.
The correction values (2) are being displayed
in the display field.
Use the pushbuttons (4) to make the correc-
tions of the longitudinal register.
The printed image is moved in the web travel
direction or against the web travel direction de-
pending on how the button has been pressed.
The correction values (2) are being displayed
in the display field.

X000103089
Performing deck travels
(1) F1 WINDMLLER & HLSCHER
(2) F4 5
CD 1 PRINT OFF P M
(3) F2 PU1 TC
--> DECK OUT
(4) F4 PC SLEEVE
AR SLEEVE
(5) SELECTED COLOR DECK display 6
PU2 MENU
+ Start Stop -
(6) DECK TRAVEL display
Select the desired color deck. F1 F2 F3 F4 2

The number of the color deck (5) is indicated in
the display field. ESC 3 4
Dw__0413
Press the F1 key.
An arrow (6) is shown in the display field.
One keystroke each causes the arrow to move
down by one position. Hold the button until the
desired deck travel is highlighted by the arrow.
Press the F4 key.
One keystroke each causes the arrow to move
up by one position. Hold the button until the
desired deck travel is highlighted by the arrow.
Press the F2 key.
The deck travel highlighted in the display is
started.
Press the F3 key.
The deck travel highlighted in the display is
canceled.After a deck travel has been can-
celed, a deck out operation must be started first
before further deck travels can be selected.

X000103089
Messages on the screen
Color deck states

OFF Color deck switched off
RUN Color deck in operation.
PRINT OFF Color deck printing OFF.
PRINT ON Color deck printing ON.
ZEROPOS Color deck in zero position.
BETWEENPOS Color deck in intermediate position.
CALPOS PC Plate cylinder in calibration mode.
CALPOS AR Anilox roll in calibration mode.
HELPFUNCT. E-Stop function
UNDEFINED Color deck in an undefined position.
Color deck modes

SLEEVEP AR Sleeve change mode of anilox roll
SLEEVEP PC Sleeve change mode of plate cylinder
DECK IN Deck in mode of all active color deck
DECK OUT Deck out mode of all active color decks

X000103089

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Rear frame
4.6 Rear frame

4.6.1 Operator panel +R40.........................................................................................................2

4 Control elements and screen pages | Rear frame Z WINDMLLER & HLSCHER
X000288929
2 3
4 5
Hg_0211
Pos. Denomination Description

(1) E-STOP Switches off the entire machine.
(2) MACHINE STOP The machine is brought to a standstill and the main drive is
switched off.
(3) PRE-ALARM/JOG Pre-alarm: An acoustic power On alert is triggered.
Jog: The machine runs at factory-set jog speed.
(4) THREADING CHAIN WITH Selection of JOG mode.
JOG MODE The power On alert is triggered when pressing the THREAD-
ING CHAIN ON pushbutton (5) once more. The drive of the
threading chain is powered up and simultaneously, the ma-
chine runs at threading speed.
(5) THREADING CHAIN ON The threading chain moves.
The threading chain moves and the machine runs at threading
speed, if the THREADING CHAIN WITH JOB MODE push-
button (4) has been pressed before.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Slitting assembly

4.7.1 Operator panel +R93.........................................................................................................2

4 Control elements and screen pages | Slitting assembly Z WINDMLLER & HLSCHER
X000301261
16 16
1 2 3 4
15 A
5 6
B
7 8
9 10 11 12 13
14 14
Ls_0304

(1) EDGE TRIM REMOVAL The edge trim removal fan is switched on or off.
ON/OFF The edge trim removal assembly is optional.
(2) SPREADER ROLLERS The spreader rollers are switched on or off.
ON/OFF The spreader rollers start to turn upon machine start.
(3) KNIVES DOWN The knives move to their working position.
(4) KNIFE OSCILLATION ON/ The drive of the oscillation unit is switched on or off.
OFF

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Slitting assembly
X000301261

(5) WEB GUIDE CONTROL The sensor head of the web guide control prior to the rewind
SENSOR SETTING LEFT moves to the left.
Display (A) shows the actual value of the sensor head setting.
(6) WEB GUIDE CONTROL The sensor head of the web guide control prior to the rewind
SENSOR SETTING moves to the right.
RIGHT Display (A) shows the actual value of the sensor head setting.
(7) WEB GUIDE CONTROL The sensor head of the web guide control downstream of the
SENSOR SETTING LEFT unwind moves to the left.
Display (B) shows the actual value of the sensor head setting.
(8) WEB GUIDE CONTROL The sensor head of the web guide control downstream of the
SENSOR SETTING unwind moves to the right.
RIGHT Display (B) shows the actual value of the sensor head setting.
(14) CUT OFF EDGE TRIM Press both pushbuttons simultaneously to cut-off the edge
trim.
The pushbuttons are located on either side of the operator
panel.
(15) EDGE TRIM REMOVAL Option
SUCTION POWER Set the switch to the desired suction power.
The switch is located on the left-hand side of the operator
panel.
(16) CUT OFF EDGE TRIM Option
Press both pushbuttons simultaneously to cut-off the edge
trim in the central slitting area.
The pushbuttons are located on either side of the operator
panel.
(A) DISPLAY The display shows the actual sensor head setting.
(B) DISPLAY The display shows the actual sensor head setting.

4 Control elements and screen pages | Slitting assembly Z WINDMLLER & HLSCHER
X000301261

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Rewind
4.8 Rewind
4.8.1 Operator panel +R90.........................................................................................................2

4 Control elements and screen pages | Rewind Z WINDMLLER & HLSCHER
X000261667
1 2
3 4 5
6 7 8
9 10 11 12 13
14 15 16 17 18
19 20 21 22 23
Wic_0414

(1) EMERGENCY-STOP Used to switch off the entire machine.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Rewind
X000261667

(2) COMPRESSED AIR SYS- Switches compressed air supply to the winder on or off.
TEM ON/OFF
SENSOR SETTING LEFT wards the operator side.
(4) DISPLAY Shows the actual value of the sensor head setting.
SENSOR SETTING wards the drive side.
RIGHT
OFF
OFF
(8) LIFT TABLE UP The lift table is raised while holding down the button.
(9) CONFIRMATION KEY The danger zone is enabled when actuating the pushbutton
SAFETY CHAIN while the chain is closed.
(10) SWING TURRET FOR- The turret approaches the next 180 degree position.
WARD
(11) SWING TURRET BACK The turret approaches the next 180 degree position in the op-
posite direction.
(12) LAY-ON ROLLER WIND- Swings the lay-on roller of winding station 1 in and out.
ING STATION 1 ON / OFF
(13) LIFT TABLE DOWN The lift table is lowered while holding down the button.
(14) MAKE READY/INITIATE Used for roll change make-ready for the rewind.
ROLL CHANGE
(16) NIP ROLL FORWARD/ Moves the nip roll forward/back.
BACK
(17) LAY-ON ROLLER WIND- Swings the lay-on roller of winding station 2 in and out.
ING STATION 2 ON / OFF
(18) ADVANCE / RETRACT The lift table is advanced or retracted to the relevant end po-
LIFT TABLE sition.

4 Control elements and screen pages | Rewind Z WINDMLLER & HLSCHER
X000261667

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Procontrol
4.9 Procontrol
4.9.1 Procontrol..........................................................................................................................3
Operator panel...............................................................................................................3
Layout of a screen page................................................................................................4
Layout of the top line.....................................................................................................5
Color codes of the flexographic color decks..................................................................7
Color codes of the gravure color decks.........................................................................9
4.9.2 Procontrol Operation.......................................................................................................10

Calling up screen pages directly..................................................................................10
Calling up the start screen...........................................................................................11
Machine module screen pages....................................................................................12
Calling up screen pages from the page overview........................................................13
Help function in Procontrol...........................................................................................14
Entering values............................................................................................................15
Selecting operating modes..........................................................................................16
Entering a text..............................................................................................................17
4.9.3 Alarms.............................................................................................................................18
Alarm overview............................................................................................................18
Alarms with acknowledgement....................................................................................19
Alarms with acknowledgement and password entry....................................................20
4.9.4 Procontrol screen pages.................................................................................................21

Main.............................................................................................................................21
Unwind.........................................................................................................................23
Winder.........................................................................................................................25
Rewind.........................................................................................................................27
Significance of the abbreviations.................................................................................29
Printing unit operations................................................................................................30
Printing unit Register...................................................................................................32
Color deck Adjustments...............................................................................................34
Drying system..............................................................................................................36
Peventive Maintenance...............................................................................................37
Trending.......................................................................................................................38
Job processing.............................................................................................................40
Downtimes...................................................................................................................42
4.9.5 Job processing................................................................................................................44

Job processing Standard.............................................................................................44
Job processing with Recipe management and Next level...........................................46
Job processing with recipe management, Next level and PreMakeReady..................50
Printouts.......................................................................................................................54
4.9.6 Data backup....................................................................................................................55
4.9.7 Cleaning the touchscreen................................................................................................56

Cleaning the screen.....................................................................................................56
Lock screen.................................................................................................................57

4 Control elements and screen pages | Procontrol Z WINDMLLER & HLSCHER
4.9.8 Operating the service pages...........................................................................................58

Specifications...............................................................................................................58
Service pages and gaining access..............................................................................59
Calling the service pages.............................................................................................59
Choice boxes in the bottom line of the service pages.................................................60
User data.....................................................................................................................63
4.9.9 Internet Remote Service..................................................................................................64

Safety instructions.......................................................................................................64
Employer's safety and supervisory obligations............................................................65
Checking the port settings...........................................................................................66
Setting up access rights...............................................................................................67
Software update...........................................................................................................69
Chat mode...................................................................................................................70
Information about the service notebook.......................................................................70

X000298585
4.9.1 Procontrol
Operator panel
The illustration of the operator panel is to be regarded as an example only. The display screens and
control panels may also be integrated in other operator panels.
The representation of graphical elements may not necessarily come up to reality on your machine.
(1) Touch screen (2) Optional screen for web inspection

(3) Main operator panel (4) Operator panel with integrated machine
operator keyboard
(5) Compartment for printer and paper

X000298585
Layout of a screen page
All necessary parameters for operating the production process are entered and monitored via the
visual display unit. Entries are made by directly touching the touch-sensitive screen surface with your
finger.
(1) Screen page number, customer name, (2) Top line with key panels
date and time
(3) Touch-sensitive machine module selec- (4) Touch-sensitive fields for process oper-
tion fields ation
(5) Display field showing the latest alarm
message

X000298585
Layout of the top line
(1) Top line
Keys in the top line

Go to the previously displayed screen page.
Call up the start screen page.
Go to the relevant operating displays for the next job.
Call up the screen page overview.
Hard copy of the current screen page if a printer is connected.
Direct selection of screen pages.

X000298585
Keys in the top line

Calling up the online help.
Go to the TRENDING, DOWNTIMES, PREVENTIVE MAINTENANCE a PRINTING

UNIT screen pages.
The display shows the current machine speed.
The display shows the set and actual values for the current job.
Message symbol indicating faults and the number of current faults.

X000298585
Color codes of the flexographic color decks
Different colors in the visual display unit indicate the different functional statuses of the plate cylinders
and anilox rolls.
(1) Flexographic color decks
Flexographic printing units

Red
Position / undefined status
Magenta
Color deck is running (anilox roll / plate cylinder)
Intermediate position (anilox roll)
Yellow
Calibrate (anilox roll / plate cylinder)
Green
Zero position (anilox roll)
Print ON (anilox roll / plate cylinder)
Print OFF (plate cylinder)
Dark blue
Sleeve change position (anilox roll / plate cylinder)

X000298585
Flexographic printing units

Light blue
Emergency mode
Gray
Burn encoder (anilox roll / plate cylinder)
Calibrating position Burn (anilox roll / plate cylinder)
White
Color deck Off

X000298585
Color codes of the gravure color decks
Different colors in the visual display unit indicate the different functional statuses of the gravure cyl-
inder and the impression roller.
(1) Gravure color deck
Gravure printing unit

Red
Position / undefined status
Green
Print ON (impression roller)
Gravure cylinder drive switched on (energized)
Light green
Pre-register mark on the web detected (RegisterSyncPosition)
Gray
Impression roller and gravure cylinder
White
No gravure cylinder picked up

X000298662

Calling up screen pages directly
(1) COMPANY LOGO button (2) Numeric keypad
1. Press the COMPANY LOGO (1) button in the top line. A virtual numeric keypad (2) pops up.
2. Enter the desired screen page number and confirm with OK.
Numeric keypad buttons

OKAY The entry of values is confirmed and the numeric keypad is closed.
CLEAR The entry field with the entered values is cleared and the numeric keypad
remains open.
CANCEL The procedure is canceled and the numeric keypad is closed.

X000298662
Calling up the start screen
The start screen can be called up from any situation.
(1) START SCREEN button
1. Press the START SCREEN button (1) in the top line. The Display shows the start screen.

X000298662
Machine module screen pages
(1) Printing unit module (2) Drying module

(3) Winder module (4) TURBOCLEAN module
1. Strike the touch-sensitive surface of the desired machine module. The surface of the machine
module is highlighted in yellow.The display shows all relevant process control panels for the
desired module.

X000298662
Calling up screen pages from the page overview.
Some of the screen pages can be accessed only by entering the customer password or by W&H
service technicians.
(1) PAGE OVERVIEW button (2) Page overview
1. Press the PAGE OVERVIEW (1) button in the top line. The display shows the page overview
(2).
2. Touch the desired button in the page overview (2).

X000298662
Help function in Procontrol
For calling up the help menu, an input field must be selected first. The input field turns yellow when
selected.
(1) HELP button (2) Help menu
1. Press the HELP button (1) in the top line. The help menu is displayed.
2. Press the OK button to close the help menu (2).

X000298662
Entering values
(1) Input field (2) Virtual numeric keypad
1. Press the touch-sensitive surface of the input field (1). A virtual numeric keypad (2) pops up.
2. The desired value can be entered via the numeric keypad 2. Confirm the entry with OK.
Numeric keypad buttons

OKAY The entry of values is confirmed and the numeric keypad is closed.
APPLY The entered values are applied and the numeric keypad remains open.
CLEAR The entry field with the entered values is cleared and the numeric keypad
remains open.
CANCEL The procedure is canceled and the numeric keypad is closed.

X000298662
Selecting operating modes
(1) Selection field (2) Selections
1. Actuate the touch-sensitive area of the desired input field (1).The display shows buttons with
selection fields (2).
2. Press the desired button. Your selection is applied and displayed in the selection field (1).

X000298662
Entering a text
(1) Input field (2) Virtual keyboard
1. Actuate the touch-sensitive area of the desired input field (1).The display shows a virtual key-
board with an input field (2).
2. Enter the desired text and confirm with OK.
Virtual keyboard keys

OKAY The entry of values is confirmed and the virtual keyboard is closed.
APPLY The entered values are applied and the virtual keyboard remains open.
CLEAR The entry field with the entered values is cleared and the virtual keyboard
remains open.
CANCEL The procedure is canceled and the virtual keyboard is closed.

X000300680
4.9.3 Alarms
Alarm overview
If an alarm has occurred, the ALARME button (2) blinks red and shows the number of alarms.

(1) Display field Shows the current alarm message
Alarm
(2) Button Opens the alarm overview
Alarm overview
(3) Button Opens an overview on alarms cleared
Alarm history
Alarm overview

X000300680
Alarms with acknowledgement

(1) Display field The display shows the acknowledged alarm.
Alarm
Alarm overview
Alarm overview
(4) Button Opens an overview on alarms cleared
Alarm history
(5) Button Acknowledges the selected fields
Acknowledge When acknowledging an alarm, the relevant alarm checkbox
receives a checkmark.

X000300680
Alarms with acknowledgement and password entry

(1) Display field The display shows the acknowledged alarm.
Alarm
(2) Input field Enter the service password.
Service password
(3) Button The alarm is acknowledged when the service password was
Acknowledge entered correctly.
(4) Button Closes the window
Cancel
(5) Button Opens the window for entering the service password
Safety acknowledgement

X000299192

Main
Main Screen page 22

(1) Selection field Select the draw control mode upstream of the rewind.
Control mode
(2) Input field Enter the web tension setpoint
Tens. Set
(3) Display field The display shows the actual web tension values
Tens. Act
(4) Input field Set up the web tension ratio for the draw upstream of the re-
Ratio set wind.
(5) Display field The display shows the draw upstream of the rewind
Actual ratio
(6) Button The nip roll is swung onto the web
NIP ROLL
(7) Input field Enter the nip roll contact pressure applied to the web
Pressure

X000299192

(8) Choice box Used to select the web guide control.
Web guide
(9) Choice box Used to select the web mode.
Web mode
(10) Input field Enter the production speed
Speed
(11) Button Switches the illumination on or off
LIGHTING
(12) Button Switches the web break detector on or off
Web break detector

X000299192
Unwind
Unwind Screen page 20

(1) Selection field Used to select the unwind mode.
Overwind/Underwind
(2) Input field Web tension setting for the unwind.
Tens. Set
(3) Input field Enter the start roll diameter
Roll diameter The initial roll diameter will be accepted if the respective motor
is switched on within the next 10 seconds after the entry.
(4) Display field The display shows the actual roll diameter
Actual roll diameter
(5) Input field Enter the value for switching on the horn when reaching a de-
Horn End of roll fined roll diameter.
(6) Selection field Select the roll tail length
Roll tail selection
(7) Selection field Select the splicing mode for the unwind unit
Splicing mode

X000299192

(8) Display field Actual value for the current splicing mode
Splicing mode
(9) Input field Enter the splicing diameter for automatic reel splice
Diameter
(10) Input field Enter the splicing speed for the unwind unit
Speed
(11) Display field The display shows the remaining roll length and the remaining
Remaining length / time time until the next roll change

X000299192
Winder
Winder Screen page 5

(1) Button Activates or deactivates ionization
IONIZATION
(2) Input field Enter the material thickness
Thickness
(3) Input field Enter the material width
Width
(4) Input field Enter the material density
Density
(5) Input field Enter the tensile modulus
Tensile modulus
(6) Selection field Select the material to be processed
Material list The DENSITY and TENSILE MODULUS values are set to the
given standard values.
(7) Input field Enter the web tension setpoint for the initial tension
Initial tension

X000299192

(8) Input field Enter the initial diameter
Initial diameter
(9) Input field Enter the final diameter
Final diameter
(10) Input field Enter the web tension setpoint for the increasing web tension
Increase
(11) Display field The display shows the actual value for the increasing web
Increase tension
(12) Display field The display shows the current web tension setpoint
Tension
(13) Display field The display shows the actual web tension
Tension
(14) Button Activates or deactivates edge guide control mode for the un-
AUTOMATIC wind unit
(15) Selection field Used to select the edge guide control mode for the unwind
Unwind unit.
(16) Button Activates or deactivates edge guide control mode for the re-
AUTOMATIC wind unit
(17) Selection field Used to select the edge guide control mode for the unwind
Rewind unit.
(18) Button After selecting the material to be processed from the MATE-
TENS. TEMP. RIAL LIST, the web tension values and the drying temperature
can be set to given standard values via the TENS. TEMP.
button.
(19) Input field Enter the web tension setpoint for the draw upstream of the
Tension rewind.
(20) Input field The display shows the actual web tension value for the draw
Tension upstream of the rewind.
(21) Selection field Used to select the draw control mode upstream of the rewind.
Control mode
(22) Input field Used to set up the web tension ratio for the draw upstream of
Ratio the rewind.
(23) Display field The display shows the actual web tension ratio for the draw
Ratio upstream of the rewind.

X000299192
Rewind
Rewind Screen page 21

(1) Selection field Select the rewind mode.
Overwind/underwind
(2) Input field Enter the initial web tension
Initial tension
(3) Input field Enter the initial diameter
Initial diameter The initial diameter can assume the core diameter as the min-
imum value and the final diameter as the maximum value.
(4) Input field Enter the final diameter
Final diameter The web tension between the initial diameter and the final di-
ameter is linearly tapered by the given percentage value. The
final diameter can assume the initial diameter as the minimum
value.
(5) Input field Enter the taper tension ratio.
Taper tension The web tension is tapered by this percentage rate in relation
to the initial web tension.
(6) Display field The display shows the actual taper tension ratio.
Taper tension

X000299192

(7) Display field The display shows the set web tension at the rewind.
Tension A taper tension rate is included.
(8) Display field The display shows the actual web tension at the rewind.
Tension A taper tension rate is included.
(9) Input field Enter the winding core diameter.
Core diameter
(10) Selection field Select the winding mode.
Winding mode
(11) Input field Enter the contact force of the nip roll.
Contact force
(12) Input field Enter the initial roll diameter of the accruing roll.
Roll diameter The initial roll diameter will be accepted if the respective motor
is switched on within the next 10 seconds after the entry. A
mismatch of the set diameter and the current roll diameter will
result in negative transient response ratios.
(13) Display field The display shows the actual roll diameter.
Roll diameter
(14) Selection field Select the knife slitter mode.
Knife slitter mode
(15) Selection field Used to select the lay-on roller mode after the roll change.
Lay-on roller mode
(16) Display field The display shows the remaining time until the next roll change
Remaining time at the rewind.
The remaining time is determined by the entered splicing di-
ameter.
(17) Input field The display shows the actual roll length.
Roll length
(18) Selection field Select the splicing mode for the rewind.
Splicing mode
(19) Input field set up the roll length.
Roll length
(20) Input field Set up the roll length in ups.
Roll length
(21) Input field Enter the splicing diameter of the accruing roll.
Splicing diameter
(22) Display field The display shows the actual splicing diameter.
Splicing diameter
(23) Display field The display shows the actual roll length in ups.
Roll length

X000299192
Significance of the abbreviations
Abbreviations Significance
AR-DS Anilox roll Drive side
AR-OS Anilox roll Operator side
PC-DS Plate cylinder Drive side
PC-OS Plate cylinder Operator side
SR Sidelay register
LR Longitudinal register
RW Anilox roll
FZ Plate cylinder
FW Color deck
HDW Main printing unit
ZDW Inline printing unit
GDZ Impression cylinder

X000299192
Printing unit operations
Printing unit operations Screen page 6

(1) Choice box Switches the color deck on or off
FW
(2) Input field Enter the print repeat length for the plate cylinder.
Size
(3) Button All active plate cylinders and anilox rolls move to their zero
DECK-OUT OPERATION position
The zero position is the limit position which is the farthest from
the impression cylinder.
(4) Button The active plate cylinders and anilox rolls approach the near-
DECK-IN OPERATION est possible position to the impression cylinder without touch-
ing the web.
(5) Button Releases the color deck brake.
BRAKE RELEASE
(6) Input field The print repeat length for a color deck changes when adjust-
Repeat length adjustm. ing the print repeat length.
(7) Selection field This color deck number is used to define the count size for
Count size print inspection and multiple-up calculation.

X000299192

(8) Button Starts the movement.
START MOVEM.
(9) Button Stops the movement.
STOP MOVEM.

X000299192
Printing unit Register
Printing unit Register Screen page 30

(1) Display field The display shows the color deck.
FW
(2) Selection field Select the color to be used in this printing unit.
Color
(3) Input field Used to reposition of the longitudinal register
forward+, back-
(4) Display field The display shows the actual values for repositioning the lon-
[m] gitudinal register.
(5) Input field Used to reposition the sidelay register.
OS+,DS-
(6) Display field The display shows the actual values for repositioning the side-
[m] lay register.
(7) Selection field Switches Enhanced Video Interface on or off
EVI
(8) Selection field Starts the register adjustment
Start register adjustment

X000299192

(9) Selection field The register moves to the mid-position.
Register mid-position

X000299192
Color deck Adjustments
Color deck Adjustments Screen page 31

(1) Input field Enter the manual adjustments
Manual
(2) Input field Enter the dynamic plate cylinder adjustments
DynPC
(3) Input field Enter the dynamic anilox roll adjustments
DynPC
(4) Input field Enter the number of plate cylinder rotations until reaching
Rotat. clean print
(5) Input field Enter the various clean print modes
Fct.
(6) Display field The display shows the anilox roll adjustments on the drive
AR-DS side.
(7) Display field The display shows the anilox roll adjustments on the operator
AR-OS side.
(8) Display field The display shows the plate cylinder adjustments on the drive
PC-DS side.

X000299192

(9) Display field The display shows the plate cylinder adjustments on the op-
PC-OS erator side.
(10) Button Erases print adjustments.
ERASE

X000299192
Drying system
Drying Screen page 7

(1) BC drying Between-color drying
(2) Choice box Used to select the dryer mode.
Dryer mode
(3) TUNNEL DRYING Tunnel drying
(4) Display area The display shows the actual dryer mode value.
Dryer mode
(5) Input field Enter the initial temperature.
Initial temperature
(6) Input field Enter the initial speed.
Initial speed
(7) Input field Enter the final speed.
Final speed
(8) Input field Enter the final temperature.
Final temperature
(9) Display field The display shows the actual temperature value.
Temperature

X000299192

(10) Display field The display shows the machine-selected solvent.
Solvent
(11) Display field The values displayed for the LEL are given as the percentage
Solvent of the total volume of the solvent-air mixture.
(12) Button The burner is set back to its initial state.
RESET
(13) Button Activates or deactivates the burner.
Burner
(14) Display field The values displayed for the LEL are given as the percentage
LEL reference value of the total volume of the solvent-air mixture.
Peventive Maintenance
Preventive Maintenance Screen page 17

(1) Button Shows all pending cleaning tasks, lubrication tasks and main-
PREVENTIVE MAINTE- tenance tasks.
NANCE

X000299192
Trending
Trending Screen page 39

(1) Button Used to open trending groups
TRENDING A-K As many as six graphs can be summarized in one trending
group.
(2) Button Opens the selected trending graph
TRENDING GRAPH As many as six graphs can be displayed simultaneously.
(3) Input field Enter the upper graph limit
Upper limit
(4) Display field The display shows the data represented in the graph.
Specifications
(5) Display field The display shows the graph.
Graph
(6) Input field Enter the lower graph limit.
Lower limit
(7) Display field The display shows the timeline of the graph.
Timeline

X000299192

(8) Display field The display shows the date of the recorded value in the graph.
Date
(9) Button Scales the graphs automatically.
AUTO SCALE
(10) Button Set up the ' Auto Scale ' mode.
AS SETUP
(11) Button Opens the setup menu for the graph.
GRAPH SETUP
(12) Button Used to advance the indicated period of graph.
DELAY PERIOD
(13) Button Decreases the displayed period of the graph.
DECREASE PERIOD
(14) Display field The display shows the currently indicated period.
Period
(15) Button Increases the displayed period of the graph.
INCREASE PERIOD
(16) Button The display shows the graph of the current time.
CURRENT TIME
(17) Button Used to retract the indicated period of graph.
DELAY PERIOD

X000299192
Job processing
Job processing Screen page 10

(1) Input field Enter the job name.
Job
(2) Input field Enter the customer name.
Customer
(3) Input field Set up the job length in meters.
Job length
(4) Input field Set up the job length in ups.
Job length
(5) Input field Set up the roll length in meters.
Roll length
(6) Input field Set up the roll length in ups.
Roll length
(7) Button Resets the job counter after a roll change
RESET JOB COUNTER
AT ROLL CHANGE

X000299192

(8) Display field The display shows the point of time when the job is started.
Starting the job
(9) Button Instantaneous resetting of the job counter
RESET JOB COUNTER
NOW
(10) Input field Enter the recipe name.
Recipe
(11) Input field Input fields for notes on the machine recipe.
Note
(12) Input field Enter the number of webs (ups) which can be printed per one
Ups per cylinder rotation of the cylinder.
(13) Display field The display shows the print repeat length for the plate cylinder.
Size
(14) Display field Display of the time when the recipe has been saved.
Memory - Time
(15) Button Saves the recipe
SAVE RECIPE

X000299192
Downtimes
Downtimes Screen page 13

(1) Display field The display shows the downtimes which have not yet been
Downtimes not yet as- assigned.
signed
(2) Selection field Select the production status
Production
(3) Display field The display shows the production times.
Production
(4) Selection field Select the production status.
Production
(5) Display field The display shows the interruptions.
Interruptions
(6) Selection field Select the production status
Production
(7) Display field The display shows the changeover times
Changeovers

X000299192

(8) Selection field Select the production status.
Production
(9) Display field The display shows the fault times.
Faults
(10) Display field The display shows the interrups in total.
Interrupts in total
(11) Display field The display shows the changeovers in total.
Changeovers in total
(12) Display field The display shows the faults in total.
Faults in total

X000300687

Job processing Standard

Job
Customer
(3) Input field Enter the job length in meters.
Job length
(4) Input field Enter the job length in ups.
Job length
(5) Input field Enter the roll length in meters.
Roll length
(6) Input field Enter the roll length in ups.
Roll length
(7) Display field The display shows the starting point of the job.
Starting the job

X000300687

(8) Button Resets the job counter at a roll change
Reset job counter at roll
change
(9) Button Resets the job counter
Reset job counter now

X000300687
Job processing with Recipe management and Next level
Recipe management

Job
Customer
Job length
Job length
Roll length
Roll length
Starting the job

X000300687

(8) Button Resets the job counter after a roll change
change
(10) Entry Enter the recipe name.
Recipe
(11) Entry Enter notes on the recipe.
Note
(12) Entry Enter the number of webs (ups) which can be printed per one
(13) Display field The display shows the print repeat length of the plate cylinder.
Size
(14) Display field The display shows the time when the recipe has been saved.
Memory - Time
(15) Button Saves the recipe.
Save recipe A recipe with the same name will be overwritten. All set values,
texts, the longitudinal and sidelay register adjustments and the
printing impressions are saved to the recipe.
Next level

X000300687

Job
Customer
Job length
Job length
Roll length
Roll length
(7) Display field The display shows the number of rolls.
Number of rolls
Recipe
Note

X000300687

Size
(12) Button Opens a pop-up menu for loading an existing recipe
LOAD RECIPE
Memory - Time

X000300687
Job processing with recipe management, Next level and PreMakeReady
Recipe management

Job
Customer
Job length
Job length
Roll length
Roll length
Starting the job

X000300687

(8) Button Resets the job counter at a roll change
change
Recipe
Note
Size
Memory - Time
Next level and PreMakeReady
PreMakeReady is used to transfer data to the color decks not involved in the current job while the
machine is running.
A job change can only be performed if the following conditions are fulfilled:
The machine must be at a standstill.
The color decks must be in their zero position.

X000300687

Job
Customer
Job length
Job length
Roll length
Roll length
(7) Display field The display shows the number of rolls.
Number of rolls
Recipe
Note

X000300687

Size
(12) Button Opens a pop-up menu for loading an existing recipe
LOAD RECIPE
Memory - Time
(15) Selection field Opens a menu for selecting the job change on the main ma-
Job change chine or on the individual color decks.
(16) Button Transfers the data to current production
Data transfer
(17) Button Changes the job and resets the job counter
Job change
(18) Button Changes the job on the next roll change
Job change during roll
change
(19) Button Transfers the data to current production, changes the job and
Both resets the job counter

X000300687
Printouts
Printouts Screen page 11

(1) Input field Enter the number of roll printout to be printed at the end of the
End of roll roll.
(2) Button Used to print the roll printout
Manual
(3) Input field Enter the number of job printouts to be printed at the end of a
End of job job.
(4) Button Used to print the job printout
Manual
(5) Button Used to print the production printout
Manual

X000301199
4.9.6 Data backup

Data backup Screen page 97

(1) Selection field Select the data for the backup
Data source
(2) Display field The display shows the data size in megabytes
Data source
(3) Selection field Select the data carrier
Data carrier
(4) Display field The display shows the status of the burning operation.
Burner status
(5) Button Starts the burning operation
BURN
(6) Button Cancels the burning operation
CANCEL
(7) Button Loads the customer-specific system configuration
LOAD SYSKON
(8) Button Saves the customer-specific system configuration
SAVE SYSKON

X000301672

Cleaning the screen
(1) PAGE OVERVIEW button

(2) CLEAN SCREEN button
1. Press the PAGE OVERVIEW button.The display shows the page overview.
2. Press the CLEAN SCREEN button.The screen is locked and can be cleaned.

X000301672
Lock screen
(1) Lock screen

(2) Remaining cleaning time
1. When the lock screen (1) is displayed. Clean the screen. The remaining cleaning time (2) is
displayed.

X000298570

Specifications
The entire data system to control the machine is made up of several self-sufficient computers, indi-
vidual controllers and intelligent components. These devices are generally equipped with random
access memory (RAM) as well as remanent FLASH memory for storage purposes. The PROCON-
TROL computer is merely used as main database, visual display unit and operating tool.
Certain parameters have to be set to operate the separate controllers. These values are fixed INI-
files and depend on the configuration of the respective machine.
Additionally, the system utilizes adjustable system constants (SYSKON files), which can be used to
configure and optimize the behavior of single components. These adjustments can be made by using
the specific service pages for the separate controllers.
Apart from the controllers, the parameters of several electronic components (i.e. absolute value en-
coders, converters) can also be changed using the respective service pages. The procedure descri-
bed here has to be read in conjunction with the information on the service screens.
Basically, the parameter values required by a controller are permanently stored in the internal FLASH
memory. From this remanent (permanent) memory, the data is transferred automatically into the RAM
of the controller during the controller booting sequence, hence the data is again available.
All parameter values required for controller operation are generally stored in the internal memory,
therefore, i.e. these controllers can operate self-sufficiently.
Data on the PROCONTROL computer

Operating system Windows XP including additional W&H software package.
Commission INI- Fixed parameters based on the machine configuration (web tensions,
file speeds, etc.)
These data cannot be changed but only read.
System parame- System parameters can be changed. They can be adapted and loaded to the
ters relative controller as new parameter values and stored to the PROCONTROL
computer as a backup.
No-volt protection If a voltage failure occurs or when shutting down the computer, the no-volt
protection (SpAusfall.rec) automatically stores certain data entered in Pro-
control.
When restarting the computer, this data will be reloaded as well.

X000298570
Service pages and gaining access
The operator can gain access to and read all of the services pages. For safety reasons, the service
pages have been assigned so-called user classes. These user classes serve to regulate who is
allowed to make changes on which service pages.
User class: Operator - Level 2
Various input and display screens are available to the operator for operating the machine. These
displays are available in the language of the customer's choice and in German. The language can
be changed by accessing the page overview display and pressing the language button.
User class: Customer's technician (service) - Level 1

At this level, the customer's technician can gain full access to a number of other pages, in addition
to the ones accessible at level 2. Access is gained by selecting the 'Page overview' screen and by
entering the custoemr's password. This password is 'wuh' in small letters, unless changed by the
customer.
If, for a short time, no selections or inputs have been made, the user class returns to level 2 auto-
matically.
Via service page ' User data ' the customer's password can be changed.
User class: W&H service technician - Level 0

Because it is possible at this level to change the basic machine settings, access is only allowed to
W&H personnel who must enter a special password for this purpose.
Calling the service pages
Selecting the service pages

(2) Service page overview
Press the PAGE OVERVIEW (1) button.

Select the desired service page from the over-
view (2). Enter the prompted password.

X000298570
Choice boxes in the bottom line of the service pages
Act -> Set
(1) ACT -> SET button

2 3
(2) Set input fields
(3) Act input fields
Press the ACT -> SET (1) button.

The values (green) from the Act input fields
(3) are transferred to the Set input fields (2)
(blue).
Apc_0232
Load Syskon
(1) LOAD SYSKON button

(2) Set input fields 2
Press the LOAD SYSKON (1) button.

The system parameters from the PROCON-
TROL computer are transferred to the Set input
fields (2) (blue).
Apc_0233

X000298570
Save Syskon
All set values are saved to the PROCONTROL computer. If not all of the Set fields are assigned
values, zero values are saved as well. Carry out ACT -> SET before changing the set values.
(1) SAVE SYSKON button

Press the SAVE SYSKON (1) button.

The set values (2) are saved to the PROCON-
TROL computer as the system parameters.
Apc_0234
-> Flash
(1) -> FLASH button

(2) Display field
Press the -> FLASH (1) button.

The actual values (green) are burned into the
controller's Flash memory. The yellow T (tem-
porary) in the display field (2) changes over to
the green F (Flash).

X000298570
Flash ->
(1) FLASH -> button

(2) Act input fields 2
Press the <- FLASH (1) button.

The data is loaded from the flash memory into
the RAM memory of the relative controller and
displayed in the actual value display fields.
Apc_0236
Send Syskon
(1) SEND SYSKON button

(3) Display field
Press the SEND SYSKON (1) button. 3

The set values (2) are saved to the RAM mem-
ory of the relative controller. The green F
(Flash) in the display field (3) changes over to
the yellow T (temporary).
Apc_0237

X000298570
User data
Calling the User data sceen page
(1) USER DATA button
Press the PAGE OVERVIEW button in the top

line.
An overview of selectable screen pages ap-
pears.
Press the USER DATA (1) button.
User data screen page
(1) User data screen page
Enter the requried data on the screen page

(1).

X000298597

Safety instructions
DANGER
Non-explosion proof equipment
Risk of explosion from non-explosion proof equipment.
Never use the service notebook within the machine's explosion-risk area.
DANGER
Remote-controlled machinery
Using remote-controlled machinery can cause serious injuries and may even lead to death. Using
remote-controlled machinery may cause damages to the machine.
The operator must permanently observe the machine while remote controlled. The machine must be
shut off immediately whenever a dangerous situation arises.
CAUTION
Danger from remote-controlled machinery.
The operator must permanently observe the machine while remote controlled. The machine must be
shut off immediately whenever a dangerous situation arises.
The INTERNET REMOTE SERVICE mode serves as a service mode only and cannot be regarded
as the normal production mode. It is imperative for the employer to fulfill his safety aud supervisory
obligations.
The employer must fulfill his supervisory obligations.
The employer must ensure that specially qualified personnel take care of the machine.
Before activating INTERNET REMOTE SERVICE mode, make sure that all safety devices are in
an orderly and proper condition and that they are in the state for which they were designed.
It is forbidden for persons to stay in the machine's danger zone while INTERNET REMOTE SERV-
ICE mode is running.
Any actions carried out in connection with the INTERNET REMOTE SERVICE generally require
the momentary individual approval of the employer.
No other than reading activities are allowed when the machine is running (production run, main-
tenance run or similar). Generally, any altering access to the machine's control system is forbidden.
It must be possible to shut down all machine/line activities by means of the EMERGENCY-STOP
mode.
Alterations to the control software or process interferences are allowed only under the supervision
of the employer and when the machine is at a standstill.

X000298597
Employer's safety and supervisory obligations
The INTERNET REMOTE SERVICE mode serves as a service mode only and cannot be regarded
as the normal production mode. It is imperative for the employer to fulfill his safety aud supervisory
obligations.
The employer must fulfill his supervisory obligations.

The employer must ensure that specially qualified personnel take care of the machine.
Before activating INTERNET REMOTE SERVICE mode, make sure that all safety devices are in
an orderly and proper condition and that they are in the state for which they were designed.
It is forbidden for persons to stay in the machine's danger zone while INTERNET REMOTE SERV-
ICE mode is running.
Any actions carried out in connection with the INTERNET REMOTE SERVICE generally require
the momentary individual approval of the employer.
No other than reading activities are allowed when the machine is running (production run, main-
tenance run or similar). Generally, any altering access to the machine's control system is forbidden.
It must be possible to shut down all machine/line activities by means of the EMERGENCY-STOP
mode.
Alterations to the control software or process interferences are allowed only under the supervision
of the employer and when the machine is at a standstill.

X000298597
Checking the port settings
(1) TCP ports for remote service
The ports for Internet Remote Service require the following settings:
DNS okay
1533 (opened)
443 (opened)
8081 (opened)
8084 (closed)
Port 8084 is locked by Windmller und Hlscher. It will be opened only if a video inquiry is submitted
via the service notebook.

X000298597
Setting up access rights
Before starting the INTERNET REMOTE SERVICE mode, screen page 110 must be activated by
entering the customer password.

(1) Selection field Select the access level.
Access level
(2) Selection field Select the time allowed for remote access.
Time
(3) Selection field Activates or deactivates a software update
SW update
(4) Display field The display shows the user asking for the right to access the
Access inquiry from: machine
(5) Button Confirms the access
YES
(6) Button Denies the access
NO

X000298597
Access level Description

Access disabled Windmller & Hlscher cannot establish a connection to the machine, existing
connections will be interrupted.
Allow access af- If Windmller & Hlscher wants to establish a connection to the machine, the
ter query access inquiry display field appears prompting you to enter: (4) the name of the
user asking for the right to access the machine. When pressing the YES button
(5), 'Access permitted' appears in the Access level display field (1).
Access permit- Windmller & Hlscher is then able to establish a connection to the machine
ted for the time entered in the Time selection field (2).
When Windmller & Hlscher is connected to the machine, the 'W&H Service' window pops up. When
pressing the STOP and ALLOW CONTROL button, access to the machine can be interrupted at any
time.

X000298597
Software update

(1) Selection field Activates or deactivates a software update
SW update Activating this mode updates the ' INTERNET REMOTE
SERVICE ' software. We recommend to activate this mode to
allow for closing security gaps.
(2) Button The STATUS INFO button (2) can only be operated by Wind-
STATUS INFO mller & Hlscher's service technicians after entering Wind-
mller & Hlscher's password.

X000298597
Chat mode
Chat mode
The 'Chat' mode allows communication with the service staff member who has gained connection
to the machine.
(1) INQUIRY TO W&H'S IDC

(2) SEND
(3) ANWER FROM W&H'S IDC
Enter your question in the INQUIRY TO W&H'S

IDC (1) field and press the SEND (2) button.
The answer of the service staff member is
shown in the ANSWER FROM W&H'S IDC
(3) field.
Information about the service notebook
DANGER
Non-explosion proof equipment
Explosions cause severe injuries.
Do not use the service notebook in the machine's explosion-risk area.
NOTE
Make sure to connect the headset and the webcam only to the interfaces marked for this purpose.
The service notebook, the webcam and the headset allow for direct communication with a staff mem-
ber of W&H's Information and Diagnosis Center (IDC).
More detailed information on how to connect and operate the equipment can be taken from the PDF
file on the service notebook.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Operator terminal -
Winder

4.10.1 Winder operator terminal...................................................................................................2

4 Control elements and screen pages | Operator terminal -
Winder
X000054321
(1) Input fields
The data for the winders, the draws and the web
guide controls can be entered and monitored via
the input fields (1) in the visual display unit.
When touching the input fields with your finger the
color turns yellow and a numeric keypad appears.
Use this keypad to enter numerical values into the
input fields. If the entered values are valid they will
be imported into the respective field when actuat-
ing the 'OK' button. Only one field can be selected.
(1) HOUSE icon

(2) UNWIND icon
(3) REWIND icon
When touching the HOUSE (1) icon the home

page including the data for the material, the draws
and the web guide controls will be displayed. The
data can be entered or modified.
When touching the UNWIND (2) icon the unwind
data will be displayed. The data can be entered or
modified.
When touching the REWIND (3) icon the rewind
data will be displayed. The data can be entered or
modified.

Z WINDMLLER & HLSCHER 4 Control elements and screen pages | Operator terminal -
Winder
X000054321
(1) SPEECH BUBBLE icon

(2) W&H icon
(3) QUESTION MARK icon
When touching the SPEECH BUBBLE (1) icon a

choice box with all available languages will be dis-
played.
When touching the W&H (1) icon a numeric key-
pad for entering numerical values will be dis-
played. If the entered number corresponds to an
image number the respective image is displayed
immediately when actuating the 'OK' button.
The help texts will be displayed when touching the
QUESTION MARK (3) icon.
If none of the input fields has been selected a help
window pops up giving you information on the
screen page.
If an input field is selected you can gain information
on the input field when touching the 'Help' icon.
Both information windows can be closed by touch-
ing the 'OK' button.
(1) MACHINE SPEED display

(2) SET AND ACTUAL VALUES display
(3) FAULT display
The MACHINE SPEED (1) display field shows the

current machine speed. When touching this field a
full-screen display of the speed will appear in the
operator terminal.
Touch one of the upper buttons to exit this mode.
The SET AND ACTUAL VALUES (2) display
shows the set and actual values for the current job.
The color of the signal lamp icon in the FAULT
(3) display field turns red if a fault has occurred.
The digit represents the number of faults. The last
message each is displayed in plain text in the lower
section of the operator terminal.
When touching the display field a list of the pending
alarm messages will be displayed.

4 Control elements and screen pages | Operator terminal -
Winder
X000054321

Z WINDMLLER & HLSCHER 5 Operation
5 Operation
5.1 Unwind
5.1.7 Roll change
5.1.9 Lifting gear
5.2 Static removal
5.3 Printing unit
5.3.5 Ink supply
5.5 Nip rolls
5.6 Easy-Set
5.6.6 EASY-TOPO
5.6.7 EASY-SET S
5.7 Easy-Reg

5 Operation Z WINDMLLER & HLSCHER
5.8 Easy-View
5.8.1 Easy-View
5.9 Easy-Col
5.9.2 Notes
5.10 Drying system

Z WINDMLLER & HLSCHER 5 Operation
5.13 Rewind
5.13.8 Roll change
5.14 Inking system
5.15.3 Conversion

5 Operation Z WINDMLLER & HLSCHER


Z WINDMLLER & HLSCHER 5 Operation | Unwind
5.1 Unwind
5.1.1 Design and function...........................................................................................................2
Design............................................................................................................................2
Function.........................................................................................................................3
Chucks...........................................................................................................................4
5.1.2 Compressed-air supply line...............................................................................................5

Safety information..........................................................................................................5
Compressed air conditioner...........................................................................................5
5.1.3 Establishing the ready-for-operation status.......................................................................6
5.1.4 Swiveling the turret manually............................................................................................8
5.1.5 Loading a roll and operating the chucks..........................................................................10

Design and function.....................................................................................................11
Chuck adapter.............................................................................................................12
Handling core chucks..................................................................................................13
5.1.6 Switching the drive of the winding shaft on or off............................................................17

Requirements..............................................................................................................17
Entering job data..........................................................................................................18
Status LED in pushbuttons..........................................................................................19
Switching on the drive..................................................................................................19
5.1.7 Roll change.....................................................................................................................20

Requirements..............................................................................................................20
Roll change make-ready..............................................................................................21
Selecting the web tail length........................................................................................23
Performing a semi-automatic roll change....................................................................24
Roll change..................................................................................................................27
Fully automatic roll change..........................................................................................28
Canceling a roll change...............................................................................................29
5.1.8 Web tension increase at the unwind...............................................................................30

Making entries into the operator terminal....................................................................30
Web tension increase mode........................................................................................31
5.1.9 Lifting gear.......................................................................................................................32

Loading the roll............................................................................................................33

5 Operation | Unwind Z WINDMLLER & HLSCHER
X000260912

Design
(1) Turret (2) Light barrier and safety chain

(3) Idler rollers (4) Winding stations 1 and 2
(5) Upper and lower nip roll (6) Upper and lower cut-off assembly
(7) Cut-off knife (8) Roll lifting platform

X000260912
Function
Two motorized winding stations (4) are provided on the turret (1) which can be swiveled at will. De-
pending on the selected operating mode, the web can be unwound either in underwind or overwind
mode The turret renders possible to swivel the ready made roll from the loading position into the
winding position or the unwinding core from the winding position into the loading position. The new
roll can be brought into the loading position by use of a roll lifting platform (8) which is available as
an option. During production, the expiring roll should be in the winding position.
When the expiring roll swivels back from the winding position, idler rollers (3) are provided to ensure
proper web travel.
The light barrier and the safety chain (2) secure the interior of the winder against any unauthorized
access.
Automatic roll change without stopping the machine. The roll ready made with glue swivels from the
loading position into the winding position. The separating assemblies (6) move to their front limit
position. Depending on the selected winding direction, the unwinding web is pressed against the new
roll either by the upper or the lower nip roll (5). The associated cut-off knife is triggered either auto-
matically or manually to cut off the unwinding web. The empty core in the loading position is slowed
and the drive switched off so that the core can be removed.

X000260912
Chucks
DANGER
Damages to winding shaft adaptors
Damages to the winding shaft adaptors may cause the winding shaft adaptors to break and result in
uncontrolled movements of the winding shaft. Risk of injury to persons and damage to the machine.
Check the winding shaft adaptors for damages every day. Make sure that the toothing of every
winding shaft support is completely embedded in the winding shaft adaptor before loading the winding
shaft. Make sure every time you remove the winding shaft that the toothing of the winding shaft is
completely outside the winding shaft adaptor.
The winding shaft adaptors must be handled in a proper way to prevent damages. Examples for
improper handling:
dropping of the winding shaft adaptor
running when the center shafts are not fully moved out (tilting of the winding shaft or improper entry
of the winding shaft data).
excessive loading of the winding shaft adaptor due to one-sided support when inserting the winding
shaft.
excessive loading of the winding shaft adaptor due to improper roll removal when using the lift table
(the winding shaft was not free to move at the time the lift table was lowered).
Normally, core support in the winding stations is

shaftless. Every winding station is provided with
two chucks (1) which are moved into or out of the
core by motor. Expanding elements in the chuck
head are used to clamp the core in place and fix it
for winding.
Optionally available adapters also render possible
to use of winding shafts.

X000255291

Safety information
WARNING
Pneumatically operated separating assemblies
Risk of severe injuries.
Always switch off the compressed air supply at the compressed air conditioner and withdraw the key
before starting any works inside the winder. There is in increased risk of injury from the pneumatically
operated separating assemblies.
NOTE
Never change the maximum or minimum working pressures! The manufacturer's warranty liability
does not include damages in the pneumatic system of the machine caused by impermissible air
pressure settings.
The compressed air provided on site must meet the quality requirements agreed upon. The manu-
facturer's warranty liability does not included damages due to an inappropriate composition of the air.
The working pressure is factory-set and must not be changed. The start-up time at the start-up valve
are factory-set and must not be changed.
Compressed air conditioner
(1) Compressed air conditioner

(2) Key switch
The compressed air conditioner (1) connects the

compressed air supply system of the winder to the
supply line on site. The winder can be disconnect-
ed from the compressed air supply locally by
means of the latchable key switch (2). When
switching off the compressed air supply, the com-
pressed air conditioner vents the pneumatics in the
winder automatically.

X000239883

Requirements: The machine's control voltage must be switched on. Compressed air supply to the
machine must be switched on.
Activating the safety devices
(1) Guard doors

(2) Safety chain
(3) Safety light grid
(4) RELEASE SAFETY CHAIN pushbutton
Close the guard door (1) on the operator side

of the relevant winder.
1
Connect the safety chain (2).
The RELEASE SAFETY CHAIN pushbutton
flashes orange.
Press the RELEASE SAFETY CHAIN push-
button (4). 2
The safety light grid (3) is activated.
1
3
Wic_0376

X000239883
Providing compressed air supply

(2) Key switch
Switch on the key switch (2) on the com-

pressed air conditioner (1).
The compressed air pressure setting is dis-
played in the manometer.
Switching on compressed air supply
(1) PNEUMATICS ON pushbutton
Press the PNEUMATICS ON pushbutton (1).

The pushbutton is located on the winder's op-
erator panel.
The pushbutton flashes green and the pneu- 1
matic components in the winder are supplied
with compressed air.
Wic_0335

X000263361

During the roll change the turret is swiveled automatically. The turret can also be swiveled manually.
Requirements:
The winder is ready for operation.
The winding shaft supports are closed.
The cut-off assemblies are in their rear limit position.
(1) Safety chain

(2) Safety light grid 1
(3) SAFETY LIGHT GRID LOCKED push-
button
The safety chain (1) must be connected and the

safety light grid (2) activated.
1
2
Activate the safety light grid by pressing the SAFE-
TY LIGHT GRID BLOCKED pushbutton (3) in the
winder panel. The LED light changes color from
orange to green and the safety light grid is active.
When disconnecting the safety chain while the tur-
ret is rotating, all rotational movement is stopped
immediately. In production mode, the machine is
The safety light grid serves as creep zone protec-
tion. When the safety chain is pushed in and the
turret is moving, all movement is stopped when 3
entering the monitored range of the light grid. In
production mode, the machine is stopped in a min-
imum of time.
Wic_0336

X000263361
(1) TURRET FORWARD pushbutton

2 1
(2) TURRET BACK pushbutton
(3) Turret movement FORWARD
(4) Turret movement BACK
When pressing the TURRET FORWARD pushbut- 1

ton (1), the winding shaft which is in the winding
position is swiveled upwards (3) through the wind-
er and into the loading position. Rotary movement
is stopped automatically upon reaching the loading
position .
When pressing the TURRET BACK pushbutton
(2), the winding shaft which is in the winding posi- 3
tion is swiveled downwards (4) through the winder
and into the loading position. Rotary movement is
stopped automatically upon reaching the loading
position .
2 1
2 1
Wic_0416 4

X000260919

Safety instructions
CAUTION
Circulating chains, belts and rotating wheels
Parts of your body, clothes, hair and objects may be caught and crushed.
Care must be taken when inserting a roll while the machine is running.
In production mode, the blocking chain may only be opened to permit operation of the roll loading
and unloading systems at the winding station.
NOTE
The center shafts are laid out for certain roll diameters and roll weights. The maximum permissible
limits must not be exceeded. There is a risk of severe damage to the winder when exceeding the
limits.
If a roll is present in the unwind, the new roll must be loaded only when the diameter of the old roll
has run down to a sufficient size. There is a risk that both rolls will collide.
To prevent the chucks or the roll from major damage, the maximum adjustment force of the chucks
is limited by safety clutches.The maximum torque of the safety clutch is factory-set and must not be
changed by the customer. The manufacturer's warranty does not include damages caused by im-
permissible torque adjustments.
The permitted core diameter must not be exceeded. There is a risk that the core is not properly fixed
in place on the core chuck and the web tension required for proper web feed cannot be reached. Fire
hazard caused by strong friction in the winding core.
The manufacturer's specifications and safety instructions for use of the winding shafts must be heed-
ed at all times. Make sure not to expose the winding shafts to excessive loads.
The core chucks of the chucks must be completely retracted into the core of the roll.
The maximum and minimum roll width that can be handled is specified in the "Technical specifica-
tions"

X000260919
Design and function
Both unwind stations are each designed as a pair of chucks. They allow shaftless support of the rolls.
A winding shaft is not required.
(1) Core chuck

(2) Chuck wedge
(3) Groove
The chuck has a core chuck (1) with three inte-

grated chuck wedges (2). The core chuck serves
to support the roll. It must be moved into the roll
core completely. The chuck wedges are used to fix
the roll on the core chuck. Compressed air is used
to press the wedges outwards.
The groove (3) in the core chuck allows precise
mounting of the chuck adapter.

X000260919
Chuck adapter
The core chucks are designed by default for a certain core inner diameter. Greater core diameters
require the use of appropriate core chuck adapters.
Appropriate chuck adapters to adapt to larger diameters are fitted over and fixed on the core chuck.
In addition to shaftless winding special chuck adapters can also be used.
(1) Adapters for cores with an inner core di-

ameter of 76 millimeters
(2) Adapters for cores with an inner core di-
ameter of 150 millimeters
(3) Winding shaft adapters
To be able to fix the adapters on the core chuck,

they must be fastened with all the screws provided
for this purpose.
Whether core adapters or winding shaft adapters
are used does not mean any limitations to the max-
imum working width of the winder

X000260919
Handling core chucks
Inflating and deflating core chucks
Before using the rolls in winding mode, the rolls must be fixed on the core chucks. Inflate the core
chucks in order to do this. The core chucks must be deflated before the roll can be taken out of the
winder. The core chucks are deflated.
This mode can only be used for chucks of the winding station which is in the unloading or loading
position.
Actuate the switch until the chuck wedges are audibly inflated or deflated.
(1) INFLATE/DEFLATE CHUCKS
Press the INFLATE/DEFLATE CHUCKS but-

ton (1).
The chucks of the winding stations which is in
the unloading or loading position are inflated.
1
Press the INFLATE/DEFLATE CHUCKS but-
ton (1).
The chucks of the winding stations which is in
the unloading or loading position are deflated.
Wic_0425

X000260919
Moving the chucks individually
In order for a new roll to be loaded into the winding station in the loading position the two chucks are
individually moved into the core. For this purpose, pushbuttons are provided on the drive and operator
side inside the winder frame. Deflate the chuck wedges to allow for the chucks to be moved. The core
for the roll to be supported has been raised to the height of the chucks by use of the hoisting gear.
The core chucks of the two chucks must be moved into the core completely to make sure that the roll
is supported over its entire length.
(1) MOVE CHUCK INDIVIDUALLY
Press the MOVE CHUCK INDIVIDUALLY but-

ton (1).
Move the chuck until the core chuck is com-
pletely located in the winding core.
To prevent the chucks or the roll from major
damage, the maximum adjustment force of the
chucks is limited by safety clutches.

X000260919
Moving the chucks in parallel
If a roll is loaded into one of the two winding stations and inflated it can be moved laterally irrespective
of the turret's position. It is possible to change the position of the web in the winder prior to and during
production mode.
(1) MOVE CHUCKS TO THE LEFT

(2) MOVE CHUCKS
Hold down the MOVE CHUCKS TO THE

LEFT (1) button.
The chucks of the corresponding winding sta- 1
tion move in parallel in the desired direction.
Hold down the MOVE CHUCKS TO THE
LEFT (2) button.
The chucks of the corresponding winding sta-
tion move in parallel in the desired direction.
Wic_0422

X000260919
Moving the chucks apart
To be able to take a roll from the unloading position out of the winding station, both chucks are
retracted from the core of the roll and moved into their outer limit position by pressing the MOVE
CHUCKS APART button.
Requirements:
The roll is in its unloading position.
The roll has been transferred onto the lift table (the contact bars are pressed).
The chuck wedges in the chucks are deflated.
(1) MOVE CHUCKS APART
Hold down the MOVE CHUCKS APART (1)

button.
While holding down the pushbutton the chucks
continue to move apart until they reach their
1
limit position.
Wic_0424

X000260919
Special Move-chucks-apart mode on the unwind
A special mode allows for the cores or rolls having a diameter less than 180 millimeters to be taken
out of the winding station from the unloading position without using the lifting gear. This mode is only
feasible when the button flashes.
Requirements:
The roll is in its unloading position.
The roll diameter is less than 180 millimeters.
The chuck wedges in the chucks are deflated.
Hold the roll by hand.
(1) The MOVE CHUCKS APART button

flashes.
Hold down the MOVE CHUCKS APART (1)

button.
While holding down the pushbutton the center
shafts continue to move apart until they reach
their end position.
Make sure that the core or roll cannot fall down.
Hold on!

Requirements
The following switching on sequence should always be observed:

Unwind - rewind - main drive
Activation requirements:
The system is powered up ready for operation.
A roll is in its winding position and the web is threaded into the machine.

X000302020
Entering job data
(1) Job data Winder
1. Enter job data into the winder screen pages or the winder operator terminal.

X000302020
Status LED in pushbuttons

the
push-
button
Blinking orange: The mode is in the switch on process.
Flashing orange: The cut-off assemblies of the unwind and rewind move towards the
roll and ascertain the roll diameter.
Flashing green: The winder motor is active.
Switching on the drive
Switching on the winding motor
NOTE
During the switch-on procedure, the cut-off assemblies move up against the roll to ascertain the
diameter. The cut-off assembly at the unwind returns to its limit position. The cut-off assembly on the
rewind stops at the roll.
(1) WINDING MOTOR 1 ON/OFF pushbut-

ton
Press and hold down the WINDING MOTOR 1

ON/OFF pushbutton (1) until the LED in the
pushbutton flashes green.
1
Let go of the WINDING MOTOR 1 ON/OFF
pushbutton.
The winding motor turns until the web is tight.
Wic_0341

X000302020
Switching off the winding motor
Before switching off the winding motor, the machine must be brought to a standstill. The main drive
must be switched off.

ton
Press the 1 WINDING MOTOR 1 ON/OFF

pushbutton (1).
The winding motor is switched off, the LED in
1
the WINDING MOTOR 1 ON/OFF pushbutton
goes dark.
Wic_0341
5.1.7 Roll change

Requirements
A roll change requires the following conditions to be fulfilled:

The machine is operational and unwinds the web.
The new roll is made ready and present in the winder
The blocking chain is connected and the safety light grid activated.
The web tail length must be defined in the Winder screen page in Procontrol.
NOTE
The new roll must be positioned only when the diameter of the old roll has run down to a sufficient
size. There is a risk that both rolls will collide.
The new roll should exceed a minimum diameter of 300 millimeters. Automatic roll changes cannot
be performed when using rolls with smaller diameters.
The roll change must be initiated within due time before the residual roll has expired.
The area of the safety light grid must not be accessed once the roll change has been initiated. If the
requested area of the safety light grid is violated, all rotary movements of the turret and all traversing
movements of the cut-off assemblies are stopped. The machine stops as quickly as possible.

X000302094
Roll change make-ready
Determining the splice position
The groove in the chuck serves as a marking for the correct splice position during a roll change.
For center shafts providing two grooves, the groove which is not marked by a marking screw must
be used.
(1) Cut edge of the web

(2) Groove without marking screw
(3) Groove with marking screw
The cut web edge (1) should be in proper align-

ment with the groove (2) in the chuck.
Apply a straight cut to the web. For chucks pro-
vided with two grooves the groove provided
with the marking screws (3) must not be used
as the marking for the cut web edge.

X000302094
Indicating label Splice
(1) Splice position
Determine the splice position (1) according to

the winding direction.
Splice make-ready
If the web is intended to pass high-temperature drying zones (120 - 140 degrees Celsius) it is abso-
lutely necessary to use heat-resistant adhesive tapes.
(1) Adhesive tapes

(2) Cut edge
(3) Fixing strips
Paste three adhesive tapes (1) of approx. 50

millilmeter width onto the beginning of the web.
Cut the web diagonally on either side (2) and
fix it using the fixing strips (3).

X000302094
Selecting the web tail length
The length of the cut off web still being fed through the machine after the splice is designated as the
web tail. This length is fixed and must not be changed.

(1) Selection field Opens the choice box for the web tail length
Web tail length
(2) Button The nip roll glues the two webs together and the cut-off knife
Manual is not activated until the MAKE READY/INITIATE ROLL
CHANGE button is pressed again.
Short is activated when approx. 1/4 of the circumference of the new
roll is unwound.
Long is activated when approx. 1 1/4 of the circumference of the
new roll is unwound.

X000302094
Performing a semi-automatic roll change
Short tail
The blocking chain must be connected and the safety light grid activated.
(1) MAKE READY/INITIATE ROLL

CHANGE pushbutton
Press the MAKE READY/INITIATE ROLL

CHANGE pushbutton (1).
The LED in the MAKE READY/INITIATE ROLL
1
CHANGE pushbutton flashes orange. The tur-
ret swivels into the winding position, the cut-off
assemblies ascertain the roll diameters. The
roll accelerates to web speed.
After roll change make-ready, the LED in the
MAKE READY/INITIATE ROLL CHANGE Wic_0353
pushbutton (1) flashes green.
CHANGE pushbutton (1) and hold it down until
the old web has been cut off.
The nip roll of the respective cut-off assembly
is released to splice the two webs. The cut-off
knife is activated when approx. 1/4 of the cir-
cumference of the new roll is unwound. After
cut-off, the residual roll briefly reverses in di-
rection to brake it.
Remove the residual roll.

Attention: Do not open the blocking chain until the separating assemblies of the unwind unit have
reached their end position.

X000302094
Long tail

CHANGE pushbutton

1
knife is activated when approx. 1 1/4 of the cir-
cumference of the new roll is unwound. After
cut-off, the residual roll briefly reverses in di-
rection to brake it.

Attention: Do not open the blocking chain until the separating assemblies of the unwind unit have

X000302094
Manual

CHANGE button

1
CHANGE pushbutton (1) briefly.
knife is not activated.
CHANGE pushbutton (1) once again briefly.
The cut-off knife is activated. After cut-off, the
residual roll briefly reverses in direction to
brake it.
In this mode, the operator can define the time
at which the cut-off knife should be activated.

Attention: Open the blocking chain only when the separating assemblies of the unwind unit have

X000302094
Roll change
Initiating a semi-automatic roll change

CHANGE pushbutton

CHANGE (1) pushbutton.
1
CHANGE (1) pushbutton.
is released to splice the two webs. The web is
cut off and the residual roll briefly rotates in the
opposite direction in order to be braked.

Caution: Open the blocking chain only when the separating assemblies of the unwind unit have

X000302094
Fully automatic roll change
A fully automatic roll change is carried out by the machine controller and not by the operator. An
acoustic signal makes the operator aware of the roll change.
(1) Roll change data
1. Enter the roll change data.Once the given diameter of the expiring roll has been reached, roll
change is carried out automatically at the set speed.

X000302094
Canceling a roll change
A roll change should be canceled before initiating the roll change.
(1) CANCEL ROLL CHANGE pushbutton
Press the CANCEL ROLL CHANGE pushbut-

ton (1) to cancel the initiated roll change proc-
ess.
The cut-off assemblies traverse to their home
1
position, the new roll is braked and the drive
switched off.
The turret does not swivel back!
Wic_0342

X000302078

Making entries into the operator terminal
(1) Input fields for the draw downstream of

the unwind unit
1. Enter the desired setpoints into the input fields for the draw downstream of the unwind unit (1)
in the winder operator terminal (optional) or into Procontrol.

X000302078
Web tension increase mode
(1) Initial tension

(2) Start diameter for web tension increase
(3) End diameter for web tension increase
(4) Percentage amount of web tension in-
crease
(5) Web tension after tension has been in-
creased
(6) Unwind roll
The roll (6) has a relatively hard wound core. To

enable the roll to be unwound at a relatively linear
web tension the web tension need to be increased
whilst the roll diameter decreases.
The web tension increases from the start diameter
(2) entered into the operation terminal to the end
diameter (3) entered. The maximum increase (4)
can be 50 percent of the specified web tension.

X000260961
5.1.9 Lifting gear

Safety instructions
CAUTION
Inappropriate or defective lifting devices
Risk of severe injuries to persons and/or damage to machinery.
Be aware that unsuitable or defective chain hoists may lose their load and thus cause injury to persons
or damage to the machine. Chain hoists and load handling attachment must be in technically perfect
condition when used. Check the hoisting equipment for adequate carrying capacity. Check the hoist-
ing equipment and the load handling attachment for wear at regular intervals and replace whenever
necessary. Never stay or work beneath a suspended load!
CAUTION
The specified load rating and capacities must be heeded.
There is a risk of severe injury to persons and/or damage to machinery.
When using the lifting gear, the manufacturer's instructions and safety regulations must be heeded.
The lifting gear is laid out for certain roll diameters and roll weights. The given limits must not be
exceeded. Staying beneath the lift table is forbidden. The lift table must be secured against inadver-
tent mechanical lowering before starting any repair or maintenance works.
NOTE
The lifting gear is intended to load or unload a roll into or from the winder.
All use in excess thereof is forbidden.

X000260961
Loading the roll
Lift table Up
The winding station to be loaded should be in its loading position.

The safety chain must be open.
The chucks should be in their outer limit position.
A roll must be available on the lift table.
(1) LIFT TABLE UP button
Hold down the LIFT TABLE UP button (1).

The lift table raises until a set position is
reached.
Let go of the LIFT TABLE UP button (1) as soon
1
as the winding core in the roll has reached the
level of the chucks.
Move the chucks individually into the winding
core.
If the winding core and the chucks have differ-
Wic_0419
ent heights, move the lift table incrementally.
Move the core chucks completely into the wind-
ing core.
Inflating the chucks
Lift table Down
(1) LIFT TABLE DOWN button
Hold down the LIFT TABLE DOWN button (1).

The lift table moves downwards into its end po-
sition.
1
Wic_0420

X000260961

Z WINDMLLER & HLSCHER 5 Operation | Static removal
5.2 Static removal

5.2.1 Static charge removal........................................................................................................2
Description and working principle..................................................................................2
Activating static charge removal....................................................................................3

5 Operation | Static removal Z WINDMLLER & HLSCHER
X000271856

Description and working principle
WARNING
Defective static charge removal device
Risk of fire and explosion from a static charge removal device when defective
Proper functioning of the static charge removal device must be ensured. Observe the maintenance
intervals.
Static charge removal mode is always used if materials are liable to static charging during a process
and thus may cause production failures or inconveniences to the personnel through unwanted dis-
charge of static electricity.
Unwanted discharge of static electricity means: Discharge of static electricity when touched or dis-
charge of static electricity in partial areas of the line. Both are unwanted discharges of static electricity.
Electrostatic systems reduce the risk of fire and explosion:
The anti-static bar serves to convert the high voltage from positive into negative supply. The high
voltage creates an electrical field at the anti-static bar emitters causing the air molecules around the
emitters to split into positive and negative ions. When material charged with static electricity passes
the electrodes, ions are exchanged between the anti-static bar and the charged material until the
material is neutralized.
(1) Charged web

(2) Discharge electrode
(3) Electrical field
(4) Neutralized web

Z WINDMLLER & HLSCHER 5 Operation | Static removal
X000271856
Activating static charge removal
(1) Activates or deactivates static charge re-

moval
Press the Static charge removal button (1) in

the web tension module.

5 Operation | Static removal Z WINDMLLER & HLSCHER
X000271856

Z WINDMLLER & HLSCHER 5 Operation | Printing unit
5.3 Printing unit

5.3.1 Layout and function...........................................................................................................2
Guards...........................................................................................................................2
Layout............................................................................................................................4
Color deck (manual opening of the color decks)...........................................................5
Doctor blade unit............................................................................................................6
5.3.2 Programs for deck in/deck out operations.........................................................................7

Programs for deck in/deck out operations.....................................................................7
Print On/ Print Off..........................................................................................................8
5.3.3 Register adjustment..........................................................................................................9

Definition........................................................................................................................9
Longitudinal register......................................................................................................9
Sidelay register............................................................................................................10
5.3.4 Nip roll in sleeve technology............................................................................................11

Layout..........................................................................................................................11
Sleeve change.............................................................................................................12
5.3.5 Ink supply........................................................................................................................15

Requirements:.............................................................................................................15
Preparatory work.........................................................................................................16
Inking...........................................................................................................................18
5.3.6 Hinged cap bearing.........................................................................................................20
5.3.7 Anilox roll sleeve change.................................................................................................21
5.3.8 Plate cylinder sleeve change...........................................................................................25
5.3.9 Sleeve change - Hybrid mandrel.....................................................................................30

Instructions on CRP adaptors......................................................................................30
Hydraulics - Adaptor....................................................................................................31
Pushing on or removing a sleeve................................................................................31
5.3.10 Safety guards on the printing unit....................................................................................35

Opening the safety guard on the web infeed side.......................................................35
Opening the safety guard on the web outfeed side.....................................................36
5.3.11 Operating the roll up doors..............................................................................................37

Overview of the control elements................................................................................37
Safety devices.............................................................................................................38
Operation.....................................................................................................................39
Operating the roll up door in the event of power failure...............................................40

5 Operation | Printing unit Z WINDMLLER & HLSCHER
X000240032

Guards
DANGER
Improperly mounted guards or covers
Explosions cause life-threatening injuries.
Improperly mounted guards or covers rub against the anilox roll causing fires or explosions. Be sure
to attach the guard or covers properly.
Only ever use brass screws to attach the anilox roll wipers.
NOTE
Because of the small working width of the machine, it must be ensured that ink hoses and lines are
prevented from getting bent or pinched in the sliding glass doors.

X000240032
(1) Sliding glass door Web outfeed side (2) Roll up doors Operator side
(3) Sliding glass door Web infeed side (4) Locked guard doors Drive side
Access to the printing unit on the operator side (2) is protected by roll up doors.
Access to the printing unit on the drive side is protected by guard doors (4).
Access at front to the color decks on the web infeed side (3) and the web outfeed side (1) is protected
by a sliding glass door.

X000240032
Layout
(1) Control elements (2) Side frame assembly

(3) Color deck (4) Impression cylinder
(5) Nip roll
A steel impression cylinder is supported in the side frame assembly (2). The impression cylinder is
motor-driven. Depending on the outfit, several color decks (3) are arranged in a ring-shaped manner
around the impression cylinder.
A nip roll (5) is mounted above the impression cylinder. It serves for the web to make contact with
the impression cylinder in a wrinkle-free manner.
The web is fed into the printing unit at the pivotable nip roll. The web travel follows the circumference
of the impression roller to the last color deck. Here, the web leaves the printing unit in the direction
of the drying system.
Slot blowers are arranged between the color decks for between-color drying (see dryer module).
The central operating modes for this module are carried out from the control panel and the control
elements (1) in the guard doors.

X000240032
Color deck (manual opening of the color decks)
(1) Stepping motor for plate cylinder adjust- (2) Hinged cap bearing Plate cylinder man-
ment drel
(3) Plate cylinder mandrel (4) Doctor blade unit
(5) Anilox roll mandrel (6) Hinged cap bearing Anilox roll mandrel
(7) Stepping motor for anilox roll adjustment
Stepping motor driven color decks are attached to the impression cylinder circumference. The des-
ignation of the color decks is defined with one (top right) to eight or ten (top left).
Each color deck consists of a plate cylinder mandrel (3), an anilox roll mandrel (5) and a doctor blade
unit (4). Stepping motors at the anilox roll (7) and at the plate cylinder are provided for axial adjustment
of the color decks (1). For the anilox roll and the plate cylinder, one stepping motor each is provided
on the drive and operator side.
Sleeve-technology is used for the plate cylinders and the anilox rolls. Compressed air is used to mount
the sleeves onto the mandrels. Compressed air flows out of the nozzles in the plate cylinder and
anilox roll mandrels and creates an air cushion that stretches the sleeve outwards. It is possible to
push on or extract the sleeves very quickly. The hinged cap bearings (2) and (6) support the journals
of the plate cylinder mandrels and the anilox roll mandrels and can be hinged away for removing the
sleeves from the respective mandrel.

X000240032
The plate cylinder and anilox roll positions are individually adjustable (drive and operator side). The
longitudinal and sidelay register adjustments are motorized. The anilox roll mandrels and the plate
cylinder mandrels are driven separately.
Doctor blade unit
(1) Pneumatic cylinder for swinging in the (2) Doctor blade chamber
doctor blade chamber
(3) Attachment of the doctor blade chamber (4) Handles
to the doctor bar
(5) Doctor bar (6) Ink duct
Screwed handles (3) which can easily be slackened are provided to attach the doctor blade chamber
(2) to the pneumatic (1) swing-type doctor bar (5).
The enclosed doctor blade chamber is used for inking the anilox roll. An ink tank contains the ink
which is pumped to the doctor blade chamber. The ink supply and return hose connections are located
at the rear of the doctor blade chamber.
Handles (4) are provided for safe transport of the removed doctor blade chamber.
For further information on the doctor blade chamber and inking please refer to the chapter under the
heading 'Inking'.

X000240054

Programs for deck in/deck out operations
Programs for deck in/deck out operations are provided to position the anilox roll and the plate cylinder
relative to the impression cylinder. Programs for deck in/deck out operations are started either from
Procontrol or the hand-held panel.
WARNING
Moving machine parts
Risk of crushing or shearing parts of your body.
Do not reach in between moving machine parts. Keep a safe distance.
Deck-in operation
Deck-in operation means the positioning of all
plate cylinders (1) and anilox rolls (2) involved in
the print job from the zero position to the pre-print
(print off) position.
The print off position depends on the format. This
position at the impression cylinder determines the
approach of the plate cylinder without touching the
web to be printed. The anilox roll is made to follow
up the plate cylinder however, without touching it.
Print On operation
During the Print On operation, the anilox rolls (2)
approach the plate cylinders (1) for inking. The
plate cylinder and the anilox roll conjointly ap-
proach the impression cylinder (3) for inking the
web to be printed.

X000240054
Print Off operation

During the Print Off operation the anilox rolls (2)
and the plate cylinders (1) get apart and move from
the Print On position to the Print Off position.
Deck-out operation
Deck-out operation means the positioning of all
plate cylinders (1) and anilox rolls (2) involved in
the print job from the Print Off position to the zero
position.
The zero position is the most remote point of the
anilox roll and the plate cylinder from the impres-
sion cylinder (3).
Print On/ Print Off
(1) PRINT ON/ PRINT OFF pushbutton
Press the PRINT ON/ PRINT OFF pushbutton

All of the selected color decks move to the Print
On position.
Press the PRINT ON/ PRINT OFF pushbutton 1
once more.
All of the selected color decks move to the Print
Off position.
Dw__1218

X000240057

Definition
In the printing machine, the web is fed through several individual color decks which are arranged
around the impression cylinder. A color separation is applied to the web in every color deck. The
trapping and separation method is used to generate the final printed image on the web. When printing
multi-color printed images on the web, different color separations must thus be made to coincide.
The printing machine is provided with so-called register adjustments to be able to precisely apply the
color separations to be printed in the different color decks to the web. The color separation offset in
the peripheral direction can be evened out by use of the longitudinal register adjustment. The color
separation offset in the axis direction of the plate cylinders can be evened out by use of the sidelay
register adjustment.
Longitudinal register
Use the color deck select button at the hand-held panel to select the desired color deck.
(1) Register on web

(2) Register on printing plate
(3) Longitudinal register offset
(4) Impression cylinder
(5) Longitudinal register adjustment buttons
at the hand-held panel
In order to even out the longitudinal register offset

(3) between the register on the printing plate (2)
and the register on the web (1), the plate cylinder
drive of the desired color deck accelerates or slows
briefly.
Slowing or accelerating is achieved by actuating
the longitudinal register adjustment buttons (5) at
the hand-held panel.

X000240057
Sidelay register
Use the color deck select button at the hand-held panel to select the desired color deck.
(1) Register on web

(2) Register on printing plate
(3) Adjusting device
(4) Sidelay register adjustment buttons at
the hand-held panel
In order to even out the sidelay register offset be-

tween the register on the printing plate (2) and the
register on the web (1) the plate cylinder of the de-
sired color deck is moved towards the left or the
right (3) within defined limits.
Move the plate cylinder using the sidelay register
adjustment buttons (4) at the hand-held panel. The
work flow direction depends on the location of the
hand-held panel and the software-related assign-
ment of the work flow direction.

X000240063

Layout
DANGER
Danger of explosion from electrostatic charging
Always push the new sleeve onto the nip roll mandrel until it hits the limit stop.
CAUTION
Improper use of compressed air
Improper use of compressed air may cause injuries
Wear safety goggles when working with compressed air.
NOTE
Do not perform a sleeve change unless all drives as well as the anilox roll drives have been switched
off.
Change sleeves only when the nip roll is swung away. Take suitable actions to prevent damage to
the impression roller during a sleeve change from occurring.
If the machine is provided with an optional Easy-Reg system, the sleeve can only be changed if the
Easy-Reg sensor of the first color deck has been brought into the measuring position by hand.
The thickness of the printing plate to be used must not exceed 4 mm.

X000240063
(1) Bolt (2) Fastening screw

(3) Holder (4) Sleeve
Sleeve change
Slackening the fastening screw
(1) Fastening screw

(2) Nip roll mandrel
Slackening the fastening screw (1).

The holder comes off the bearing of the nip roll
mandrel (2).

X000240063
Removing the bolt
(1) Bolt
Pull the bolt (1) in the direction of the arrow.

The connection between the pneumatic cylin-
der and the holder is removed.
Swiveling the holder
(1) Holder
Swivels the holder (1) backwards.

The nip roll mandrel is exposed.

X000240063
CAUTION
Wear safety goggles when working with compressed air.Do not aim compressed air at persons.
(1) Compressed air switch
Compressed air On switch

Air escapes from the nozzles in the mandrel.
Removing the sleeve
DANGER
Danger of explosion from electrostatic charging
Explosions cause extremely serious injuries
Always push the new sleeve onto the nip roll mandrel until it hits the limit stop.
(1) Sleeve
Removes the sleeve
After changing the sleeve, all working steps must be carried out in reverse order to render the machine
operable.
NOTE
Ensure that all screws are properly tightened to prevent damage to the machine from occurring.

X000240075
5.3.5 Ink supply

Requirements:
DANGER
Potentially explosive atmosphere
Conditions to comply with in order to reduce the fire and explosion hazard to a minimum:
The following conditions apply for ink containers used on the machine:
All equipotential bonding cables must be connected.
Keep contact surfaces clean.
Disconnect the ground terminal last when removing the ink container and establish the connection
to the ground terminal first when refitting the ink container.
Only ever use suitable, conductive ink containers made of low-sparking material. Do not use con-
tainers made of aluminimum, titanium or magnesium.
Ink containers provided by the customer must be furnished with connectors for the equipotential
bonding cables to be connected to the machine.
Always keep the covers of the ink containers closed. Only ever open the ink containers for ink
replenishment.
Wear static dissipative shoes.
The following conditions apply for solvent containers used on the machine:
Only ever use suitable, conductive solvent containers made of low-sparking material. Do not use
containers made of aluminimum, titanium or magnesium.
The individual solvent containers on the color decks providing solvents to control the ink viscosity
should only be topped up with the amount of solvent required for one shift.
The solvent containers should be topped up outside the machine.
Solvent containers on color decks not involved in production must not contain any solvents.
Put the solvent pumps out of service.
Keep the lids of the solvent containers closed to prevent volatilizing and thus interference effects
of the ambient air from occurring.
The equipotential bonding cables for the solvent containers provided on the machine must be
connected.
Check equipotential bonding for effectiveness. Reestablish the functionality of equipotential bond-
ing whenever necessary.
To make filling safe, the container to be emptied and the one to be filled must be connected to the
equipotential bonding cable.
The pump and valve unit is connected to the ink hoses in the machine and ready for operation.
The plate cylinder mandrel and the anilox roll mandrel are fitted with the associated sleeves.
The doctor blade unit is completely mounted and installed.

X000240075
Preparatory work
Ink duct
DANGER
Improperly mounted ink ducts
Improperly mounted ink ducts may rub against the anilox roll and cause fires or explosions. Be sure
to mount the ink ducts properly.
NOTE
When working on the upper color decks, make sure that both ladders at front are properly attached
to the mechanism provided for this purpose. Only ever use the ladders provided for this purpose. Two
persons are needed for working on the upper color decks.
(1) Ink duct
Insert the ink duct into the desired color deck.

X000240075
Ink hoses
NOTE
Ink hoses which are not connected to a doctor blade chamber must be engaged to their parking
position and locked in place against slipping off.
(1) Holder
Disconnect the ink hoses of the desired color

deck from the holder.
Leave the ink hoses not used in the holder.
Doctor blade chamber
(1) Ink return hose

(2) Ink supply hose
Connect the ink supply hose (2) and the ink re-
turn hose (1) to the doctor blade chamber.

X000240075
Inking
Continuous rotation
Continuous rotation mode must be ready for operation.
(1) CONTINUOUS ROTATION pushbutton
Press the CONTINUOUS ROTATION push-

button.
The anilox roll rotates.
1
Dw__1193
Doctor blade On/Off
(1) DOCTOR BLADE IN / OUT button
Press the DOCTOR BLADE IN / OUT push-

button.
The doctor blade is swung on to the ailox roll.
Put the respective pump and valve unit into op- 1
eration according to the instructions given.
Dw__1194

X000240075
Setting up the contact pressure for the doctor blade unit
(1) REDUCE DOCTOR BLADE PRES-

SURE
1 3
(2) Display
(3) INCREASE DOCTOR BLADE PRES-
SURE
2
The buttons REDUCE DOCTOR BLADE
PRESSURE (1) or INCREASE DOCTOR
BLADE PRESSURE (3) are used to set up the
contact pressure of the doctor blade unit at the
desired color deck.
Dw__1166
The set contact pressure is shown in the dis-
play (2).

X000240085
NOTE
Before opening the hinged cap bearings on the plate cylinder or the anilox roll, the respective color
deck must be moved into its zero position.
Dw__1167
(1) Hinged cap bearing

X000293750

Lateral splash guard
There is no need to remove the lateral splash guard when changing the sleeve.
(1) Handle Splash guard holder

(2) Hand lever
Pull the handle (1) of the splash guard holder

forwards.
The lateral splash guard is removed from the
anilox roll sleeve. The bearing can be pivoted.
Loosen the hand lever (2).
Opening the bearing
(1) Handle
Use the handle (1) to pull the bearing back until

it hits the stop.
Swivel the bearing away from the mandrel.

X000293750
Changing the sleeves (color decks 1-4)
WARNING
Cutting blades, knives or sharp-edged machine parts
Risk of severe gashes from cutting blades, knives or sharp-edged machine parts.
Safety devices must never be bypassed. Wear cut-proof gloves.
CAUTION
Hot surfaces
Risk of burning your skin when getting in contact with hot surfaces.
Wear safety gloves, safety shoes and long-sleeved clothing. Keep a safe distance. Keep away sub-
stances with low ignition temperatures.
CAUTION
CAUTION
Rotating rollers
Pay attention to the instruction plate.Be sure to position your hands correctly.
NOTE
Pushers must be used only when in their zero position. This mode must never be used during running
production.
The pusher should be used only when the respective mandrel is pressurized.
NOTE
The anilox roll sleeve and the anilox roll mandrel are provided with a rotation direction arrow. Push
on the anilox roll sleeve so that the rotational direction arrows of the anilox roll sleeve and the anilox
roll mandrel point in the same rotational direction.
The rotational direction of the anilox roll mandrel and the impression roller is the same.

X000293750
(1) ANILOX ROLL MANDREL COM-

PRESSED AIR ON button
Press the ANILOX ROLL MANDREL COM-

PRESSED AIR ON (1) button.
Air escapes from the nozzles of the anilox roll
1
mandrel.The LED in the button flashes green.
Hold down the ANILOX ROLL MANDREL
COMPRESSED AIR ON (1) button.
The forcing aid causes the anilox roll sleeve to
be pushed several centimeters down the man-
Dw__1255
drel. The LED in the button flashes green.
Remove the anilox roll sleeve from the anilox
roll mandrel.
Push the new anilox roll sleeve onto the anilox
roll mandrel until it hits the stop.
The anilox roll sleeve must be arranged in a
specified position on the anilox roll mandrel.
After pushing on the new anilox roll sleeve.
press the ANILOX ROLL MANDREL COM-
PRESSED AIR ON button.
The anilox roll mandrel is deflated. The LED in
the button goes dark.

X000293750
Changing the sleeve (color decks 5-8)
(1) ANILOX ROLL MANDREL COM-

Press the ANILOX ROLL MANDREL COM-

PRESSED AIR ON (1) button.
Air escapes from the nozzles of the anilox roll
1
mandrel.The LED in the button flashes green.
Hold down the ANILOX ROLL MANDREL
The forcing aid causes the anilox roll sleeve to
be pushed several centimeters down on the
Dw__1256
mandrel. The LED in the button flashes green.
Remove the anilox roll sleeve from the anilox
roll mandrel.
Push the new anilox roll sleeve onto the anilox
roll mandrel until it hits the stop.
The anilox roll sleeve must be arranged in a
specified position on the anilox roll mandrel.
After pushing on the new anilox roll sleeve.
press the ANILOX ROLL MANDREL COM-
PRESSED AIR ON button.
The anilox roll mandrel is deflated. The LED in
the button goes dark.

X000293730

Releasing the interlock
WARNING
The combination of a non conductive adaptor and a conductive sleeve is forbidden.
WARNING
The bleeder resistance of the sleeve - carrier cylinder combination or the sleeve - adaptor - carrier
cylinder combination measured from the sleeve surface to the grounded conductive carrier cylinder
should be less than 106 Ohm.
(1) Hand lever

(2) Handle
Loosen the hand lever (1).

Use the handle (2) to pull back the bearing until
it hits the stop.
Opening the bearing
(1) Handle
Swivel the bearing at the handle (1) away from

the mandrel,

X000293730
Positioning the plate cylinder sleeve
The plate cylinder sleeve must be arranged in a specified position on its mandrel. It is provided with
a locking groove for this purpose. A locking pin is found on the mandrel as a mounting aid. The plate
cylinder sleeve is properly mounted if the locking pin of the mandrel is located in the locking groove.
(1) Locking groove

(2) Locking pin
When pushing on the plate cylinder sleeve

make sure that the locking pin (2) is located in
the groove (1).

X000293730
Changing the plate cylinder sleeve (color decks 1-4)
WARNING
Cutting blades, knives or sharp-edged machine parts
Risk of severe gashes from cutting blades, knives or sharp-edged machine parts.
Safety devices must never be bypassed. Wear cut-proof gloves.
CAUTION
Hot surfaces
CAUTION
CAUTION
Rotating rollers
Pay attention to the instruction plate.Be sure to position your hands correctly.
NOTE
Pushers must be used only when in their zero position. This mode must never be used during running
production.
The pusher should be used only when the respective mandrel is pressurized.
(1) PLATE CYLINDER MANDREL COM-

Press the PLATE CYLINDER MANDREL

Air flows out of the nozzles of the plate cylinder
1
mandrel. The plate cylinder can be pushed on
or removed. The LED lights up green.
Hold down the PLATE CYLINDER MANDREL
Dw__1257

X000293730
The forcing aid causes the plate cylinder

sleeve to be pushed several centimeters down
the mandrel. The LED in the button flashes
green.
Remove the plate cylinder sleeve from the
plate cylinder mandrel.
Push the new plate cylinder sleeve onto the
plate cylinder mandrel until it hits the stop.
The plate cylinder sleeve must be arranged in
a specified position on the plate cylinder man-
drel.
After pushing on the new plate cylinder sleeve,
press the PLATE CYLINDER MANDREL
COMPRESSED AIR ON button.
The plate cylinder mandrel is deflated. The
LED in the button goes dark.
Changing the plate cylinder sleeves (color decks 5-8)
(1) PLATE CYLINDER MANDREL COM-

Press the PLATE CYLINDER MANDREL

1
mandrel. The plate cylinder can be pushed on
or removed. The LED lights up green.
Hold down the PLATE CYLINDER MANDREL
The forcing aid causes the plate cylinder
Dw__1258
sleeve to be pushed several centimeters down
on the mandrel. The LED in the button flashes
green.
Remove the plate cylinder sleeve from the
plate cylinder mandrel.
Push the new plate cylinder sleeve onto the
plate cylinder mandrel until it hits the stop.
The plate cylinder sleeve must be arranged in
a specified position on the plate cylinder man-
drel.
After pushing on the new plate cylinder sleeve,
press the PLATE CYLINDER MANDREL
COMPRESSED AIR ON button.
The plate cylinder mandrel is deflated. The
LED in the button goes dark.

X000293730
Sleeve change onto the plate cylinder adaptor (color decks 1-4)
A print repeat length greater than 500 millimeters requires an adaptor and a sleeve. The adaptor is
mounted just like a plate cylinder sleeve is.
The sleeve must be arranged in a specified position on its adaptor. It is provided with a locking groove
for this purpose. A locking pin is found on the adaptor as a mounting aid. The sleeve is then correctly
mounted if the locking pin of the adaptor is located in the locking groove.
(1) PLATE CYLINDER ADAPTOR COM-

Press the PLATE CYLINDER ADAPTOR

COMPRESSED AIR ON 1button.
1
adaptor. The LED in the button flashes green.
Remove the sleeve from the plate cylinder
adaptor or push it onto the plate cylinder adap-
tor.
The adaptor sleeve is to be arranged on the
Dw__1159
plate cylinder adaptor like on a plate cylinder
sleeve.
The plate cylinder adaptor is deflated. The LED
goes dark.

X000293730
Sleeve change onto the plate cylinder adaptor (color decks 5-8)
A print repeat length greater than 500 millimeters requires an adaptor and a sleeve. The adaptor is
mounted just like a plate cylinder sleeve is.
The sleeve must be arranged in a specified position on its adaptor. It is provided with a locking groove
for this purpose. A locking pin is found on the adaptor as a mounting aid. The sleeve is then correctly
mounted if the locking pin of the adaptor is located in the locking groove.


1
adaptor. The LED in the button flashes green.
Remove the sleeve from the plate cylinder
adaptor or push it onto the plate cylinder adap-
tor.
The adaptor sleeve is to be arranged on the
Dw__1260
plate cylinder adaptor like on a plate cylinder
sleeve.
The plate cylinder adaptor is deflated. The LED
goes dark.

Instructions on CRP adaptors
NOTE
When a damage to the CRP adaptors may have occurred due to inadmissible stress conditions within
or outside the printing press (web wound around the printing cylinder after a web break or similar
stresses), the former parts must individually be taken out of the machine one by one.
In the event of a fault as described above, the operating company is obliged to check the CRP adaptor
for possible deformations and cracks in the first place and to adhere to the adaptor manufacturer's
instruction manual. Additionally, the remaining adjacent machine components must be checked for
possible damages or mistadjustments.

X000293739
Hydraulics - Adaptor
Settings at Procontrol
(1) ADAPTOR TYPE choice box
Touch the ADAPTOR TYPE (1) choice box and

select the adaptor.
Entry 0: pneumatically clamping adaptor
Entry 1: hydraulically clamping adaptor
Pushing on or removing a sleeve
Pushing on and clamping an CRP / aluminium adaptor in place
For safety reasons, a sleeve change within the machine must only be carried out with confined hy-
draulic pressure between the hybrid shaft and the adaptors.
When the hydraulic clamping device is released, the air supply to the adaptor sleeves must be
switched off.
(1) Pneumatic screw driver
Push the CRP or aluminium adaptor onto the

hybrid shaft using the clamping slot.
Use the pneumatic screw driver (1) to clamp
the CRP or aluminium adaptor in place.

X000293739
Pushing on the sleeve (color decks 1-4)


Air escapes from the adaptor nozzles.
1
Push the adaptor sleeve onto the adaptor ac-
cording to the locating groove.
The air escaping from the adaptor nozzles is Dw__1159
switched off.
Pushing on the sleeve (color decks 5-8)


1
Push the adaptor sleeve onto the adaptor ac-
cording to the locating groove.
The air escaping from the adaptor nozzles is Dw__1260
switched off.

X000293739
Removing the sleeve (color decks 1-4)
The following sequence:
1. Remove the sleeve
2. Switch off the compressed air supply to the adaptor sleeve
3. Remove the adaptor
must be strictly observed.


1
Remove the adaptor sleeve
The air escaping from the adaptor nozzles is
switched off. Dw__1159

X000293739
Removing the sleeve (color decks 5-8)
The following sequence:
1. Remove the sleeve
2. Switch off the compressed air supply to the adaptor sleeve
3. Remove the adaptor
must be strictly observed.


1
Remove the adaptor sleeve
The air escaping from the adaptor nozzles is
switched off. Dw__1260
Releasing the CPR / aluminium adaptor
(1) Pneumatic screw driver
If necessary, use the pneumatic screw driver

(1) to release the CRP or aluminium adaptor
and take it out of the machine.

X000132184

Opening the safety guard on the web infeed side
Pneumatic button
(1) Pneumatic button
Press the pneumatic button (1).
Safety guard
After approx. ten seconds the safety guard will be depressurized and lowers down.
(1) Safety guard
The safety guard (1) swivels upwards and the

area behind the safety guard can be entered..
After approx. ten seconds the safety guard will
be depressurized and lowers down.If the pneu-
matic button is pressed again while the safety
guard lowers down, the safety guard swivels
upwards again.

X000132184
Opening the safety guard on the web outfeed side
Opening the safety guard
(1) Safety guard
Push the safety guard (1) upwards and enter

the area behind the safety guard.
After releasing the safety guard, the guard
slowly lowers down in its home position.

X000113225

Overview of the control elements
Overview
(1) Roll up doors (2) Interior control elements on the color

deck page 1-4 (1-5) and the color deck
page 5-8 (6-10)
(3) External control elements on scissor lift-
ing table (accessible from the scissor lift-
ing table)

X000113225
Safety devices
WARNING.
Rotating rollers
Parts of your body, clothes, hair and objects will be pulled in and crushed.
Keep a safe distance. It is forbidden to remain behind the closed roll up door.
(1) Light barrier
The area behind the roll up door is monitored by a

light barrier (1). If this area is entered while the roll
up door is descending then the movement is stop-
ped and the roll up door moves back to its upper
end position.
(1) Terminal strip
A terminal strip is attached to the bottom of the roll

up door. If the terminal strip is actuated while the
roll up door is descending then the movement is
stopped and the roll up door moves back to its up-
per end position.
(1) Button ROLL UP DOOR OPEN

(2) Button ROLL UP DOOR STOP
Control elements for stopping the movement and

opening the roll up door are located on the color
deck side 1-4 (1-5) and the color deck side 5-8
(6-10) in the area behind the roll up door.

X000113225
Operation
NOTE
Never attach other than the service carts supplied by W&H to the lift table. Overloading may occur if
the load protrudes too far.
The total load on all service cart mandrels must not exceed 264 kg.
Only materials required for a sleeve change must be transported or deposited on the lift table. Clear
the lift table after finishing the works.
Prevent projection of the sleeve after a sleeve change. Always push the sleeves onto the mandrel
until it hits the limit stop or push it off the mandrel completely.
Load the service cart for the upper color decks as follows:
3 anilox roll sleeves
3 adaptors
3 plate sleeves
(1) Open door

(2) Stop door
(3) Close door
Press the OPEN DOOR pushbutton (1).

The roll up doors move upwards into the end
position.
Press the STOP DOOR pushbutton (2).
The roll up doors are being stopped.
Press the CLOSE DOOR pushbutton (3).
The roll up doors move downwards into the end
position.

X000113225
Operating the roll up door in the event of power failure
(1) Adapter
(2) Adapter opening on the roll up door drive
Remove adapter (1) from the holder on the

drive.
Insert adapter (1) into the adapter opening on
the roll up door drive (2).
Turn the adapter (1) with a matching socket
wrench and move the roll up door to the desired
position.
Remove adapter (1) from the adapter opening
on the roll up door drive (2) and insert into the
holder on the drive.

Z WINDMLLER & HLSCHER 5 Operation | Web guide control unit

5.4.1 Web guide control.............................................................................................................2
Function.........................................................................................................................2
Control elements............................................................................................................3

5 Operation | Web guide control unit Z WINDMLLER & HLSCHER
X000287997

Function
The figure serves as a schematic of the web guide control components. The web guide controls on
the machines may not be the same as shown in the figure.
(1) Sensor heads (2) Servo drive

(3) Control unit (4) Pivoting frame
One or several sensor heads detect the position of the web and transfer the respective data to the
control unit. The control unit checks the measured position against the given value. If there is a
difference the control unit sends a corresponding correction signal to the servo drive. The servo drive
moves the pivoting frame and the web is repositioned properly.
Possible control modes (depending on the machine layout)

Web guide control Sensor head control as per the left or right web edge
Web center guide Control as per the web center using two sensor heads

Z WINDMLLER & HLSCHER 5 Operation | Web guide control unit
X000287997
Possible control modes (depending on the machine layout)

Contrast control Control as per the continuous line, the broken imprinted line or the contrast
edge
Control elements
Web guide control On / Off
Go to screen page 5 in Procontrol.
(1) WEB GUIDE CONTROL ON / OFF but-

ton
(2) CONTROL MODE button
Press the WEB GUIDE CONTRON ON/OFF

button for the desired web guide control sys-
tem.
Web guide control is switched on. Depending
on the selected mode, one or both the sensor
heads move towards the web. Once the sensor
heads have reached the web, controlling is en-
abled and the pivoting frame is free to move. If
no web transport takes place, the control mode
of the pivoting frame is blocked.
Touch the CONTROL MODE (2) list box.
Select the desired control mode.
Press the WEB GUIDE CONTROL ON/OFF
switch once more.
Web guide control is switched off. The sensor
heads move to the extreme limit position and
the pivoting frame is centered.

5 Operation | Web guide control unit Z WINDMLLER & HLSCHER
X000287997
Changing the control mode in the Main screen page
(1) Web guide control mode after the unwind

(2) Web guide control mode prior to the re-
wind
Change the control mode for the desired web

guide control.
Adjusting the sensor head
The buttons and the display are integrated in the operator panels for the rewind and unwind.
(1) SENSOR HEAD ADJUSTMENT PUSH-

BUTTON
1 2 1
(2) DISPLAY
Press the SENSOR HEAD ADJUSTMENT

pushbutton (1) for the desired direction.
The sensor head is moving in the desired di-
rection while holding down the pushbutton. At
the same time, the web is shifted by use of the
control system. For this, the web guide control
must be switched on. If there is no web trans-
port, the sensor head adjustment is blocked. Wic_0466
The actual value of the sensor head adjust-
ment is shown in the display (2).

Z WINDMLLER & HLSCHER 5 Operation | Nip rolls
5.5 Nip rolls

5.5.1 Operating the nip rolls.......................................................................................................2
Arrangement of the nip rolls...........................................................................................2
User interface for the nip rolls........................................................................................3

5 Operation | Nip rolls Z WINDMLLER & HLSCHER
X000309509

Arrangement of the nip rolls
The figure only serves as a schematic diagram of the nip rolls in the machine.The representation may
not come up to reality on your machine.
1 2
3 4
All_0134
(1) Nip roll Impression cylinder (2) Nip roll Draw Unwind
(3) Nip roll Draw Cooling roller (4) Lay-on roller Rewind

Z WINDMLLER & HLSCHER 5 Operation | Nip rolls
X000309509
User interface for the nip rolls
The user interface is located on page 22 in Procontrol.
1 2 3
7 6 5 4
Wic_0328

(1) Draw Nip roll On Swings in the nip roll at the draw downstream of the unwind
(2) Impression cylinder Nip Swings in the nip roll at the impression cylinder
roll On
(3) Draw Chill roll Contact Swings in the nip roll at the chill roll draw
pressure
(4) Draw Chill roll Contact Used to set up the contact pressure of the nip roll at the chill
pressure roll draw.
(5) Impression cylinder Drive Drive side: Used to set up the contact pressure of the nip roll
side Contact pressure at the impression cylinder.
(6) Impression cylinder Op- Operator side: Used to set up the contact pressure of the nip
erator side Contact pres- roll at the impression cylinder.
sure
(7) Draw Contact pressure Used to set up the nip roll at the draw downstream of the un-
wind

5 Operation | Nip rolls Z WINDMLLER & HLSCHER
X000309509

Z WINDMLLER & HLSCHER 5 Operation | Easy-Set
5.6 Easy-Set
5.6.1 Safety instructions.............................................................................................................2

Layout............................................................................................................................3
Function.........................................................................................................................4
5.6.3 Automatic functional steps and messages........................................................................5

Functional steps.............................................................................................................5
Messages......................................................................................................................5
5.6.4 Material requirements and technical specifications...........................................................6

Material requirements....................................................................................................6
Technical specifications.................................................................................................7
5.6.5 Requirements and operation.............................................................................................7
5.6.6 EASY-TOPO.....................................................................................................................8
Function.........................................................................................................................8
EASY-TOPO display screen..........................................................................................9
Changeover to EASY-TOPO.........................................................................................9
Buttons in the top line..................................................................................................10
Selecting the cylinders.................................................................................................10
Setting up the viewport and the type of view...............................................................11
5.6.7 EASY-SET S...................................................................................................................12

Function and requirements for use..............................................................................12
Operation.....................................................................................................................12
5.6.8 Quick reference guide.....................................................................................................15

5 Operation | Easy-Set Z WINDMLLER & HLSCHER
X000277015
WARNING
Camera box
Open the box only when the machine is at a standstill.
CAUTION
Bright light source
Bright light sources cause impaired vision.
Never look directly into the light source. Open the box only when the machine is at a standstill.

X000196985

Layout
CAUTION
Risk of injury from rotating rollers.
The EASY-SET HD unit may only be swiveled away when the machine is at a standstill.
EASY-SET in the working state
(1) Support and web guide unit

(2) Crank handle for swinging the unit in and
out
EASY-SET in the swung out state (maintenance

work)
(1) Two or three image recording units

(2) Background lighting

X000196985
Function
EASY-SET HD defines an optimal printing pressure for the color deck. The process takes place in
two steps.
When EASY-SET HD is selected, the gap between the inked-up plate cylinder and the substrate is
set first. To do this, the printing gap is modified continually until a stable ink transfer between the plate
cylinder and the web to be printed is ensured. Set the inking gap between the anilox roll and the plate
cylinder so that an ink transfer between the plate cylinder and the web to be printed barely exists.
Both steps in the process are carried automatically without any action of the operator. During proof
printing, settings are disabled for the drying systen, the web guide control, the machine speed as well
as the printing pressure for the color decks and register settings.
The progress of proof printing is displayed under "Status" on screen page 35 on Procontrol. After
proof printing has ended, the determined impression pressures are saved and the machine moves
into its printing position.
Automatic proof printing for all of the pre-selected color decks may be canceled at any time by stop-
ping the machine. For aborting proof printing shall for one single color deck, select the 'Print Off' mode
at the hand-held panel for the respective color deck.
The waste run and time requirements depend on:

the number of involved color decks
the print repeat length

X000196988

Functional steps
Proof printing using the EASY-SET HD system is subdivided in several functional steps (phases)
which are being displayed for every selected color deck on screen page 34 on Procontrol.
Phases
Phase 1: Initialization Material requirements check for successful proof printing with EASY-
SET HD.
Phase 2: Measuring run 1 Determination of the precise impression pressure point for the printing
(Plate cylinder impression gap.
pressure)
Phase 3: Measuring run 2 Determination of the precise impression pressure point for the inking
(Anilox roll impression gap.
pressure)
Phase 4: EASY-REG D When EASY-REG D is selected, the system automatically goes to
option screen page 32, EASY-REG D. The operator is requested to select
the EASY-REG halftone dots in the printed images displayed.
The dots should be selected as quickly as possible to prevent unnec-
essary waste.
For further information on the EASY-REG D system please refer to
the relevant operating instructions.
Phase 5: Completion An acoustic signal indicates the completion of the proof printing proc-
ess.
Messages
If EASY-SET HD has finished or canceled the proof printing process, a corresponding message is
displayed in Procontrol and in most cases an acoustic signal is sounded in addition.
After successful proof printing the choice boxes for the color decks are displayed in green. If a fault
has occurred the choice boxes for the color decks are displayed in red.
The reason for canceling will be displayed in Procontrol if EASY-SET HD has canceled the proof
printing process. Help texts associated with the message give additional information.

X000196991

Material requirements
Supported materials
Opaque (non-transparent) substrate yes
Transparent substrate yes
Metallized substrate to be agreed upon with W&H
Further substrates to be agreed upon with W&H
Tubular materials no
Material properties
The substrate must be visually unique (no ink changes in the material).
The substrate must be unprinted on both sides.
The substrate must be free of holes, dents and kinks.
The substrate must lie wrinkle-free against the impression cylinder.
The substrate must pass the cameras wrinkle-free.
Inks and lacquers

Low-contrast inks and lacquers are not supported.
Adapt the proof printing speed to the ink's drying properties.
Printing plate layout

EASY-SET HD supports the layout which is typical for flexo printing, consisting of impression cyl-
inder, adapter, sleeve, adhesive tape and printing plate.
Improperly mounted printing plates affect the results of EASY-SET HD.
Example: Turned-up edges or air bubbles
Minimum printing block layout 1.14 millimeters (printing plate) + 0.55 millimeters (ad-
hesive tape) = 1.69 millimeters
Motif
For proof printing all image elements greater than 5 x 5 mm 2 will be considered.
Fine screens, especially those of low-contrasty inks will not be supported.

X000196991
Technical specifications
Visual image resolution

Resolution approx. 85 dpi (300 micrometers)
Impression pressure accuracy

At 50 micrometers first flaws in the printed image become visible
Proof printing speed

120 m/min

Selecting the proof printing method
The machine is at a standstill.

Go to screen page 34.
(1) PROOF PRINTING choice box

(2) List of proof printing methods
Press the PROOF PRINTING (1) choice box.

Select the EASY-SET HD proof printing meth-
od from the list (2).
Selecting the substrate (material)
(1) MATERIAL choice box

(2) List of materials
Press the MATERIAL (1) choice box.

Select the required material from the list (2).
As options, the list contains at least a non-
transparent substrate, a transparent substrate
and a special coordinated substrate. If re-
quired, user-specific substrates can be dis-
played.

X000196994
Selecting optional register methods
(1) REGISTER choice box

(2) List of register methods
Press the REGISTER (1) button.

Select the required register method from the
list (2).
Selecting and starting the color decks
(1) COLOR DECKS choice box

(2) START SETTING button
Activate the desired color decks by pressing

the choice boxes (1).
All color decks should have the same print re-
peat length.
Press the START SETTING (2) button.
EASY-REG D and EASY SET HD setting is
started for all active color decks.
Pay attention to the messages on the screen.
5.6.6 EASY-TOPO
Function
EASY-TOPO serves to check the proof print results of EASY-SET D and the printing plates in use.
The measurement results recorded during proof printing with EASY-SET HD are diagramed by EASY-
TOPO on the EASY-VIEW monitor.
The topology of the printing plate is either displayed as the top view, a stationary 3D view or a rotating
3D view.

X000158669
EASY-TOPO display screen
(1) Top line (2) Scale for depicting the contact pressure
(3) Depiction of the printing plate topology (4) Overview of printed image
(5) Control panels for viewport
A false color representation is provided for the operator depicting the proof printing behavior on the
selected color deck, red sections presumably indicate that printing pressure may be too high.
Changeover to EASY-TOPO
(1) EASY-TOPO button
Pressing the EASY-TOPO (1) button on the EASY-

VIEW display screen gets you to the EASY-
TOPO display screen.

X000158669
Buttons in the top line
(1) SERVICE button

(2) EASY-VIEW button
(3) HELP button
Pressing the SERVICE (1) button gets you to the

service pages. The service pages are protected by
a password and cannot be accessed by the user.
Pressing the EASY-VIEW (2) button gets you back
to the EASY VIEW display.
When pressing the HELP (3) button a help text ap-
pears for a control element selected afterwards.
Selecting the cylinders
(1) COLOR DECK NUMBER button

(2) ANILOX ROLL button
(3) PLATE CYLINDER button
Press the COLOR DECK NUMBER (1) button to

select the color deck to be displayed.The display
will only show the numbers of those color decks
which have been used for proof printing with
EASY-SET.
The PC (Plate cylinder) (3) or AR (Anilox roll) (2)
buttons are used to determine whether either the
contact pressure of the plate cylinder or that of the
anilox roll is to be displayed.
The color deck buttons as well as the plate cylinder
or anilox roll buttons are displayed in different col-
ors. These colors correspond with the range from
the first contact of the cylinder (kiss print) to the
perfect printout printing pressure whereby the col-
or gradient goes from green to red. The darker the
red color on the screen, the longer will it take to
built up the complete printed image.

X000158669
Setting up the viewport and the type of view
(1) Scale
(2) Topology card as per the view selected
(3) Overview of printed image
(4) Buttons for selecting the view
The viewport has three sections. A scale (1) on the

left-hand side depicts the correlation between
false colors and the pressure (measured in m
from the print pressure position). On the right-hand
side an overview display depicts the currently se-
lected cylinder in the color to be used for printing.
The beginning of the print repeat in the depiction
can be selected by clicking on the overview screen
(3).
The main section of the viewport shows the topol-
ogy cards in the 2D or 3D view selected. The 3D
view is to be seen as a plate configuration, where
protruding details make contact at the slightest
printing pressures (these parts will be pressed
more and are depicted in red), details at a lower
level require high printing pressures for printing
(they will never be exposed to overpressure and
are always shown in green).
The view of the printing plate can be selected by
use of the respective button (4). View options::
Top view (2D) depicted in false colors
Stationary 3D view
Rotating 3D view
The 3D view orientation depicts the overview dis-

play (3) and is rotated according to the topology
card selected.

X000165600
5.6.7 EASY-SET S
Function and requirements for use
By reducing the printing gap between the plate cylinder and the impression cylinder incrementally,
EASY-SET S determines the point at which the plate cylinder and the impression cylinder make
contact. EASY-SET S recognizes the resistance at this point and the plate cylinder movement is
stopped immediately. This procedure prevents damage to the printing plate from occurring, even if
the machine is at a standstill. The anilox roll is moved parallel to the plate cylinder. An additional
printing impression value (preset value) determined and preset by the operator beforehand is added
to these position values. The proof printing result decisively depends on the printing plate used.
For proper functioning of the Easy-Reg S system, the following conditions must be fulfilled:
The machine must be ready for production.
The color decks that will be needed must have been set up.
The correct plate size must have been entered.
The printing plate must correspond to the default values.
The measurement run must be started from the pre-print position.
Operation
The displayed screen pages show the maximum enhancement to EASY-SET S. The screen pages
on the machine may differ from this.
Entries in the visual display unit

(2) COLOR DECK
Select EASY-SET S from the PROOF PRINT-

ING (1) choice box to select the color decks for
proof printing using the respective buttons (2).
The schematic display of the plate cylinder
turns from gray to green.

X000165600
Selecting optional register methods
Select the required register method (EASY-

REG S) from the REGISTER (1) choice box.
Starting the measurement cycle
During the measurement cycle, the plate cylinder is moved until it touches the rotating impression
cylinder. This guarantees that the printing plates are not damaged during the measurement cycle.

(2) PRESET button
Start the measurement cycle by pressing the

START SETTING (1) button.
After starting the measurement cycle, the
"Main drive On" message appears. The ma-
chine must be switched on and the machine
starts to rotate. The measurement takes ap-
prox. 4 minutes. The EASY-SET S settings are
complete when the color of all the pre-set plate
cylinders schematically displayed on the
screen has changed from magenta to green.
Check the printed image after the measure-
ment cycle has ended. If necessary, increase
the printing pressure values by pressing the
respective PRESET (2) buttons and start a new
measurement cycle.

X000165600
Setting preset values
The preset values are rule-of-thumb values and must be determined by the operator.
(1) PRESET entry fields
Enter the desired preset values in the entry

fields (1).
Entries on screen page 105 can only be made
after entering the customer password.

X000142494
The machine is at a standstill and the color decks are in their zero or pre-print position.
The process takes place sequentially, i.e. the register position is defined first and the proof printing
position is to be determined afterwards.

(2) Color decks choice box
Select the proof printing method EASY-SET S

from the REGISTER (1) choice box.
Press the choice boxes for the desired color
decks (2).
Select the proof printing method EASY-SET D
from the PROOF PRINTING (3) choice box.
You can select 'EASY-SET D' or 'EASY-SET D
Fast'. When using 'EASY-SET D', the plate cyl-
inder position and the anilox roll position are
measured and when using 'EASY-SET D Fast',
only the anilox roll position is measured.
decks (4).
Press the START SETTING pushbutton (5).
Pay attention to the messages and start the
main drive on demand.
The speed is approx. 2m/min.
Pay attention to the messages and switch on
the drying system on demand.
The machine speeds up to approx. 120 m/min.
When reaching the set temperature, the proof printing position for the selected color decks is set
automatically . If a fault occurs, the machine is stopped. When proof printing is successful the machine
remains in production.

X000142494

Z WINDMLLER & HLSCHER 5 Operation | Easy-Reg
5.7 Easy-Reg
5.7.1 How to operate EASY-REG S...........................................................................................2
Switching on requirements............................................................................................2
Operation.......................................................................................................................2
Register label.................................................................................................................4
5.7.2 Quick reference guide.......................................................................................................6

5 Operation | Easy-Reg Z WINDMLLER & HLSCHER
X000142222

Switching on requirements
For proper functioning of the Easy-Reg S system, the following conditions must be fulfilled:
The color decks that will be needed must have been set up.
The correct plate size must have been entered.
The register labels must have been correctly pasted on relative to the printing plate.
We recommend to start register setting from the color decks' zero position.
Operation
How to start Easy-Reg S
The color deck moves into the measuring position, the plate cylinder rotates and the longitudinal and
sidelay register positions are determined.
(1) COLOR DECK choice box

Select the desired color decks via the choice

boxes (1).
Start the EASY-REG S setting via the START
SETTING (2) button.
The longitudinal and sidelay registers are de-
termined by measuring the register labels.
The duration of the measurement run depends
on the machine type. During the measurement
run the plate cylinders are depicted in magenta
on the screen in a schematic manner. After the
measurement run has ended successfully, the
color turns green and the color decks are in
their pre-print position.

X000142222
Selecting the optional proof printing method
(1) List box PROOF PRINTING METHOD

(2) List of proof printing methods
Press the button PROOF PRINTING METH-

OD (1).
Select the required proof printing method from
the list (2).
Swinging the sensor manually
For cleaning, it must be possible to swing the sensor in its measuring position manually.
(1) COLOR DECK

(2) Button FOLD OUT SENSOR
(3) Button START DECK-OUT
(4) Message window
Switch on the desired color deck (1).

Press the button FOLD OUT SENSOR (2).
Press the START DECK-OUT (3).
Carry out the action prompted in the message
window (4) and confirm with OK.
The sensor moves in its measuring position.

X000142222
Register label
For proper use of the Easy-Reg system the pressure-sensitive register labels must be exactly posi-
tioned on the sleeve by using a plate mounter.
(1) Register label (2) Sleeve on the drive side

(3) Printing plate (4) Easy-Reg sensor
(A) Distance between the outer sleeve edge (B) Possible distance between the microdot
(drive side) and the center of the register of the printing plate and the center of the
label register label in the sidelay register.
(C) Possible distance between the microdot (D) Reference line for the pregister position
of the printing plate and the center of the
register label in the longitudinal register.
In order to facilitate register label pasting the protective film across the pasting surface is split in three.

X000142222
When beginning to peel off the register label (1) from the side, the two outer protective films remain
on the label. The central part (2) of the protective film is removed. The register label can now be
positioned above the sleeve without sticking on the plate mounter. Once the correct position has been
reached the central pressure-sensitive part is being pressed on the sleeve. The register label is fixed,
the remaining two protective films can be peeled off and the register label be finally attached.
The register label is being applied parallel to the outer sleeve edge by using the center line cross.
The cross line (1) of the plate mounter as shown in the image should be aligned to the label's center
line cross. The midpoint of the register label's reference point is found on the reference line (D). The
distance (A) for each printing width is determined once again. The distance is the result of the related
sleeve length minus 5 millimeters
The plate to be mounted should be aligned taking the microdots relative to the register label as a
reference. The distances (B) and (C) to the microdot can be selected to choice andshould be within
a tolerance range of +/- 0.01 millimeters for each sleeve to be used for the relevant job.

X000142494
The machine is at a standstill and the color decks are in their zero or pre-print position.
The process takes place sequentially, i.e. the register position is defined first and the proof printing
position is to be determined afterwards.

Select the proof printing method EASY-SET S

from the REGISTER (1) choice box.
decks (2).
Select the proof printing method EASY-SET D
from the PROOF PRINTING (3) choice box.
You can select 'EASY-SET D' or 'EASY-SET D
Fast'. When using 'EASY-SET D', the plate cyl-
inder position and the anilox roll position are
measured and when using 'EASY-SET D Fast',
only the anilox roll position is measured.
decks (4).
Press the START SETTING pushbutton (5).
Pay attention to the messages and start the
main drive on demand.
The speed is approx. 2m/min.
Pay attention to the messages and switch on
the drying system on demand.
The machine speeds up to approx. 120 m/min.
When reaching the set temperature, the proof printing position for the selected color decks is set
automatically . If a fault occurs, the machine is stopped. When proof printing is successful the machine
remains in production.

Z WINDMLLER & HLSCHER 5 Operation | Easy-View
5.8 Easy-View
5.8.1 Easy-View.........................................................................................................................2
Introduction....................................................................................................................2
Monitor...........................................................................................................................3
Image display in the main viewport................................................................................6
Camera setting..............................................................................................................8
Lighting settings...........................................................................................................10
Switching on image enhancement...............................................................................12
Switching on the splitscreen function...........................................................................14

5 Operation | Easy-View Z WINDMLLER & HLSCHER
X000075640
5.8.1 Easy-View
Introduction
Easy-View is used to monitor the printed web on a large-scale monitor. The entire print width is shown.
Easy-View is an enhancement to Easy-Set-D, uses the installed cameras of the Easy-Set D system
for displaying the images and is operated on the main control panel using a computer mouse.
The camera system consists of 2 to 3 linear cameras depending on the width of the machine. Each
linear camera covers a web width of 680 millimeters. Easy-View compiles the individual images of
the cameras to a complete image.
The camera resolution is 0.3 millimeter per pixel element. This is equivalent to about 33 pixels per
centimeter or 85 pixels per inch. The camera supplies about one image per second. The image
repetition rate can vary with the web speed, the print repeat length and the selected enlargement
stage.
At the transition points of the cameras visible image faults can occur which can be cleared by the
image enhancement function (shading correction.
Whereas other modules (for example, Easy-Set D) control the cameras, the camera control functions
of Easy-View are deactivated and a signal field is displayed in the overview bar. Once the access of
the modules to the cameras is finished (for example, after completing the automatic print by Easy-
Set D), the camera functions for Easy-View are reactivated once again.
Detailed information on the respectrive control panels are displayed in the country language using
the control panel ONLINE HELP (question mark) in the top line of the monitor.

X000075640
Monitor
(1) Top line (2) Main viewport

(3) Toolbar (4) Control panel for the main viewport
(5) Overview window
If selection fields are activated, the color of the selection fields turns from light gray to dark gray.
In the main viewport (2) the image of the web is displayed as desired (fitted in, zoomed or at original
size). The complete print repeat length of the web is shown in the overview window.

X000075640
Top line
(1) Selection field Service mode

(2) Display Easy-View state
(3) Display Image updating
(4) Selection field Online help
(5) Display Printed web
(6) Display Machine speed
The Service mode can be changed over via the

selection field (1). The service mode is protected
by a password and cannot be accessed by the
user.
The signal lamp (2) indicates the Easy-View state.
If the signal lamp lights up green, Easy-View has
access to the Easy-Set D cameras, if the signal
lamp lights up yellow, Easy-View cannot access
the cameras (e.g. if an EasySet D proofing process
is under way).
The symbol in the display field (3) turns if the cam-
eras send images to the Easy-View system and
the image in the main viewport is updated.
If the selection field Online help (4) is activated the
help information referring to other selection fields
is faded in. The following applies: The Online help
should be activated first and then the field on which
information is required.
The display field (5) shows the Easy-View web
counter. The counter is set to zero by clocking on
the field. The display field (6) shows the current
machine speed.
Toolbar
(1) Selection field Fixing the menu and dis-

play bar
(2) Selection fields for additional control
panels
If the selection field (1) is switched on, the lower

menu and display bar is fixed and permanently
visible. If the selection field is switched off, the bar
is faded out automatically. It is faded in only if the
cursor touches the lower edge of the screen.
If a selection field (2) from the toolbar is activated,
additional selection fields in the main viewport to
suit the desired function are faded in.

X000075640
Selection fields for image display in the main

viewport
(1) Selection fields
The image display in the main viewport is man-

aged by means of the selection fields (2).

X000075640
Image display in the main viewport
(1) Main viewport (2) Selection fields for image display in the
main viewport
(3) Field of view in the overview window
Zoom function selection fields
(1) Selection field Zoom larger

(2) Selection field Zoom reduced
(3) Field of view in the overview window
By means of the selection fields Zoom larger (1) or

Zoom reduced (2) the display of the image in the
main viewport can be enlarged or reduced. Simul-
taneously, the field of view in the overview window
(3) is framed. If a certain position in the overview
window is clicked on with the cursor, the frame
jumps to this very position and the respective field
of view is displayed in the main viewport.

X000075640
Selection field Image size
(1) Selection field Image fitted in

(2) Selection field Original image size
The image presentation in the main viewport can

be pre-selected via the selection fields Image size.
Upon activating the selection field (1), the com-
plete size length is displayed in the main viewport.
If the selection field (2) is activated, the image is
displayed at its original size.
Change the image position and define the be-

ginning of the print repeat
(1) Selection field Turn image horizontally

and vertically
(2) Selection field Turn image vertically
(3) Selection field Turn image horizontally
(4) Selection field Define beginning of print
repeat
(5) Position of new print repeat
The image presentation in the main viewport can

be pre-selected via the selection fields Image size.
Upon activating the selection field (1) the image in
the main viewport is turned upside down. Upon
activating the selection field (2) the image is re-
flected only vertically, whereas the image is re-
flected only horizontally when activating selection
field (3). Activating the selection fields again re-
turns the image to its previous position.
The selection field (4) is used to redefine the be-
ginning of the print repeat. To determine the new
beginning of the print repeat, the selection field is
to be activated and the position in the main view-
port or in the overview window is to be clicked on
with the cursor. The new beginning of the print re-
peat is now defined and the image in the main
viewport changes accordingly when updating the
image.

X000075640
Camera setting
(1) Selection field Image capture (2) Additional selection fields
If selection field (1) is activated, additional selection fields (2) are faded in for image capture. By
reactivating the selection field (1) or by clicking in the main viewport outside the originated new field
the additional selection fields are faded out again.

X000075640
Additional selection fields for image capture
(1) Selection field Permanent image capture

(2) Selection field Individual image capture
(3) Selection field Save individual image
Upon activating the selection field (1) a permanent

image capture is started. The image in the main
viewport is permanently updated.
Upon activating the selection field (2) the individual
image is displayed in the main viewport. Using the
selection field (3), this image can be saved on the
local hard disc provided with a date and time
stamp. The saved images cannot be accessed by
the operator but can be read out by W&H service
personnel, if required.

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Lighting settings
(1) Selection field lighting (2) Additional selection fields
If selection field (1) is activated, additional selection fields (2) are faded in for lighting. By reactivating
the selection field (1) or by clicking on the main viewport outside the originated new field the additional
selection fields are faded out again.

X000075640
Additional selection fields for lighting
(1) Switch off the lighting

(2) Lighting for opaque print materials
(3) Lighting for transparent print materials
(4) Lighting for reflective print materials
(5) Mixed lighting
Switch on adequate lighting depending on the print

material. Only one lighting mode can be selected.
Lighting can only be switched on or off via addi-
tional selection fields. Lighting cannot be switched
on or off via the selection field in the toolbar.
Lighting is switched off after a few seconds if the
web is at a standstill. Lighting is switched back on
automatically when the web starts running again.

X000075640
Switching on image enhancement
At the transition points of the cameras visible image faults can occur which can be cleared by the
image enhancement function (shading correction.
(1) Selection field Image enhancement (2) Additional selection fields
If selection field (1) is activated, additional selection fields (2) are faded in for image enhancement.
By reactivating the selection field (1) or clicking on the main viewport outside the originated new field
the additional selection fields are faded out again.

X000075640
Additional selection fields for image enhance-

ment
(1) Selection field Activate/deactivate image

enhancement
(2) Selection field Define left web edge
(3) Selection field Define right web edge
(4) Selection field Enter and save correction
values
Defining the web edges
(1) Selection field Left web edge

(2) Selection field Right web edge
(3) Left web edge
(4) Right web edge
Perform the PRINT OFF function before defining

the web edges!
Activate the selection field (1) to define the left web
edge. Click on the left web edge with the cursor. A
boundary line (3) at the web edge is faded in.
Activate the selection field (2) to define the right
web edge. Click on the right web edge with the
cursor. A boundary line (4) at the web edge is fad-
ed in.
Activating image enhancement
(1) Selection field Save correction data

(2) Selection field Activate/deactivate image
enhancement
After defining the web edges, activate the selection

field (1) to calculate the required correction value.
Upon calculation, the selection field (2) is being
activated automatically.
After activating image enhancement the PRINT
ON function can be switched back on.

X000075640
Switching on the splitscreen function
The splitscreen function serves to compare the reference image with the current print. As a rule, the
complete print repeat length is recorded in case of a single frame shooting. All changes like zooming
or moving the field of view have an effect on both windows.
(1) Selection field Splitscreen function (2) Additional selection fields
If selection field (1) is activated, additional selection fields (2) are faded in for the splitscreen function.
By reactivating the selection field (1) or by clicking in the main viewport outside the originated new
field the additional selection fields are faded out again.

X000075640
Additional selection fields for the splitscreen

function

(3) Selection field Save individual image
Switching on the splitscreen function

(2) Reference image
(4) Current image
By means of the selection field individual image

capture (1) an individual image is generated and
displayed as a refrerence image (2) on the right
side of the screen page.
After that the selection field Permanent image cap-
ture (3) should be activated in order to have current
images displayed in the left side of the screen
page.

X000075640

Z WINDMLLER & HLSCHER 5 Operation | Easy-Col
5.9 Easy-Col
5.9.1 EASY-COL - Overview......................................................................................................3
Input units and measuring station..................................................................................3
Spectrodensitometers available.....................................................................................4
Ink weighing system......................................................................................................5
Platform weigher............................................................................................................6
5.9.2 Notes.................................................................................................................................7
Safety instructions.........................................................................................................7
Colorimetry instructions when using EASY-COL...........................................................7
Scrolling through comprehensive menus.......................................................................8
5.9.3 Assignment screen page...................................................................................................9
5.9.4 Manual color correction...................................................................................................11

Notes...........................................................................................................................11
Manual color correction...............................................................................................11
5.9.5 Color correction with leftover ink.....................................................................................13

Notes...........................................................................................................................13
Color correction with leftover ink..................................................................................14
5.9.6 Color corrections using the Lab/LCh color values...........................................................16

Notes...........................................................................................................................16
Color corrections with color values..............................................................................16
5.9.7 Color correction using a recipe........................................................................................18

Notes...........................................................................................................................18
Color correction using a recipe....................................................................................19
5.9.8 Color correction using the color chart..............................................................................21

Notes...........................................................................................................................21
Color correction using the color chart..........................................................................21
5.9.9 Color settings..................................................................................................................24

Color-difference formula currently used.......................................................................24
Input fields "General parameters"................................................................................25
Input fields "Recipe settings".......................................................................................26
Display fields "Plausibility setting"...............................................................................27
5.9.10 Measuring the substrate to be printed.............................................................................28
5.9.11 Defining the target color location.....................................................................................30
5.9.12 Measuring the actual color location.................................................................................33
5.9.13 Making corrections..........................................................................................................36

Making corrections.......................................................................................................36
Completion...................................................................................................................40
Secondary color correction..........................................................................................41

5 Operation | Easy-Col Z WINDMLLER & HLSCHER
5.9.14 Metering by use of a platform weigher............................................................................42

Metering with platform weigher....................................................................................42
Operation terminal - Metering......................................................................................43
5.9.15 Anilox roll calibration.......................................................................................................46
5.9.16 Consumption screen page..............................................................................................50
5.9.17 Control elements on the ink weighing system.................................................................52

Ink weighing system....................................................................................................52
Operating and setup elemets.......................................................................................53
5.9.18 Attaching the ink weighing system to the pump and valve unit.......................................55
Notes...........................................................................................................................55
Mounting the ink weigher system................................................................................55
5.9.19 Operating the ink weighing system.................................................................................56

Warnings......................................................................................................................56
General information.....................................................................................................57
Using the hobbocks by means of the hobbock support...............................................58
Attaching ink containers or hobbock supports to the ink weighing system..................59
5.9.20 Checking and calibrating the ink weighing system..........................................................60

Notes...........................................................................................................................60
Testing the ink weighing system..................................................................................61
Calibrating the ink weighing system............................................................................61

X000200246

Input units and measuring station
(1) Operator column (2) Operator column when retrofits are de-
livered
(3) Measuring support plate and spectro-
densitometer

X000200246
Spectrodensitometers available
NOTE
Be sure to only use the spectrodensitometer delivered together with EASY-COL or one which is
identical in construction.
(-) X-Rite eXact
Standard equipment

X000200246
Ink weighing system
(1) Ink weighing system

X000200246
Platform weigher
(1) Weigher (2) Operator terminal

X000178317
5.9.2 Notes
Safety instructions
DANGER
Fire and explosion hazard caused by static charging
Fire or explosion may hurt persons and cause damage to the machine. Only electrically non-con-
ductive ink containers must be used for solvent-based inks. Connect the ink containers to the equi-
potential bonding lines at the weigher.
Risk of injury from inks, solvents and cleaning agents
Inks, solvents and cleaning agents may harm skin and eyes. Wear suitable protective clothing, gloves
and safety goggles. Always ensure adequate ventilation air. Wear an appropriate breathing mask, if
necessary. Always observe the safety data sheets and safety instructions applicable to the product
when handling inks, solvents and cleaning agents. The safety data sheets include details regarding
health, accidents and environmental protection and can be requested from the suppliers.
NOTE
If the platform weigher is used for metering, a maximum weigher load of 60 kilograms must not be
exceeded. Higher loads may result in weigher defects.
Colorimetry instructions when using EASY-COL
To achieve unique colorimetric data we recommend to print measurement points for each color. The
measurement points should have a diameter of at least six millimeters and be printed together with
the motif.
It is important for accurate colorimetry to always use the same backing since the backing is also
included in the colorimetry.
If color charts or color targets are used as the color original, then the validity must be observed. The
colors are subject to an aging process and the color perception changes. Therefore, the color chart
or the color target must always correspond to the same state.
During color matching with EASY-COL the viscosity in the relative color deck must not be changed.
After color correction, check and reset the viscosity, if necessary.

X000178317
Scrolling through comprehensive menus
Menus for recipes, color charts or anilox rolls may be quite comprehensive. To make it easier for the
operator to scroll through long lists, EASY-COL automatically lists the names in alphabetical order.
The structrure is exemplified by use of a color chart.
Menu buttons
(1) Scroll buttons

(2) Back to previous selection
(3) Back to start menu
Select PANTONE color 485 C (example)
(1) PANTONE 4 [...]

(2) PANTONE 48 [...]
(3) PANTONE 485 C
Touch the PANTONE 4 [...] (1) list box. This box

contains all colors beginning with 4. Use the scroll
buttons to scroll through the menu, if necessary.
The next menu appears. Press the PANTONE 48
[...] (2) list box here. This box contains all colors
beginning with 48. Use the scroll buttons to scroll
through the menu, if necessary.
The next menu appears. Search for the PANTONE
485 [...] list box here and press the button. Use the
scroll buttons to scroll through the menu, if neces-
sary.
The appropriate tonal value is selected and dis-
played in the display field RECIPE NAME.

X000176660

Select screen page 1052 at the operator column or screen page 33 at Procontrol.
On this screen page, the individual color decks are assigned the color name, recipe name, ink system
and anilox roll. At the beginning, all color decks are deactivated. The list boxes RECEIPE and COLOR
CHART are only available as options.
The list pops up when striking the list box for the desired color deck.
(1) OFF button
A previously active color deck will be deactivated.
(1) MANUAL button
The color corrections for the pre-selected color

deck will be made manually without using EASY-
COL.
(1) LEFTOVER INK button
EASY-COL makes color corrections for the pre-

selected color deck.
Every ink, the recipe of which is unknown, repre-
sents a leftover ink.

X000176660
(1) LAB/LCH button
EASY-COL makes color corrections for the pre-

selected color deck.
Every color has its own Lab color or LCh color val-
ues, a spectrum is not given.
(1) Display field STATUS
The display field STATUS indicates the next work

step.
Option
(1) RECIPE button
EASY-COL is used to correct a color the formula

of which is known. Selecting the recipe determines
the unique target color location.
This button pops up only if the module 'Connection
to ink room' is enabled.

X000176660
Option
(1) COLOR CHART button
It is possible to select a target color location from

a digital (e.g. Pantone or HKS) chart or from the
one specified by the customer.
This button only pops up if the module 'Digital
chart' is enabled.

Notes
If EASY-COL shall not be used for color correction, select MANUAL for the relative color decks. All
entries made in the screen pages serve as an overview and have no effect on the calculations of
EASY-COL.
Manual color correction
Selecting manual color correction
(1) Color deck list box

(2) MANUAL button
Select screen page 1052 at the operator col-

umn or screen page 33 at Procontrol.
Touch the list box (1) for the desired color deck.
Select MANUAL (2) from the list.
The list disappears and MANUAL is displayed
in the color deck list box.
At the same time, list boxes and display fields
appear next to the selected color deck below
the columns 'Recipe name' and 'Anilox roll'.

X000176684
Selecting the color name
(1) Color list box

(2) Input field/display field for color selection
(3) Color list
(4) Keyboard
Touch the list box (1).

Select the desired color from the color list (3).
The name of the selected color is displayed in
the input field/display field (2).
The colors listed can be determined on screen
page 96.
If the list does not contain the desired color
name, then strike the input field/display field for
color selection (2) to enter the color name man-
ually by use of the displayed keyboard (4).

X000176684
Selecting the anilox roll
(1) Anilox roll choice box

(2) Input field/display field for anilox roll se-
lection
(3) Anilox roll list
(4) Keyboard
Touch the choice box (1).

Select the desired anilox roll from the list (3).
The name of the selected anilox roll is dis-
played in the input field/display field (2).
The names listed can be determined on screen
page 95.
If the list does not contain the desired anilox
roll, then press the input field /display field for
anilox roll selection (2) button to be able to en-
ter the anilox roll parameters manually using
the displayed keyboard.

Notes
Select LEFTOVER INK, if the components of an ink to be used are not definitely known. LEFTOVER
INK must also be selected if the ink recipe is known however, the recipe cannot be found in the recipe
database. A reliable color sample must be available at the machine as a reference. If a digital refer-
ence color location is given, select the optional COLOR CHART mode.

X000176692
Color correction with leftover ink
Recipe selection
The RECIPE button will pop up only if the optional module 'Connection to ink room' is enabled.
The COLOR CHART button will pop up only, if the optional module 'Digital color charge' is enabled.

(2) LEFTOVER INK button.

Select LEFTOVER INK (2) from the list.
Leftover ink selection
The "Enter color" prompt appears in the status display.
(1) Input field/display field RECIPE NAME

(2) Keyboard
Press the input field/display field RECIPE

NAME (1).
The keyboard appears.
Use the keyboard (2) to enter the desired color
name.
The name can be a random combination of
numbers and characters. Do not use special
characters. The minimum length of the color
name should be one character.
Confirm the entry with OK.

X000176692
Ink system selection
The information "Enter ink system" appears in the status display.

If the ink system selection is faulty, proper color correction cannot be ensured.
(1) Input field/display field INK SYSTEM

(2) List of ink systems
Press the input field/display field INK SYS-

TEM (1).
The list of ink systems appears.
Select the desired ink system from the list (2).
The ink system appears in the input field/dis-
play field.
Anilox roll selection
The information "Enter anilox roll" appears in the status display.

If the anilox roll selection is faulty, proper color correction cannot be ensured.
(1) Input field/display field ANILOX ROLL

(2) List of anilox rolls

After the parameters have been completely en-
tered, the information "Measure substrate" ap-
pears in the status display for the relative color
deck.

X000176692
Completion
(1) Status display

(2) EASY-COL button
Pay attention to the instructions in the status

display (1).
Press the EASY-COL (2) button.
The EASY-COL screen page appears.

Notes
If only color values (tristimulus values) of a color are available, select Lab/LCh tristimulus values. For
selecting the Lab/LCh tristimulus values no reference samples are required. Use the LEFTOVER
INK list box if reference samples are available.
Color corrections with color values
Recipe selection

(2) Lab/LCh button

Select Lab/LCh (2) from the list.

X000176705
Selecting the Lab/LCh color values
The "Enter color" prompt appears in the status display.

(2) Keyboard
Press the input field/display field.

The keyboard appears.
Use the keyboard (2) to enter the desired color
name.
The name can be a random combination of
numbers and characters. Do not use special
characters. The minimum length of the color
name should be one character.
Confirm the entry with OK.

(1) Input field/display field INK SYSTEM

(2) List of ink systems

TEM (1).
The list of ink systems appears.
Select the desired ink system from the list (2).
The ink system appears in the input field/dis-
play field.

X000176705



After the parameters have been completely en-
tered, the information "Measure substrate" ap-
pears in the status display for the relative color
deck.
Completion
(1) Status display

(2) EASY-COL button

display (1).
The EASY-COL screen page appears.

Notes
RECIPE can be selected, if for the desired color deck freshly matched ink is supplied from the ink
preparation system to the machine and the recipe has been stored to the recipe database. For this
optional mode, the module 'Connection to ink room' must be enabled. When using a recipe, this recipe
determines the reference color location.

X000176711
Color correction using a recipe
Recipe selection

(2) RECIPE SELECTION button

Press the list box (1) for the desired color deck.
Select RECIPE (2) from the list.
Recipe selection
The information "Select recipe" appears in the status display.

The ink system is automatically loaded from the recipe and cannot be changed here. Be sure to
always select the appropriate recipe for the ink system to be used. Using a wrong recipe may cause
improper color correction.

(2) Recipe list
(3) UPDATE RECIPE LIST button

NAME (1).
Select the desired recipe from the list (2).
If recipes are missing, the recipe list can be
loaded again by pressing the button UPDATE
RECIPE LIST (3).

X000176711

After a recipe has been selected, the name of the anilox roll for which the recipe was originally
calculated appears in the anilox roll column. If another anilox roll is to be used this must be specified.
Using a wrong anilox roll may result in improper color correction.

(3) Status display
Press the input field/display field ANILOX

ROLL (1).
A list (2) containing all registered anilox rolls
appears.
Select the desired anilox roll from the menu.
display (3).
Completion
(1) Status display

(2) EASY-COL button

display (1).
Press the button EASY-COL (2).
The screen page EASY-COL appears.

X000176815

Notes
The list box COLOR CHART must be selected if a digitally stored reference color location is to be
used for correction purposes and the color recipe is unknown. This optional function can be used only
if the module 'Digital color chart' is enabled.
Different color charts can be used for the relative color decks.
Color charts available

Customer A color chart specified by the customer containing stored reference color
locations from previous jobs.
HKS K (No) A digital HKS K chart for films and coated paper.
PANTONE Solid A digital PANTONE chart for films and coated paper.
Coated (No)
PANTONE + Solid A digital PANTONE + chart for films and coated paper.
Coated (No)
Color correction using the color chart
List box

(2) COLOR CHART button

Press the COLOR CHART (2) button in the list.

X000176815
Color chart selection
(1) Input field/display field COLOR CHART

(2) Selection menu COLOR CHART
Select the desired color chart from the list (2).

The name of the selected color chart is dis-
Selecting the reference color location
(1) Input field / display field RECIPE NAME

(2) Reference color location display field

NAME (1).
A list (2) of the reference color locations ap-
pears.
Select the desired reference color location from
the list.
The name of the reference color location is dis-
When using color charts offering a wide range
of colors, the reference color location can be
selected step by step.

X000176815

(1) Display/list box INK SYSTEM

(2) Display field Ink system

TEM (1).
A list (2) of the ink systems appears.
Select the desired ink system from the list.
The name of the ink system is displayed in the
input field/display field (1).
The message "Select anilox roll" appears in the status line.

(1) Selection menu ANILOX ROLLS

Press the input field/display field ANILOX

ROLL (1).
A list (2) of anilox rolls appears.
Select the desired anilox roll from the list.
The name of the anilox roll is displayed in the
input field/display field (1).

X000176815
Completion
(1) Status display

(2) EASY-COL button

display (1).
The screen page EASY-COL appears.

Color-difference formula currently used
The color-difference formula currently used will be displayed under EASY-COL. The color-differ-
ence formula, the observer or the illuminant can be changed on a separate screen page.
(1) Display field of the color-difference for-

mula
Select either screen page 1053 at the operator

column or screen page 76 at Procontrol.
The color-difference formula (1) currently used
will be displayed.

X000177474
Input fields "General parameters"
Illuminant
(1) ILLUMINANT list box

(2) Illuminant list

Touch the ILLUMINANT (1) list box .
Select the desired illuminant from the list (2).
The name of the illuminant is shown in the list
box (1).
Observer
(1) OBSERVER list box

(2) List of observer angles
Touch the OBSERVER list box (1).

Select the desired observer angle from the list
(2).
The name of the observer angle is shown in the
list box (1).
Color-difference formula
(1) E FORMULA list box

(2) List of color-difference formulas
Touch the E FORMULA (1) list box.

Select the desired E formula from the list (2).
The name of the E formula is shown in the list
box (1).

X000177474
Input fields "Recipe settings"
Metamerism illuminant
(1) METAMERISM ILLUMINANT list box

(2) Illuminant list

Touch the list box METAMERISM ILLUMI-
NANT (1).
Select the desired illuminant from the list (2).
The name of the illuminant is shown in the list
box (1).
Ink mixing
(1) INK MIXING list box

(2) List of ink types
Touch the list box INK MIXING (1).

Select the desired inks from the list (2).
The name of the ink is shown in the list box
(1).
Basic recipe folder
(1) Input field BASIC RECIPE FOLDER

(2) Keyboard
Press the input field BASIC RECIPE FOLD-

ER (1).
Use the keyboard (2) to enter the desired rec-
ipe name.

X000177474
Display fields "Plausibility setting"
(1) Display fields PLAUSIBILITY SETTING
The plausibility values are set during the startup of

EASY-COL and will be displayed in the display
fields (1).

X000177779

Display fields when hatched indicate that no measurements have been taken so far or that no meas-
ured values are available. All necessary measurements must be taken at the measuring place by use
of the same backing.
General substrate measurement
(1) Button SUBSTRATE MEASUREMENT

(2) Display field SUBSTRATE
(3) Button SUBSTRATE MEASUREMENT
COLOR DECK

Press the button SUBSTRATE MEASURE-
MENT (1).
Measure the substrate.
After successful measurement, the display
field SUBSTRATE (2) shows the color of the
substrate. The same applies for the display
fields of all active color decks. If a display field
in the column SUBSTRATE remains hatched,
the substrate for this color deck must be meas-
ured separately. This will occur, if the selected
recipes or ink types prescribe different meas-
urement setups for the spectral photometer.
MENT COLOR DECK (3).
After successful measurement, the color of the
substrate is shown in the display field of the
column "Substrate" (2).
Averaging measurement of the substrate
(1) Display field MEASUREMENTS


Several measurements add up to an average
value. The measurements (1) are counted in
the measurement field.
The display fields SUBSTRATE (2) will be as-
signed automatically.

X000177779
Individual substrate measurement
If the substrate color differs from all other colors in the color decks, an individual substrate meas-
urement becomes necessary. This occurs for example, if reverse printing is carried out with a white
background and this is not the case in one of the color decks.
(1) Button "Substrate measurement Color

deck"
(2) Display field "Substrate"

Press the button "Substrate measurement Col-
or deck" (1).
If a general substrate measurement has been
taken already before, the display field "Sub-
strate" (2) is hatched again.
The color deck can be changed over to the
general substrate again by pressing the button
"Substrate measurement Color Deck" (1)
again. This cannot be done however, if the
measurement conditions for the recipe or the
selected ink type differ from those prevailing
during the general substrate measurement.
Multiple measurement including an average
determination is also possible.
After successful measurement, the color of the
substrate is shown in the display field "Sub-
strate" (2).
Note that: small measuring fields in the column
"Substrate" (2) mean that the assignment has
been allocated automatically. Great measuring
fields mean that the assignment has been
made by an individual substrate measurement!

X000177787

Shaded display fields indicate that no measurements have been taken here. No measured or refer-
ence values are available. All necessary measurements must be taken at the measuring place by
use of the same backing.
Measuring the target color location for the leftover ink
When using leftover inks the target color location must be measured. To do this, the target color
location is measured on the reliable reference sample using the spectrophotometer. The reference
sample may be a sample signed by the customer, a color chart or similar. If an ink is used on a
color deck for which a valid recipe exists, the display field in the column "Target" will automatically
be assigned the correct color shade. The same applies for the entry via the Lab/L Ch tristimulus
values and using the option 'Digital color chart'.
(1) Button TARGET COLOR LOCATION

(2) Display field TARGET COLOR LOCA-
TION

Press the button "Target color location (1).
Measure the target color location.
After successful measurement, the target color
location (2) will be displayed indicating the
measured color shade.
Press the button 'Transfer to customer's color
chart', if the option 'Digital color chart'is availa-
ble.
The measured target color location is transfer-
red to the customer's color chart and the refer-
ence color location is stored under the name of
the leftover ink.

X000177787
Measuring the average target color location
(1) Button "Target color location"

(2) Display field "Target color location"
(3) Button 'Transfer to customer's color
chart' (optional)

Select the target color location (1).
value. The measurements are counted in dis-
play field (2).
Press the button 'Transfer to customer's color
chart', if the option 'Digital color chart'is availa-
ble.
The measured target color location is transfer-
red to the customer's color chart and the refer-
ence color location is stored under the name of
the leftover ink.

X000177787
Entering the target tristimulus values (Lab/LCh)
When entering Lab or LCh tristimulus values, such values must have been determined under the
same measurement conditions (observer and illuminant) as set on the machine. If the measure-
ment conditions do not match, color deviations between the desired and the entered color value
will occur. Color matching by use of Lab/LCh tristimulus values must be set on screen page 1052
(operator column) or on screen page 33 (Procontrol).
(1) Button TARGET COLOR LOCATION

(2) Display field TARGET COLOR LOCA-
TION
(3) Input fields for Lab/LCh tristimulus val-
ues
(4) OK button

Press the button "Target color location (1).
The color list box pops up.
Enter the desired color values into the input
fields (3).
The color is displayed in the display field NEW
COLOR.
Press OK (4).
The set values are transferred to the display
field TARGET COLOR LOCATION (2). When
pressing CANCEL the color value will be dis-
carded.

X000177977

Display fields when hatched indicate that no measurements have been taken so far or that no meas-
ured values are available. All necessary measurements must be taken at the measuring place by use
of the same backing.
Carrying out the measurement
After measuring the target color locations, the actual color locations must be measured. To do so,
take a first proof of the sample to be matched out of the machine.
(1) AUTOMATIC COLOR CORRELATION

(2) Display field ACTUAL COLOR LOCA-
TION
(A) Display field AUTOMATIC COLOR
CORRELATION is active or not active

Press button AUTOMATIC COLOR CORRE-
LATION (1).
After pressing the button, the color of display
field (A) in the button AUTOMATIC COLOR
CORRELATION (1) will turn from gray to
green.
AUTOMATIC COLOR CORRELATION mode
is active when display field (A) lights up green
and not active when the display field is gray.
Measure the actual color locations.
The measured color is shown in display field
ACTUAL TONAL VALUE (3) and automatically
assigned to the correct color deck.
Measuring the average actual color location value

TION

Do the measurings.
value. The measurements are counted in the
display field (1).

X000177977
Correlating the actual color location manually
If actual color locations cannot be correlated automatically after the measurement, the individual
measurements must be correlated with the relative color decks manually.
(1) Button AUTOMATIC COLOR CORRE-

LATION
(2) Button MEASURE ACTUAL COLOR LO-
CATION
TION

Press the button AUTOMATIC COLOR COR-
RELATION (1).
The mode is switched off and the field turns
gray.
Press the button MEASURE ACTUAL COLOR
POINT (2) of the desired color deck.
Carry out the measurement.
The measured shades are shown in the display
field ACTUAL COLOR LOCATION (3).
New setpoint
Be aware that this mode is irreversible.
(1) Button ACTUAL TO SET

Press the button ACTUAL TO SET (1).
The currently measured value will be applied
for the respective color deck as the new target
color location. The target color location is
changed by confirming the displayed informa-
tion.

X000177977
Faulty measurements (color deck correlation)
A fault message will be generated, if a measured value from the colorimeter cannot be correlated
uniquely with a color deck.
(1) Fault message

(2) OK button
Press OK (2).
The fault message "Unable to correlate meas-
ured color with color deck" (1) will be deleted.
Faulty measurement (average value)
A fault message will be generated, if a measured value cannot be correlated with an actual average
value measured.
(1) Fault message

(2) OK button
Press the OK (2) button.

The fault message "Measured color deviates
too much from previous measurements" (1) will
be deleted.

X000177991

Making corrections
Color space diagram and starting correction
After all necessary entires for each individual color deck have been made, the correction values
can be calculated (see status display 'Calculate correction value'). The 'Correction' button gets you
to the screen page 'Calculate correction value'. This button is available only after all necessary
entries have been made. If corrections cannot be made, attention must be paid to the instructions
in the status display.
(1) Display field COLOR DIFFERENCE

DELTA E
(2) Window 'Color space diagram'
(3) CORRECTION button
(4) Scale
Press the display field COLOR DIFFERENCE

DELTA E (1).
The window 'Color space diagram' (2) pops up.
The blue crosses represent the nominal color
location. The green crosses represent the ac-
tual color location relative to the nominal color
location. The measured actual color location
magenta in the displayed example is too red,
too yellow and too bright.
The scale (4) is displayed above the yellow
mark and on the right-hand side of the red
mark.
Note that: the scale changes automatically as
per the color difference Delta E.
Press the CORRECTION (3) button of the de-
sired color deck.
The display gets you to the operator page "Col-
or detail" of the respective color deck.

X000177991
Warning and alarm limits
The color diference value Delta E between the set and the actual value is displayed in color in the
display field. If no threshold value is available, the displayed numerical value is black. A green
numerical value indicates that the deviation lies below the warning limit. A yellow numerical value
indicates that the deviation lies between the warning and alarm limit. Deviations exceeding the
alarm limit are displayed in red.
(1) Input field WARNING

(2) Input field ALARM
(3) Display field COLOR DIFFERENCE
DELTA E
Enter the desired value in input field WARN-

ING (1).
Enter the desired value in input field ALARM
(2).

X000177991
Calculation of the correction values
When selecting the list box Recipe on screen page 1052 (operator column) or screen page 33
(Procontrol), two correction values are calculated for those color decks the formulas of which are
known. When using Recipe color correction mode, the calculated correction value is made up
exclusively of the base colors used in the formula. When using Color range correction mode, also
other base colors which did not form part of the formula as yet, can additionally be used. In both
cases, the expected color difference Delta E after the correction is displayed.
When selecting LAB/LCh tristimulus values, Leftover ink or Color chart on screen page 1052 (op-
erator column) or on screen page 33 (Procontrol), only the Color range correction will be calcu-
lated for the relevant color decks.
The greater the expected color difference Delta E displayed after the correction, the more likely is the
formula near its color space limit.
As a rule of thumb:
The expected color difference should be less than 5 for the first correction.
For the second correction, the value should be less than 2.
(1) CALCULATE button

(2) DO button
(3) DELETE button
Press the CALCULATE (1) button.

The respective color differences Delta E for
correcting the recipe color and the color range
are calculated and displayed.
Press one of the two DO (2) buttons (Recipe
color correction or Color range correction).
The selected correction value is sent to the
platform weigher. The calculated correction
value which has not been selected will be de-
leted.
After a correction value has been sent to the
platform weigher, another correction value for
this color deck can temporarily not been calcu-
lated.
Press the DELETE button.
The correction values sent to the platform
weigher are deleted.

X000177991
Alternative anilox roll
After the anilox roll has been changed, the expected color difference compared to the ink available
in the color deck can be displayed. Use the PROPOSAL button to calculate the optimal anilox roll
which is supposed to have the least color difference Delta E relative to the reference color location.
The expected Delta E after changing an anilox roll is displayed in the field DELTA E OLD ANILOX
ROLL.
Before changing the anilox roll, the operator has to decide on whether the proposed anilox roll is
suitable for printing the motif.
An alternative anilox roll can only be calculated during the first correction process after having cal-
culated the correction value.
The anilox roll currently used is shown in the ' Display field ' (5).
(1) PROPOSAL button

(2) CHANGE button
(3) List box 'Alternative anilox roll'
(4) Color difference Delta E
(5) Display field showing the anilox roll cur-
rently used
Press the PROPOSAL (1) button.

When pressing the button the anilox roll with
the least color difference Delta E is displayed.
Touch the list box 'Alternative anilox roll' (3).
A list box shows all anilox rolls available in the
system. Select the desired anilox roll.
The expected color difference after changing
an anilox roll is shown in display field (4).
Press the Change (2) button.
The anilox roll can be changed now.
When pressing the 'Change' button, the selected anilox roll will be displayed at the respective color
deck on screen page 1052 (operator column) and on screen page 33 (Procontrol).
A color correction using "Recipe color correction" or "Color range correction" mode can only be
made after the next actual color location has been measured.

X000177991
Making a correction
After a correction recipe has been sent to the platform weigher, the screen display returns to the
screen page EASY-COL. The status display "Make correction" informs you that the calculated
correction for this color deck has not yet been made.
Always press the SAVE CORRECTION button after the correction has been made. On pressing the
button, the correction of the basic recipe with the added corrections will be generated.
Without saving, a second correction value cannot be calculated.
(1) Button SAVE CORRECTION VALUE
Press the button SAVE CORRECTION VAL-

UE (1).
The added ink quantities for metering will be
saved to the recipe.
The button SAVE CORRECTION VALUE will
be displayed only upon receipt of the feedback
from the platform weigher that all corrections
have been metered.
Completion
(1) Display field ACTUAL COLOR POINT

(2) Button SAVE CORRECTION VALUE
After the correction value has been saved, the but-

ton SAVE CORRECTION (2) disappears. The
measured Actual color location (1) is deleted. The
actual color location must be measured again after
the next proof. Only then can a re-correction of the
calculation be made.

X000177991
Secondary color correction
If there is not enough ink left to do the job, use the SECONDARY COLOR CORRECTION mode to
mix the additionally required ink. Original ink must be left to do this and all correction values must
have been saved before.
In the display field Original ink quantity 1, the available original ink for this color deck must be entered
(minimum quantity: 1kg).
Then, the names of the base inks and the associated quantities which must be added to the original
ink appear in the column (2).
The display field TOTAL QUANTITY (3) shows the quantity of original ink and the added ink quantity.
The display field REQUIRED QUANTITY (4) shows ink quantity required to finish the job. By changing
the original ink quantity you can thus match the exact ink quantity required to finish the job.
When pressing the DO button, the secondary correction value for this color deck will be sent to the
platform weigher.
Example:
50kgs of original ink will be required for color deck 3 on the machine. 20kgs will be filled into the
machine first. During color matching with EASY-COL, 2kgs of yellow and 1kg of waste will be added.
If this ink quantity is insufficient to finish the print job, original ink must be replenished. As the original
ink is however, not matched, replenishment would result in a color drift. By use of the SECONDARY
CORRECTION mode, EASY-COL can now calculate the correction quantities to be added (e.g.: 1kg
yellow and 0.5kg waste per 10kgs of original ink) so that the ink replenished is identical to that avail-
able in the color deck.
For secondary correction, the ink viscosity must be checked. The viscosity of the re-corrected ink
must be the same as that of the ink available in the color deck.

X000040594

Metering with platform weigher
Main menu
If no metering jobs exist, the buttons to the left of the diagrammed color decks are grayed out (inac-
tive). If metering jobs exist, the button to the right of the respective color deck indicates the ink quantity
to be metered (active).
(1) Button if no metering job exists

(2) Button if a metering job exists
Press button (2) if a metering job exists.

The display shows the METERING screen.

X000040594
Operation terminal - Metering
Start screen for metering
DANGER
Static charging.
Fire or explosion may hurt persons and cause damage to the machine.
For solvent-based ink, only use an electrically conductive ink container. Connect the ink containers
to the equipotential bonding lines located on the weigher.
DANGER
Inks, solvents and cleaning agents
Inks, solvents and cleaning agents may cause skin and eye irritation.
Wear suitable protective clothing, gloves and safety goggles. Always ensure adequate ventilation air.
Wear an appropriate breathing mask, if necessary. Always abide by the safety data sheets and safety
instructions that apply to the respective product when handling inks, solvents and cleaning agents.
The safety data sheets include details regarding health, accidents and environmental protection and
can be requested from the suppliers.
NOTE
The maximum admissible total weight for loading the platform weigher is 60 kg. Higher loads may
result in weigher defects.
(1) Ink container display

(2) START TARA button
(3) CANCEL button
(4) CANCEL button
Put the ink bucket on the weigher.

Press the START TARA (2) button.
The input mask for the component appears.
Press the CANCEL (3) button.
All entries are discarded.
Press the CANCEL (4) button.
All entries are discarded. The display returns to
the main menu.

X000040594
Adding components
The various components (2) listed in the respective column are filled into the ink container on the
weigher.
(1) Metering display

(2) Components in the correction recipe
Fill the given component (1) into the ink con-

tainer.
Setpoint = quantity to be metered
Actual = quantity currently metered
Leftovers = quantity still to be metered
Progress bar
The progress bar indicates the current filling quantity in percent. The color of the progress bar changes
from red to green the moment the filling quantity reaches the tolerance range which is depicted by
dashes below and above the 100 percent mark.
(1) Metering indicators

(2) NEXT COMPONENT button
(3) Correction recipe
Meter the respective component according to

the select given in the METERING INDICA-
TORS (1) field.
Finish metering upon reaching the select.
Press the NEXT COMPONENT (2) button.
The next component from the correction recipe
(3) appears in the METERING INDICATORS
field and can now be metered.
After metering of all the components is com-
plete, press the FINISH METERING button.

X000040594
Overdosing
If overdosing has occurred a warning appears recommending you to cancel the metering.
(1) Continue
(2) Cancel
Select the CONTINUE (1) button.

Metering continues irrespective of the warning.
Overdosing is stored by the system.
Select the CANCEL (2) button.
Metering is stopped and needs restarting.
Finishing the metering
(1) Display in the button
Select the FINISH METERING button in the

operating screen for metering.
The display shows the METERING JOB
screen.The status of the color deck for which
metering has been executed changes to ME-
TERING FINISHED (1).
This information persists in the METERING
JOB screen until the EASY-COL computer has
saved finished metering.

X000200279

Selecting a menu item

(2) LEFTOVER INK/RECIPE

Select either the LEFTOVER INK button or the
RECIPE (2) button from the list.
If necessary, repeat this for other color decks.
Selecting the Teach menu item

(2) TEACH button
Press the PAGE OVERVIEW (1) button in the

top line.
Select the TEACH (2) button from the list.
The screen page TEACH appears.

X000200279
Selecting a teach recipe
(1) RECIPE NAME list box

(2) Recipe list
(3) Range display field
(4) Formula display field
Touch the RECIPE NAME (1) list box.

Select the recipe intended for the anilox roll
from the Teach recipe list (2).
The recipe name is shown in the list box (1). In
addition, the name of the color range (3) asso-
ciated to the recipe and the formula of the rec-
ipe (4) are displayed.
The formula of the inks supplied to the printing
press must correspond with this recipe.
Defining the calibration speed
The calibration speed should correspond with the standard production speed. Use the average
speed value for calibration, if production speeds are different.
In case of significant differences in production speed, the anilox rolls can also be calibrated for
different speeds.
(1) Display field SPEED

(2) Numeric keypad
Press the input field SPEED (1).

Use the numeric keypad (2) to enter the speed.
The set value will be applied and shown in the
display field SPEED if the OK button on the
keyboard is pressed.

X000200279
Measuring the substrate
When using transparent films printed with opaque white, measuring must take place on the opaque
white area.
(1) SUBSTRATE MEASUREMENT button


MENT (1).
Use the colorimeter to measure the substrate.
After successul measurement, the display field
SUBSTRATE (2) takes on the measured color.
The number shown in the display field gives the
number of individual measurements which
have been taken on the substrate.
Allocating and denominating the anilox roll
Anilox rolls can only be allocated to those color decks which have been activated on screen page
1052 (operator column) or on screen page 33 (Procontrol).
(1) COLOR DECK

(2) ANILOX ROLL
(3) Keyboard
Press the COLOR DECK (1) button to select

the color deck for which colorimetry is to be
carried out.
Press the input field ANILOX ROLL (2).
Use the keyboard to enter the name of the ani-
lox roll to be calibrated. It can be assigned any
name. We recommend to use an informative
name (e.g. screen ruling, cell volume and, if
necessary, the machine's name)
The entered name is shown in the input field
ANILOX ROLL and assigned the addition
which corresponds with the selected calibra-
tion speed.
Use the set values to do the teach sample
proofing.

X000200279
Calculating the ink transfer
Requirements:
A proof has been made using the entered speed, the entered anilox roll and the entered ink formula.
(1) Display field COLOR

(2) Display field CREATE
(3) THICKNESS button
Take a print sample.

Use the colorimeter to measure a printed solid
area.
After successul measurement, the display field
COLOR (1) takes on the measured color. The
number shown in the display field indicates the
number of individual measurements taken. We
recommend multiple measurement, i.e. at least
three individual measurements should be tak-
en.
Press the CREATE (2) button.
Calculation is started. During calculation, the
CREATE button is locked out.
After calculation has finished, the CREATE
button is unlocked and the calculated value is
shown in the display field THICKNESS (3).
This value indicates the anilox roll's ink transfer
in percent relative to the ink supplier's calibra-
tion data set.
Calibration of the anilox roll is finished.

X000200329

Go to screen page 1051 (operator column) or 51 (Procontrol). This screen page can be called up on
Procontrol or at the EASY-COL operator terminal.
(1) Display field DECK NUMBER

(2) Display field INK QUANTITY
The ink quantity available in the ink container is

shown in the column INK QUANTITY (2). A red
display signals that the container is empty.
(1) Display field REMAINING OPERATING

TIME
(2) Display field COVERAGE
The column REMAINING OPERATING TIME (1)

indicates the minutes left for printing before the ink
container is empty when the machine is running at
current production speed. When the machine is at
a standstill, the display shows zero.
The column COVERAGE (1) indicates the meter-
age which can be printed before the ink container
is empty when the machine is running at current
production speed.
(1) Display field LEFTOVER INK QUANTI-

TY
(2) Ink consumption display field CURRENT
The column LEFTOVER INK QUANTITY (1)

shows the expected leftover ink quantity at the end
of the job. A green, positive display informs you
that there is sufficient ink left to finish the job. A red,
negative display informs you that the ink quantity
is insufficient to finish the job and urges you to re-
plenish at least the requested ink quantity.
The column CURRENT (2) indicates the current
ink consumption in kgs/1000m.

X000200329
(1) Ink consumption display field PROOF

(2) Display field for ink consumption during
PRODUCTION PRINTING
The column PROOF (1) shows the total ink quan-

tity consumed during machine setup.
The column PRODUCTION PRINTING (1) shows
the ink quantity consumed for the current job.
(1) AGITATOR list box

(2) INK CONTAINER list box
This box is used to select whether the ink container

shall be used with or without an agitator. If the entry
is incorrect, the ink weighing system will be unable
to supply correct data.
When using EASY-COL, correction proposals can
arise which may cause an overfilling of the con-
tainer.
The ink container to be used can be selected. If the
entry is incorrect, the ink weighing system will be
unable to supply correct data.

X000200337

Ink weighing system

X000200337
Operating and setup elemets
The ink weighing system serves to ascertain and display the ink consumption in the individual color
decks.
Weighing arms (1) for the ink container or the cal-

ibrating weights.
Switch (1) for raising or lowering the weighing

arms.
Ink container with supports (1) for the weighing

arms and rollers (2) to allow easy transportation.

X000200337
Device (1) for weigher calibration by use of three

separate weights (2).
Procontrol screen page for operating the ink

weighing system.
Procontrol screen page for calibrating the ink

weighing system.

X000029517
Notes
DANGER
There is a risk due to electrostatic charging.
All potential equalization cables must be connected. It is forbidden to operate the system without the
potential equalizing cables being correctly connected.
The contact surfaces must be kept clean.
The potential equalization cable must be clamped in place first when mounting the ink weigher system
and you must ensure that the potential equalization cable is taken off last when removing the ink
weigher system.
Mounting the ink weigher system
Mechanical connection
(1) Hook attachment

(2) Fastening rod
(3) Equipotential bonding cable
Connect the equipotential bonding cable (3) to

the fastening rod (2).
Move the ink weighing system in front of the
pump and valve unit.
Make sure that the hook attachment (1) goes
beyond the fastening rod (2).
Pneumatic connection for agitator
(1) Extensions
Attach the delivered extensions (1) for the ag-

itator to the connections on the pump-valve
system.

X000029517
Electrical and pneumatic connection for the ink weigher system
(1) Electrical and pneumatic connection
Connect the supply lines coming from the ma-

chine to the corresponding opposite parts on
the ink weigher system.
The bushings are accessible when the cover is
folded downward. After connection fold the
cover back up again.
Suspend the drip tray
(1) Drip tray
Push the holding fixtures for the drip tray (1)

into the respective counterparts and then sus-
pend the drip tray.

Warnings
CAUTION
Risk of injuries from moving machine parts
Your hands may be crushed or sheared. Do not reach in between moving machine parts. Keep a
safe distance.
Do not reach under the ink container when raised.

X000165418
General information
Keep the ink weighing system clean. Remove spilled ink immediately, however, after changing the
ink container at the latest.
Do not put any objects on the ink containers.
If the remaining operating time calculated for a color deck is 10 minutes or less, the display turns from
green to red numbers.
An increase in printing speed results in an immediate reduction of the remaining operating time.
The job length must have been correctly entered in the Job operating page.
For a correct display of the ink quantity consumed in the current job, the job counter must be
reset.
Optional hobbock support

The optional hobbock support renders possible to utilize the ink weighing system with standard hob-
bocks from the ink manufacturers. The hobbocks should meet the following requirements:
min. height: 340 millimeters
max. height: 425 millimeters
min. inner diameter: 270 millimeters
max. base diameter: 325 millimeters
When using solvent-based inks the hobbock must be made of electrically conductive material and
integrated in the equipotential bonding system.

X000165418
Using the hobbocks by means of the hobbock support
Inserting the hobbocks into the hobbock support
(1) Hobbock support

(2) Hobbock
(3) Limit stop
Push the hobbock (2) into the hobbock support

(1).
Push the hobbock until it hits the limit stop (3).
Fitting the lid
(1) Lid guiding

(2) Lid guiding support
Put the lid on the hobbock.

The lid guidings (1) must properly fit into the
respective supports (2) of the hobbock support.

X000165418
Adjusting the support height of the lid guidings
Adjust the height of the lid guiding whenever necessary.
(1) Guide rail

(2) Screws
Undo the screws (2).

Shift the guide rail (1) as per the height of the
hobbock.
Tighten the screws (2).
These instructions should be followed for either
side of the hobbock support.
Attaching ink containers or hobbock supports to the ink weighing system
Installing the ink containers or the hobbock supports
(1) Ink container

(2) Ink supply hose
(3) Ink return hose
Move the ink container (1) or the hobbock sup-

port before the ink weighing system.
Connect the ink supply hose (2) and the ink re-
turn hose (3) to the ink container or the hob-
bock.

X000165418
Raising the ink container or the hobbock support
CAUTION
Risk of injuries from moving machine parts
Your hands may be crushed or sheared. Do not reach in between moving machine parts. Keep a
safe distance.
Do not reach under the ink container when raised.
(1) Rotary switch

(2) Weighing arms
Switch over the rotary switch (1).

The weighing arms (2) raise the ink container
or the hobbock support.
Check whether the ink container supports or
the hobbock support properly fit into the weigh-
ing arms.
The weighing container must be free to move.
Caution: Risk of crushing!

Notes
Proper functioning of the ink weighing system requires regular checking of the system and the as-
sociated calibration unit. To do so, fit the calibrating unit into the ink weighing system instead of the
ink container. The calibration unit contains three removable individual weights weighing about fifteen
kilograms each. The exact weight is stamped on the individual weights.
If deviations are detected during the checking, the ink weighing system needs recalibration. Only
specially trained personnel are allowed to do the calibration work.

X000140836
Testing the ink weighing system
Mounting the calibration unit
(1) Calibration unit with calibration weights

(2) Weight stamped on the calibration unit
(3) Weight stamped on the individual
weights
Move the calibration unit (1) before the ink

weighing system and raise.
Display in Procontrol
(1) CONSUMPTION
Pay attention to the CONSUMPTION (1) dis-

play.
Take the individual weights out of the calibra-
tion unit sequentially.
When a weight is removed, the display must
show the weight reduced by the one stamped
on the individual weight. If this is the case, cal-
ibration of the ink weighing system is still okay.
If deviations occur during the measurement,
the ink weighing system must be recalibrated.
Calibrating the ink weighing system
Going to the service page

(2) SERVICE INK CONSUMPTION button
Press the PAGE OVERVIEW (1) button in the

top line.
Select the SERVICE INK CONSUMPTION (2)
button from the list.
The SERVICE PAGE WEIGHER screen page
appears.

X000140836
Setting up the zero point
(1) SET MIN button
Raise unstressed weighing arms at the ink

weighing system.
Press the SET MIN (1) button.
The zero point is set and the values are trans-
ferred to the controller.
Setting up the maximum value
(1) Input field

(2) SET MAX button
Move the calibrating unit weighted with three

individual weights before the ink weighing sys-
tem and raise.
Enter the weight stamped on the calibrating
unit in input field (1).
This weight is composed of the calibration
unit's empty weight and the total weight of the
three individual calibration weights.
Press the SET MAX (2) button.
The maximum value is set and the values are
transferred to the controller.
After successful calibration the ink weighing system must be checked once again as described
before.

Z WINDMLLER & HLSCHER 5 Operation | Drying system
5.10 Drying system

5.10.1 Safety instructions for use of the drying system................................................................2

Layout............................................................................................................................4
Function.........................................................................................................................5
5.10.3 Operating the drying system.............................................................................................6

Operating status of the drying system...........................................................................6
Operating the drying system........................................................................................10
5.10.4 Measuring stations..........................................................................................................13
5.10.5 Calculation examples......................................................................................................15

Definitions....................................................................................................................15
Example calculation for a flexo printing press.............................................................17
5.10.6 Dryer rating plate.............................................................................................................19
5.10.7 Flow diagram with solvent vapor concentration controller...............................................20

5 Operation | Drying system Z WINDMLLER & HLSCHER
X000192273
DANGER
Gas warning device not maintained
The employer is responsible for the correct working state, the checking and the adjustment of the gas
warning device. The employer is liable to ensure that the gas warning device is set to the correct
solvent/solvent mixture before starting a new print job. The gas warning device must be checked at
regular intervals for proper functioning.
DANGER
Drying system not tested
The dryer and all the other safety devices must be tested by an expert at least once a year. The
machine must not be operated unless the dryer is in a proper working condition.
DANGER
Dampers improperly set
The dryer provides various dampers which are set during commissioning. These factory-set dampers
must not be readjusted by the customer. Improper adjustments might result in an impermissibly high
solvent vapor concentration. An increased danger of explosion will exist if the permitted threshold
limit values (LEL) are exceeded.
DANGER
Measuring error with the gas warning device
Any parts that were opened or removed for cleaning and/or maintenance work must be closed or
refitted. Otherwise, faulty solvent concentration measurements might be recorded. The doors or cov-
ers at the dryer must remain closed during operation. All measuring points on the measuring stations
must be closed with appropriate blind plugs.
DANGER
Improperly connected equipotential bonding cables
Cables are secured to the dryer at different places (green/yellow). These cables are used for creating
equipotential bonding between the specific components. These cables must never be removed or
loosened. A very high voltage level with severe potential differences might result if the connector is
broken or becomes loose. Check the equipotential bonding connectors at regular intervals.

X000192273
DANGER
Wrong color deck selection
Fire or explosion may hurt persons and cause damage to the machine. Electrostatic discharges may
also occur when using inks that contain metal, e.g. gold ink.
Therefore, inks containing metal should only be used in the last color deck.
DANGER
Wrong solvent
Dryers to be used in operating zone 2 in compliance with DIN EN 1539 are laid out for solvents
according to class T2 (explosions sub-group IIB, temperature class T2, gravure printing) and T3
(explosion sub-group IIB, temperature class T3, flexo printing). Solvents containing phenol and ep-
oxide require a special upgrade to be made to the gas warning device! Only the quantity of solvent
that is listed on the dryer rating plate attached to the machine is to be supplied. Only ever use the
data specified on the rating plate for the dryer attached to the machine to calculate the maximum
permitted amount of solvent. For calculation purposes please refer to the chapter "Drying system"
under the heading "Calculation examples" in the instruction manual.
DANGER
Wrong flow temperature when using drying systems which are operating in operating zone 2
in compliance with DIN EN 1539
The flow temperature to the dryer (e.g. heat exchanger) in flexographic printing presses must not
exceed: 160 degrees Celsius / 320 degrees Fahrenheit (80%, T3). The T3 approval is voided with
flow temperatures greater than 160 degrees Celsius / 320 degrees Fahrenheit. The flow temperature
to the dryer (e.g. heat exchanger) in gravure printing presses must not exceed: 240 degrees Celsius /
464 degrees Fahrenheit (80%, T2). The T2 approval is voided with flow temperatures greater than
240 degrees Celsius / 464 degrees Fahrenheit.
CAUTION
Hot surfaces
CAUTION
Webs running onto rolls or rollers (infeed nips)
Wear tight-fitting clothes and a hairnet. Work without gloves. Keep hands clear of the running ma-
chine. Keep a safe distance. Only ever use the threading chain for web thread-up.

X000258314

Layout
1 2 3 4
5
All_0101
(1) Recirculating air fan/exit air fan (2) Heating register

(3) Tunnel drying (4) Slot nozzles Tunnel drying
(5) Nozzle blower in the between-color dry-
ing

X000258314
Function
NOTE
The drying system is a passive module and has no main switch. The drying system is operational
only after the energy supply has been switched on as described in the POWER SUPPLY documen-
tation module.
One slot blower (2) each is arranged in the web running direction around the impression cylinder
behind the color decks. They are provided to dry the just applied ink and to extract the solvent-laden
air. An exhauster downstream of the last color deck is optional.
The superstructure on the printing press is made up of a drying box equipped with slot blowers. They
serve to dry the ink which has just been applied in the last color deck and to finally dry the ink applied
in the other color decks.In addition to that, the solvent-laden air in the drying box is extracted.
Heating up and distributing the make-up air for the slot nozzles in the drying box and the slot blowers
on the between-color drying system is carried out separately. As an option, the make-up air can be
heated up by means of heat exchangers, electrical heaters or gas burners. The respective slot blow-
ers are provided with the heated-up make-up air by means of the recirculating air blower. The make-
up air flow towards the slot blowers is accomplished via distributor pipes.
The solvents absorbed in the make-up air are transferred to the exhaust air distributor together with
the fresh air (leakage air). Part of the exhaust air quantity is recirculated as make-up air. The re-
maining part of the exhaust air quantity is extracted from the press (exit air).

X000288251

Operating status of the drying system
WARNING
The operator is responsible for the correct working state, the checking and the adjustment of the gas
warning device. The employer is liable to ensure that the gas warning device is set to the correct
solvent/solvent mixture before starting a new print job. The gas warning device must be checked for
proper functioning at regular intervals.
WARNING
The dryer and all the other safety devices must be tested by an expert at least once a year. The
machine must not be operated unless the dryer is in a proper working condition.
WARNING
The dryer provides various dampers which are set during commissioning. These factory-set dampers
must not be readjusted by the customer. Improper adjustments might result in an impermissibly high
solvent vapor concentration. An increased danger of explosion will exist if the permitted threshold
limit values (LEL) are exceeded.
WARNING
Any parts that were opened or removed for cleaning and/or maintenance work must be closed or
refitted. Otherwise, faulty solvent concentration measurements might be recorded. The doors or cov-
ers at the dryer must remain closed during operation. All measuring points on the measuring stations
must be closed with appropriate blind plugs.
WARNING
Opening explosion pressure relief dampers
Overpressure in the drying system causes the explosion pressure relief dampers to open automati-
cally. Risk of injury for persons when opening the dampers. Do not deposit objects in front of the
dampers. Do not block the dampers.

X000288251
WARNING
Electrostatic discharges may also occur when using inks that contain metal, e.g. gold ink. Therefore,
inks containing metal should only be used in the last color deck.
WARNING
The drying system has been designed for the use with class T2 solvents for gravure printing and class
T3 solvents for flexographic printing. Solvents containing phenol and epoxide require a special up-
grade to be made to the gas warning device! Only the quantity of solvent that is listed on the dryer
rating plate attached to the machine is to be supplied. Only ever use the data specified on the rating
plate for the dryer attached to the machine to calculate the maximum permitted amount of solvent.
For calculation purposes please refer to the chapter "Drying system" under the heading "Calculation
examples" in the instruction manual.
WARNING
If the processing air is heated by heat exchangers, the flow temperature of the heat exchanger must
be set up such that the surface temperature never exceeds 80% of the ignition temperature of the
solvent being used.
The heat exchangers that have been installed for dryers designed for flexographic printing have been
laid out for max. flow temperatures of 240 degrees Celsius / 464 degrees Fahrenheit (80 %, T2). The
T3 approval is voided with flow temperatures greater than 160 degrees Celsius / 320 degrees Fah-
renheit.
The heat exchangers that have been installed for dryers designed for gravure printing have been laid
out for max. flow temperatures of 240 degrees Celsius / 464 degrees Fahrenheit (80 %, T2). The T2
approval is voided with flow temperatures greater than 240 degrees Celsius / 464 degrees Fahrenheit.
NOTE
Hot air mode
The hot air mode may only be used when the machine is running and the blowers are switched on.
The blowers can only be switched off when the machine is at a standstill.
NOTE
Preheating mode
This mode renders possible that the heaters operate although the machine is not running. It takes 5
minutes to switch on this mode. When switching on the machine drive during this period, preheating
mode changes over to heating mode. Switch off the switched on heaters after the machine has stop-
ped. The blowers remain switched on. They can be switched off by pressing the BLOWER button
once again.

X000288251
The current operating status of the drying system can be retrieved in ' Procontrol '.
Pos. Description
(1) Status symbol of the blowers in the between-color drying
(2) Status symbol of the burners in the between-color drying
(3) Status symbol of the blowers in the tunnel drying
(4) Status symbol of the burners in the tunnel drying
Symbol State of the sta- Description

tus symbol
Flashing red: the blowers are inactive.
Flashing green: the blowers are active.

X000288251
Symbol State of the sta- Description

tus symbol
Flashing red: the burners are inactive.
Flashing yellow: the burners are on standby.
Flashing alter- the burners are in their startup phase.

nately yellow
and green:
Flashing green: the burners are active.

X000288251
Operating the drying system
Activating the fans in the drying system
NOTE
The burners need to be shut off completely once within 24 hours to ensure troublefree functioning of
the burners.
The drying system is the largest energy-consuming component in the machine.

The tunnel drying and between-color drying temperatures should be set up energy-efficient, i.e. as
low as possible for the current printing job. Additionally, adequate blast air speeds for both drying
systems should be selected.
(1) Drying button
Press the drying button (1).

The LED in the drying button (1) blinks orange
and the fans are in their startup phase.
The fans are ready for operation when the LED 1
in the button flashes orange.
tro_0268
Cold air operation is now possible. The drying air is not heated.

X000288251
Activating the burner in the drying system
The fan and the burner can be activated and deactivated and the drying parameters can be
changed at any time before switching on the drive.
The burners can be activated individually or conjointly.
(1) Burner button Activate/deactivate be-

tween-color drying
(2) Burner button Activate/deactivate tunnel
drying
(3) Drying button
Call up screen page 7 in ' Procontrol '.

Activate the burner by actuating the respective
button (1) and/or (2).
Press the drying button (3).
The LED in the drying button (3) blinks orange
and the fans are in their startup phase.
The LED in the drying button (3) blinks green
and the burners are in their startup phase.
The drying sysstem is ready for operation when
the LED in the drying button (3) flashes green.

X000288251
Switching on the drying system from standby mode
When the drying system is ready for operation and the drive is not started within approx. three
minutes, the burners go into standby mode. The LED in the drying button (1) flashes green.
(1) Drying button
Press the drying button (1) to switch on the

burners from standby mode.
The burners are in their startup phase.
The drying system is ready for operation when 1
the LED in the drying button (1) flashes green.
Press and hold down the drying button (1) to
switch off the drying system.
The LED in the drying button (1) goes dark.
tro_0269

X000259773

X000259773
Measuring Denomination Remark

point
P 1.3 Static pressure Make-up air pressure Make-up air monitoring
switch BCD
P 1.4 Total pressure Make-up air pressure
switch BCD
P 1.7 Static pressure Make-up air reference Pressure measurement for make-up air
pressure BCD regulation
P 2.3 Static pressure Make-up air pressure Make-up air monitoring
switch TD
P 2.4 Total pressure Make-up air pressure
switch TD
P 2.7 Static pressure Make-up air reference
pressure TD
P 2.9 Static pressure Nozzle air reference
pressure TD
P 3.1 A Static pressure Exit air measuring nozzle Redundant exit air monitoring
BCD
P 3.2 A Total pressure Exit air pressure switch
BCD
P 3.1 B Static pressure Exit air measuring nozzle
BCD
P 3.2 B Total pressure Exit air pressure switch
BCD
P 3.3 Static pressure Reference air pressure Pressure measurement for exit air regu-
Exit air lation
BCD P IN 1 Between-color drying - Solvent sample Sampling for LEL monitoring/regulation
for analyzer
BCD P IN 2 BCD - Solvent sample for analyzer (USA) Sampling for LEL monitoring/regulation
(USA)
TD P IN 1 Between-color drying - Solvent sample Sampling for LEL monitoring/regulation
for analyzer
TD P IN 2 BCD - Solvent sample for analyzer (USA) Sampling for LEL monitoring/regulation
(USA)
P OUT 1 Recirculation of sovlent sample
P OUT 2 Recirculation of sovlent sample
P OUT 3 Recirculation of sovlent sample (USA)
PT 1 BCD Temperature sensor Redundant temperature monitoring
PT 2 TD Temperature sensor Redundant temperature monitoring

X000232662

Definitions
Term Definition
Abbreviation Unit Explanations

Mmax g/h Maximum throughput of releasable flammable substances
per hour introduced into the dryer or released in the dryer.
Vmin(s) m3(s)/h Minimum exit air flow rate at drying temperatures, based on
20 C and 1013 mbar, measured in consideration of the flow
resistance in the dryer and the air ducts (see rating plate).
Vmin,t m3/h Minimum exit air flow rate at drying temperature, measured
in consideration of the flow resistance in the dryer and the air
ducts.
t C Drying temperature
LEL g/m3 (S) Lower explosive level of the released flammable substances
at 20 C.
Notes:
The values specified by the ink or coating material manufac-
turers must be used.
If the components of a solvent blend are known, while the LEL
of the blend is not, the LEL of the solvent cormponent with
the lowest value has to be applied.
If no specifications are available, then 40 g/m3 shall be used
as the reference value.
LELt g/m3 Lower explosive level of the released flammable substances
at drying temperature.
CLELperm, t % of Maximum permitted concentration level of releasable flam-
LEL mable substances at drying temperature.
CLELperm % of Maximum permitted concentration level of releasable flam-
LEL mable substances at drying temperature.
f Ventilation coefficient, quality factor of ventilation, W&H's es-
timate = 1
Cperm g/m3(S) Maximum permitted amount of releasable flammable sub-
stances in the entire vapor space.
LEL % Value for unknown temperature dependence on LEL. Value
= -20
PW m Printing width for the current job
S g/m2 Total amount of solvent applied in all color decks. To be cal-
culated from the amount of ink applied and the area cover-
age.

X000232662
Abbreviation Unit Explanations

Vmach m/min Permitted machine speed
BCD Between-color drying
TD Tunnel drying

X000232662
Example calculation for a flexo printing press
NOTE
The depicted calculations do not come up to reality on the machine. They are only intended as a
possible calculation for the drying system.
NOTE
Minimum exit air flow rate based on 20 degrees Celsius and 1013 millibar.
Values searched for

Abbreviation Unit Value
Mmax kg/h ?
Vmach m/min ?
Given values
Abbreviation Unit Value
Vmin(s) m3(s)/h 4370 m3/h (see rating plate)
CLELperm 20 C % of LEL 40 operating area 1 (see table with default values)
LEL g/m3 40 (unknown solvent)
f 1
LEL %/100K -20 (temperature dependence of LEL)
t C 120
PW m 0.5 m current printing width
S g / m2 4.6 (solvent application)
Table with default values

Specifications according to EN 1539 *Operating zone 1 = 40 %
*Operating zone 2 = 60 %
Indications according to AS 1375 (Appendix F6) 25 % AS 1375 safety factor = C4
Indications according to NFPA 86 45%
Term Definition
*Operating zone 1 Refers to the operating zone in which the temperatures in any section of
*Operating zone 2 Refers to the operating zone in which the temperatures in any section of
General formula for calculating the max. throughput of releasable substances (solvent
throughput):
Mmax = (Vmin(s) x LEL x CLELperm 20 C / 100 x (1 - LEL / 10000 x (t - 20))) / 1000

X000232662
General formula for calculating the maximum machine speed:

vmach = (Mmax x 1000) / (Lm x PW x 60)
Mmax TD = (4370 m3/h x 40 g/m3 x 40 % / 100 x (1 - 20 % / 10000 x (120 C - 20))) / 1000

Mmax = 55 kg/h
vmach = (55 kg/h x 1000) / (4.6 g/m2 x 0.5 m x 60)
vmach = 399 m/min
When applying this amount of ink, the permitted machine speed is 399 m/min

X000260079
CAUTION
Example of dryer labels
Only the amount of solvent that is listed on the dryer rating plate attached to the machine is to be
supplied. Only the data listed on the dryer rating plate attached to the machine is to be used to
calculate the maximum permitted amount of solvent. For calculation purposes please refer to the
chapter "Drying system" under the heading "Calculation examples" in the instruction manual.
NOTE
Only those values specified on the rating plates attached to the dryers are relevant for your calcula-
tion!
Typ XXXX DB 820
HEIZFLCHENTEMPERATUR (max.) > 700 C

HEATING SURFACE TEMPERATURE (max.) > 700 C
TEMP. SURF. CHAUFF. (maxi) > 700 C
TROCKNUNGSTEMPERATUR (max.) 100 / 120 C

DRYING AIR TEMPERATURE (max.) 100 / 120 C
TEMP. SCHAGE (maxi) 100 / 120 C
LSEMITTELDURCHSATZ unbek. Lsemittel UEG 40 g/m 55 kg/h

SOLVENT THROUGHPUT unknown solvent LEL 40 g/m 55 kg/h
DBIT SOLVANT solvant inconnu LIE 40 g/m 55 kg/h
LSEMITTELDURCHSATZ N-PROPANOL UEG 52 g/m 85 kg/h

SOLVENT THROUGHPUT N-PROPANOL LEL 52 g/m 85 kg/h
DBIT SOLVANT N-PROPANOL LIE 52 g/m 85 kg/h
LSEMITTELDURCHSATZ ETHANOL UEG 59 g/m 94 kg/h

SOLVENT THROUGHPUT ETHANOL LEL 59 g/m 94 kg/h
DBIT SOLVANT THANOL LIE 59 g/m 94 kg/h
FORTLUFTVOLUMENSTROM (20C, 1013 mbar) 4370 m/h

ESCAPING-AIR VOLUME FLOW (20C, 1013 mbar) 4370 m/h
DBIT AIR CHAPP. (20C, 1013 mbar) 4370 m/h
30205399 30205401
Tro_0257

X000258363
Designation Explanations
BCD Between-color drying
TD Tunnel drying
PAM Printing area monitoring
ASH n. l. FW Exhaustion after the last color deck (option)
P/I Pressure tranmitter
PS Flow monitor
PT 100.1/2 Redundant temperature monitoring
BCD SA 1 Solvent analyzer Monitoring Europe
Solvent analyzer Control Europe/USA
TD SA 1 Solvent analyzer Monitoring Europe
Solvent analyzer Control Europe/USA
BCD SA 2 Solvent analyzer Monitoring USA
TD SA 2 Solvent analyzer Monitoring USA
P OUT... Connections Solvent sample recirculation
P 3.1.../3.2... Redundant exit air monitoring

X000258363
Designation Explanations
1 Make-up air BCD+TD
2 Make-up air of between-color drying
3 Fresh air of between-color drying
4 Additional fresh air of between-color drying
5 Exhaust air of between color drying
6 Make-up air of tunnel drying
7 Fresh air of tunnel drying
8 Additional fresh air of tunnel drying
9 Exhaust air of tunnel drying
10 Exit air BCD+TD
11 Exhaust air BCD+TD
12 Exhaust air of exhaust hood after the last color deck
Identification of the dampers
K 1.1... Dampers at the distributor pipe Make-up air
K 1.3... Dampers at the distributor pipe Exhaust air
K 1.4 Additional fresh air flap Between-color drying
K 2.31/K 2.32 Dampers Exhaust air Tunnel drying
K 2.4 Additional fresh air flap Tunnel drying
K3 Exit air damper
PW Flow restrictor Make-up air Tunnel drying

X000258363

Z WINDMLLER & HLSCHER 5 Operation | Solvent analyzer

5.11.1 Solvent analyzer Setup.....................................................................................................2
Sampling system Design...............................................................................................3
Setup Solvent................................................................................................................4

5 Operation | Solvent analyzer Z WINDMLLER & HLSCHER
X000229737

Safety instructions
DANGER
Fire and explosion hazard due to improper adjustment of the solvent analyzers.
Fire and explosion may hurt persons and cause damage to the machine.
Before starting a new job be sure to check whether the solvent analyzers on the machine have been
adjusted to the correct solvent or solvent mixture.
Response factor:
The response factor specifies the sensitivity of the sensor with respect to a specific solvent relative
to propane.

X000229737
Sampling system Design
1 2 3
4
11
5
6
7
11
8
12
2 3
11
9
10
3
2
Tro_0248
5
(1) Analyzer Pressure chamber monitoring (2) Flowmeter with ring initiator
(3) Filter element (4) Solvent sample Pressure chamber mon-
itoring On
(5) Compressed air On (6) Injector
(7) Recirculation of sovlent sample (8) Solvent sample Between-color drying On
(9) Analyzer Tunnel drying (10) Solvent sample Tunnel drying On
(11) Terminal box (12) Analyzer Between-color drying
NOTE
For a detailed functional description see the manufacturer's instruction manual.

X000229737
Setup Solvent
Calling a password-protected screen page
(1) Page overview

(2) Password entry
Actuate the page overview (1) button and go to

the page overview.
Enter your password (2) and call screen pages
420 / 423.
Checking the solvent setup for correctness
(1) Solvent designation
Check on the screen pages whether the ap-

propriate solvent or solvent mixture (1) has
been entered.

X000229737
Selecting solvents
(1) Solvent ID number

(2) Solvent designation
(3) Display of response value
(4) Display of temperature correction values
(5) Solvent display
Open the online help.

Use the online help to find out the solvent ID
number.
Enter the ID number of the desired solvent in
input field (1).
The solvent parameters are assigned to the
fields (2), (3) and (4).
Enter the numeric value zero in the respective
input field if the introduced solvent is not listed
in the online help.
The sum of the percentage shares of the en-
tered solvents (5) should be 100%.
If the mixture contains more than four solvents,
select a specialty mixture from the listbox and
enter it in input field (1). Consult the W+H Serv-
ice Department in this particular case.
Enter the solvent composition for the first up to
the last but one color deck for the between-col-
or drying (screen page 420). Enter the solvent
composition for the last color deck for the tun-
nel drying (screen page 423).
Example Ethanol:
Take the related numeric value from the online
help and enter in input field (1).
The word 'Ethanol' automatically appears in
display field (2) and the related response value
is displayed in display field (3). The input field
for the response factor is disabled.
If additional solvents are contained, please pro-
ceed accordingly on lines two to four.

X000229737
Entering the solvent mixture
(1) Solvent content

(2) Input field
Enter the solvent content in the ink in input field

(1).
Here, the solvent content is the percentage
share of a solvent based on 100% solvent.
If the mixture contains more than four solvents,
enter 'zero' in input field (2) to allow entry of a
specialty mixture. Consult the W+H Service
Department in this particular case.
The sum of the percentage shares (1) must be
100%.
The response factor for a solvent mixture will
be defined automatically.

Z WINDMLLER & HLSCHER 5 Operation | Slitting assembly

5.12.1 Safety information.............................................................................................................2

Mode..............................................................................................................................2
Web infeed side.............................................................................................................3
Web outfeed side...........................................................................................................4
5.12.3 Positioning of the cutting assembly...................................................................................5
5.12.4 Setting the spreader roller.................................................................................................7
5.12.5 Changing the blades.........................................................................................................8
5.12.6 Setting up the edge trim removal......................................................................................9
5.12.7 Draw prior to the rewind..................................................................................................11

5 Operation | Slitting assembly Z WINDMLLER & HLSCHER
X000288403
CAUTION
Knives or blades
Risk of cuts from knives or blades.
Wear cut-resistant gloves as per anti-cut class 5 according to European standard EN 388.

Mode
The slitter is used to cut the web in longitudinal direction at any position desired. To do this, blade
holders fitted with blades are pneumatically pivoted into the web.
The blade holders can be shifted manually across the entire working width.
Adjustable spreader rollers ensure that the cut webs can be rewound without overlapping.
When working with an edge trimming unit the trims may be removed by means of an edge trim removal
system which can be supplied as an option.

X000288417
Web infeed side
(1) Knife carrier drive shaft with blade hold- (2) Handwheel for fine adjustment of the
ers knife carrier drive shaft
(3) Lever to swing the swiveling roller in and (4) Handwheel to set up the blade angle
out. Set the wrap angle
(5) Electrical operator panel for the slitting (6) Pneumatic operator panel for the draw
assembly and the web guide control and the rewind (option)

X000288417
Web outfeed side
(1) Edge trim removal (option) (2) Spreader roller drive

(3) Knife roller oscillation drive (4) Draw drive prior to the rewind (option)

X000288463

Positioning the blade holders
CAUTION
Risk of gashes
Connect the compressed-air supply line only to those blade holders that are actually required.
(1) Locking lever

(2) Compressed-air supply
(3) Blade holder
Release the locking lever (1).

Move the blade holder (3) into the required po-
sition.
Tighten the locking lever.
Connect the compressed-air supply line (2) to
the plug nipple.
Knife shaft positioning
(1) Handwheel
(2) Locking lever

Turn the handwheel (1) to move the knife shaft
horizontally.
The adjusting range is plus / minus ten milli-
meters.
Tighten the locking lever.

X000288463
Pivoting the blade into the web
(1) BLADE DOWN/UP
Press the BLADE DOWN/UP button (1).

The blade moves to the working position and
cuts the web.
Press the BLADE DOWN/UP button (1) again. 1
The blade raises into its rest position.
Ls_0277
Switching on the oscillating unit
The blade is swung into the web.
(1) KNIFE OSCILLATION ON/OFF
Press the KNIFE OSCILLATION ON/OFF but-

ton (1).
The drive for knife oscillation is switched on
and the shaft with the blade holders starts to
1
oscillate.
Press the KNIFE OSCILLATION ON/OFF but-
ton (1) again.
The drive for knife oscillation is shut down.
Ls_0278

X000288453

Setting the wrap angle
(1) Locking pin

(2) Lever
Pull and keep the locking pin (1) pulled.

Use the lever (2) to swivel the swivel roller in
the desired position and thus to determine the
wrap angle at the spreader roller.
The wrap angle cannot be readjusted infinitely
but only in the given positions.
Let the locking pin go.
The swiveling roller is locked in this position.
Setting the blade angle
(1) Locking lever

(2) Handwheel

Turn the handwheel (2) to set the blade angle.
Retighten the locking lever after the setting.
Switching on the spreader roller
(1) SPREADER ROLLER ON/OFF
Press the SPREADER ROLLER ON/OFF

pushbutton (1).
The drive of the spreader roller is powered up
ready for use. The spreader roller starts to ro-
tate upon machine start.
Press the SPREADER ROLLER ON/OFF
pushbutton (1) once more.
The drive of the spreader roller is shut down.
Ls_0252

X000110952

Removing the blade holders
CAUTION
Knives or cutting blades
Risk of cuts from knives or cutting blades.
(1) Compressed-air supply

(2) Upper part Blade holder
(3) Lower part Blade holder
Remove the compressed-air supply line (1)

from the blade holder.
Pull the upper part (2) of the blade holder up
and out of the lower part (3).
The upper part is connected to the lower part
by means of a magnet. The upper part can be
separated from the lower part without using a
tool.
Replacing the blade
Requirements:
The upper part of the blade has been removed and is ready for use at a suitable working place.
(1) Screw
(2) Support
(3) Blade
Remove the screw (1) and the support (2).

Replace the blade (3).
Fit the support (2) and tighten using the screw
(1).

X000110952
Turning the blade holder
Both sides of the blade can be used without any problem by turning the upper part of the blade holder.
(1) Upper part Blade holder

(2) Lower part Blade holder
Pull the upper part (1) of the blade holder up

and out of the lower part (2).
The upper part is connected to the lower part
by means of a magnet. The upper part can be
separated from the lower part without using a
tool.
Turn the upper part (1) through 180 degrees
and fit it back into the lower part (2).

Horizontal positioning of the suction socket
(1) Locking lever

(2) Suction socket

Use the holder to move the suction socket (2)
in the desired position.
Re-tighten the locking lever.

X000288476
Vertical positioning of the suction socket
(1) Locking lever

(2) Suction socket

Push the suction socket (2) up or down in the
desired position.
Re-tighten the locking lever.
Switching on edge trim removal
The suction nozzles should be connected to the edge trim removal system.
(1) EDGE TRIM REMOVAL ON/OFF
Press the EDGE TRIM REMOVAL ON/OFF

pushbutton (1).
The drive of the edge trim removal system is
powered up.
1
Press the EDGE TRIM REMOVAL ON/OFF
pushbutton (1) once more.
The drive of the edge trim removal system is
shut down.
Ls_0263

X000288424

Setting up the contact pressure
(1) Precision control valve for the DRIVE

SIDE CONTACT PRESSURE
(2) Precision control valve for the OPERA-
TOR SIDE CONTACT PRESSURE
Use the precision control valve (1) to set up the

contact pressure for the nip roll on the drive
side.
The set pressure is displayed at the manome-
ter.
Use the precision control valve (2) to set up the
contact pressure for the nip roll on the operator
side.
The set pressure is displayed at the manome-
ter.
Swinging in the nip roll
(1) NIP ROLL ON / OFF pushbutton
Press the NIP ROLL ON / OFF button (1).

The nip roll swings in.
The pushbutton flashes when the nip roll is
swung in.
Press the NIP ROLL ON / OFF button (1) once
more.
The nip roll swings away.

X000288424

Z WINDMLLER & HLSCHER 5 Operation | Rewind
5.13 Rewind
5.13.1 Special function, bypassing the safety light grid................................................................2

Design............................................................................................................................3
Function.........................................................................................................................4
Winding station..............................................................................................................5
5.13.3 Compressed-air supply line...............................................................................................6

Safety information..........................................................................................................6
Compressed air conditioner...........................................................................................7
5.13.4 Establishing the ready-for-operation status.......................................................................8
5.13.5 Swiveling the turret manually..........................................................................................10
5.13.6 Inserting the core.............................................................................................................12
5.13.7 Switching the drive of the winding shaft on or off............................................................14

Requirements..............................................................................................................14
Entering job data..........................................................................................................15
Status LED in pushbuttons..........................................................................................16
Switching on the drive..................................................................................................16
5.13.8 Roll change.....................................................................................................................17

Requirements..............................................................................................................17
Winding core make-ready............................................................................................18
Performing a semi-automatic roll change....................................................................19
Fully automatic roll change..........................................................................................20
Cancel roll change.......................................................................................................21
5.13.9 Nip roll and lay-on roller..................................................................................................22

Winding mode for the nip roll.......................................................................................22
Operating the nip roll and the lay-on roller...................................................................23
5.13.10 Taper tension on the rewind............................................................................................24

Values to be entered into the operator terminal...........................................................24
Taper tension control mode.........................................................................................25
5.13.11 Lifting gear.......................................................................................................................26

Removing the roll.........................................................................................................27
Inserting the winding core............................................................................................28
5.13.12 Automatic chucks (option)...............................................................................................30

5 Operation | Rewind Z WINDMLLER & HLSCHER
X000058888
CAUTION
Machine starting automatically
Depending on production, various parts of the line may start automatically. Parts of your body, clothes,
hair and objects may be caught and crushed.
Samples may be cut out however, be careful not to separate the web when doing so. Separating the
web may result in rotating movements of the drive. The drive will be switched off in a delayed manner
via the DANCER ROLLER AT MAXIMUM mode. All chucks of the center shafts must be inflated and
covered by winding cores. Pay attention to the visual and acoustic warning signals. Keep a safe
distance.
As a standard feature, every winding station in unloading position is switched off automatically when
opening the safety chain or entering the safety area of the light grid.
The machine can optionally be configured as follows:
After the configuration, the winding station which is in its unloading position remains switched on
even if the safety chain is opened or the safety area of the safety light grid is entered.
This is subject to the prerequisites that:

the machine is at a standstill and the web does not move.
The following movements are prevented when opening the safety chain and entering the safety area
of the safety light grid:
The turret does not rotate.
The separating assembly does not traverse.

X000260860

Design
(1) Turret (2) Light barrier and safety chain

(3) Idler rollers (4) Winding stations 1 and 2
(5) Nip roll (6) Cut-off assembly
(7) Cut-off knife (8) Lay-on roller
(9) Roll lifting platform

X000260860
Function
Two motorized winding stations (4) are provided on the turret (1) which can be swiveled at will. De-
pending on the selected operating mode, the web can be wound up either in underwind or overwind
mode The turret renders possible to swivel the ready made core from the unloading position into the
winding position or the finished roll from the winding position into the unloading position. During pro-
duction, the accruing roll should be in the winding position.
If the roll is swiveled from the winding position into the unloading position, idler rollers (3) are provided
to ensure proper web travel. The web is additionally guided by a lay-on roller (8) installed inside the
turret. It can either continually rest against the roll or be swung in on a roll change.
The light barrier and the safety chain (2) secure the interior of the winder against any unauthorized
access.
Automatic roll change without stopping the machine. When initiating a roll change, the separating
assembly moves into its rear limit position. The winding core ready made with glue is swiveled into
the winding position and the finished roll into the removal position. The separating assembly returns
to its front limit position and the nip roll (5) presses the web against the winding core. Depending on
the selected operating mode, one of the two cut-off knives (7) cuts the web. The roll in the unloading
position slows and the relevant drive is switched off. The finish-printed roll can be unloaded by use
of a roll lifting platform (9) which is available as an option.

X000260860
Winding station
DANGER
Exceeding the default speed
Risk of serious injuries to persons and/or damage to machinery.
Please observe the manufacturer's instruction manual with respect to the winding shafts and winding
cores. Limitations resulting from the use of the winding shafts/winding cores must not be exceeded.
If the calculated speed of the winding shaft/winding core exceeds the manufacutrer's specifications
then the machine speed must be reduced when changing the roll.
Formula for calculating the speed of the winding shaft

n = V / (d x ) n = Speed of the winding shaft during a flying reel splice
V = Machine speed in meters/minute during a flying reel splice
d = Outer core diameter in meters
= 3.14159....
DANGER
Using winding shafts when defective
Winding shafts must be handled in such a way that they are protected against damage (e.g. due to
impacts, crushing or dropping). Damage to winding shafts (even if not visible) could result in winding
shaft breakage under operating conditions.
DANGER
The winding cores to be provided by the employer should be laid out for the capacities stipulated in
the technical specifications for the winder, especially when working without winding shafts.
DANGER
Clamping elements coming loose
During operation, all clamping elements of the winding shafts must be covered with suitable material
(extended cores, additional cores or similar).
DANGER
Inappropriate winding cores
During operation, all clamping elements of the winding shafts must be covered with suitable material
(extended cores, additional cores or similar).

X000260860
Every winding station has two winding shaft sup-

ports (1). The roll is pushed onto the middle of the
winding shaft and fixed pneumatically. The roll is
loaded into the winding shaft supports of the de-
sired winding station by use of a roll loading system
which is available as an option.
1 1
Wic_0348

Safety information
WARNING
Pneumatically operated separating assemblies
Always switch off the compressed air supply at the compressed air conditioner and withdraw the key
before starting any works inside the winder. There is in increased risk of injury from the pneumatically
operated separating assemblies.
NOTE
Never change the maximum or minimum working pressures! The manufacturer's warranty liability
does not include damages in the pneumatic system of the machine caused by impermissible air
pressure settings.
The compressed air provided on site must meet the quality requirements agreed upon. The manu-
facturer's warranty liability does not included damages due to an inappropriate composition of the air.
The working pressure is factory-set and must not be changed. The start-up time at the start-up valve
are factory-set and must not be changed.

X000255291
Compressed air conditioner

(2) Key switch
The compressed air conditioner (1) connects the

compressed air supply system of the winder to the
supply line on site. The winder can be disconnect-
ed from the compressed air supply locally by
means of the latchable key switch (2). When
switching off the compressed air supply, the com-
pressed air conditioner vents the pneumatics in the
winder automatically.

X000239883

Requirements: The machine's control voltage must be switched on. Compressed air supply to the
machine must be switched on.
Activating the safety devices
(1) Guard doors

(2) Safety chain
(3) Safety light grid
(4) RELEASE SAFETY CHAIN pushbutton
Close the guard door (1) on the operator side

of the relevant winder.
1
Connect the safety chain (2).
The RELEASE SAFETY CHAIN pushbutton
flashes orange.
Press the RELEASE SAFETY CHAIN push-
button (4). 2
The safety light grid (3) is activated.
1
3
Wic_0376

X000239883
Providing compressed air supply

(2) Key switch
Switch on the key switch (2) on the com-

pressed air conditioner (1).
The compressed air pressure setting is dis-
played in the manometer.
(1) PNEUMATICS ON pushbutton
Press the PNEUMATICS ON pushbutton (1).

The pushbutton is located on the winder's op-
erator panel.
The pushbutton flashes green and the pneu- 1
matic components in the winder are supplied
with compressed air.
Wic_0335

X000239888

During the roll change the turret is swiveled automatically. This can also be done manually.
Requirements:
The winding shaft supports are closed.
The optional lifting table is in its home position.
The cut-off assemblies are in their rear limit position.
(1) Safety chain

(2) Safety light grid 1
(3) SAFETY LIGHT GRID LOCKED push-
button
The safety chain (1) must be connected and the

safety light grid (2) activated.
1
2
Activate the safety light grid by pressing the SAFE-
TY LIGHT GRID BLOCKED pushbutton (3) in the
winder panel. The button stops flashing and the
safety light grid is activated.
When disconnecting the safety chain while the tur-
ret is rotating, all rotational movement is stopped
immediately. In production mode, the machine is
The safety light grid serves as a creep zone pro-
tection. When the safety chain is pushed in and the
turret is moving, all movement is stopped when 3
entering the monitored range of the light grid. In
production mode, the machine is stopped in a min-
imum of time.
Wic_0336

X000239888
(1) TURRET FORWARD pushbutton

2 1
(2) TURRET BACK pushbutton
(3) Turret movement FORWARD
(4) Turret movement BACK
When pressing the TURRET FORWARD pushbut- 1

ton (1), the winding shaft which is in the winding
position is swiveled upwards (3) through the wind-
er and into the loading position. Rotational move-
ment is stopped automatically upon reaching the
loading position .
When pressing the TURRET BACK pushbutton
(2), the winding shaft which is in the winding posi-
3
tion is swiveled downwards (4) through the winder
and into the loading position. Rotational movement
is stopped automatically upon reaching the loading
position.
1 2
1 2
Wic_0337 4

X000239726

Positioning the core on the winding shaft
NOTE
The permissible limits of the core inner diameter must not be exceeded.
(1) Core
(2) Valve
Push the core (1) onto the winding shaft and

align to the middle.
Inflate the winding shaft via the valve (2) to fix
it in place using the air gun provided at the
winder.

X000239726
Opening the winding shaft support
The winding station to be loaded should be in its frontal loading position.
(1) Loading trough

(2) Outer part Winding shaft support
(3) Safety catch
(4) Proximity sensor
Open the safety chain.

Turn the winding shaft support manually until
the loading trough (1) points upwards.
Push the safety catch (3) upwards, hold it down
and push the Outer part Winding shaft support
(2) towards the outer side of the winder.
The proximity sensor (4) recognizes that the
winding shaft support is open. This procedure
should be followed for both winding shaft sup-
ports.

X000239726
Closing the winding shaft support
The winding shaft including the core has been loaded into the winding shaft supports by use of a
lifting gear or another device provided vor this purpose.
(1) Outer part Winding shaft support

(2) Safety catch
(3) Proximity sensor
Pull the Outer part Winding shaft support (1)

towards the inner side of the winder.
The safety catch should audibly click into
place!
The proximity sensor (3) recognizes that the
winding shaft support has been closed. If this
procedure has not properly finished, the ma-
chine is shut off and the winding shaft support
must be checked. This procedure should be
followed for both winding shaft supports.

Requirements
The following switching on sequence should always be observed:

Unwind - rewind - main drive
Activation requirements:
The system is powered up ready for operation.
A roll is in its winding position and the web is threaded into the machine.

X000302020
Entering job data
(1) Job data Winder
1. Enter job data into the winder screen pages or the winder operator terminal.

X000302020
Status LED in pushbuttons

the
push-
button
Blinking orange: The mode is in the switch on process.
Flashing orange: The cut-off assemblies of the unwind and rewind move towards the
roll and ascertain the roll diameter.
Flashing green: The winder motor is active.
Switching on the drive
Switching on the winding motor
NOTE
During the switch-on procedure, the cut-off assemblies move up against the roll to ascertain the
diameter. The cut-off assembly at the unwind returns to its limit position. The cut-off assembly on the
rewind stops at the roll.

ton
Press and hold down the WINDING MOTOR 1

ON/OFF pushbutton (1) until the LED in the
pushbutton flashes green.
1
Let go of the WINDING MOTOR 1 ON/OFF
pushbutton.
The winding motor turns until the web is tight.
Wic_0341

X000302020
Switching off the winding motor
Before switching off the winding motor, the machine must be brought to a standstill. The main drive
must be switched off.

ton
Press the 1 WINDING MOTOR 1 ON/OFF

pushbutton (1).
The winding motor is switched off, the LED in
1
the WINDING MOTOR 1 ON/OFF pushbutton
goes dark.
Wic_0341
5.13.8 Roll change

Requirements
A roll change requires the following conditions to be fulfilled:

The machine is operational and unwinds the web.
The new winding shaft incl. the sleeve is made ready and present in the winder
The blocking chain is connected and the safety light grid activated.
NOTE
A roll change must be initiated in due time before reaching the maximum roll diameter of the accruing
roll.
After the roll change, the finished roll should be taken out of the winder immediately. There is a risk
of colliding with the new roll to be wound up in the winding position.
NOTE
The area of the safety light grid must not be accessed once the roll change has been initiated. If the
requested area of the safety light grid is violated, all rotary movements of the turret and all traversing
movements of the cut-off assembly are stopped. The machine stops as quickly as possible.

X000302098
Winding core make-ready
(1) Winding core
Apply the sleeve (1) with glue or adhesive tape.

X000302098
Performing a semi-automatic roll change
The sleeve diameter must be properly entered into Procontrol or the optional operator terminal .

CHANGE pushbutton

1
CHANGE pushbutton (1) flashes orange. The
turret swings into the winding position, the cut-
off assembly moves close to the winding core.
The winding core accelerates to web speed.
The nip roll presses the web against the sleeve
and the cut-off assembly cuts through the web
according to the winding direction selected.
The wound up roll is braked and the winding
station switched off.
The cut-off assembly stops at the new roll ac-
cording to "Surface winding" or "Gap winding"
mode entered before.
Remove the roll.

Caution: The blocking chain should be opened only after the roll change has ended.

X000302098
Fully automatic roll change
A fully automatic roll change is carried out by the machine controller and not by the operator. An
acoustic signal makes the operator aware of the roll change.
(1) Roll change data
1. Enter the roll change data.Once the given diameter of the expiring roll has been reached, roll
change is carried out automatically at the set speed.

X000302098
Cancel roll change
A roll change must be canceled before releasing the cut-off knife.
(1) CANCEL ROLL CHANGE pushbutton
Press the CANCEL ROLL CHANGE pushbut-

ton (1) to cancel the initiated roll change proc-
ess.
The cut-off assembly traverses to its home po-
1
sition, the winding shaft incl. the sleeve is
braked and the drive switched off.
The turret does not swivel back!
Wic_0342

X000239744

Winding mode for the nip roll
After switching on the winding motor, the nip roll stops at the roll. Depending on the selected winding
mode, i.e. gap or surface winding, the nip roll either makes contact with the roll or a gap remains
between the nip roll and the material roll. The increasing roll diameter causes the nip roll to be re-
tracted automatically by the amount of the roll diameter increase.
(1) GAP WINDING
The GAP WINDING mode is used to achieve soft

wound rolls. To prevent web wandering, the nip roll
must be swung onto the roll.
(1) SURFACE WINDING
When using the SURFACE WINDING mode (1),

the nip roll is forced against the roll by a contact
force which can be set by the operator.

X000239744
Operating the nip roll and the lay-on roller
Swinging the nip roll in and out
(1) NIP ROLL FORWARD/BACK pushbut-

ton
Actuate the NIP ROLL FORWARD/BACK

pushbutton (1).
The nip roll moves towards the roll. While mov-
1
ing, the LED in the button flashes orange.
The nip roll rests against the roll according to
the winding mode selected before. The LED in
the button flashes green.
Actuate the NIP ROLL FORWARD/BACK
Wic_0344
pushbutton (1).
The nip roll moves to its limit position. The LED
in the button goes dark.
Swinging the lay-on roller in and out
By default, the lay-on roller is automatically loaded to the roll to be changed during a roll change.
After completion of the roll change the lay-on roller is unloaded from the roll. This function can be
switched on or off in Procontrol. In addition, there is a possibility to manually load the lay-on roller to
the winding station.
(1) LAY-ON ROLLER ON / OFF pushbutton
Actuate the LAY-ON ROLLER ON/OFF push-

button (1).
The lay-on roller swings onto the roll.
The lay-on roller rests against the roll. The LED 1
in the button flashes green.
Actuate the LAY-ON ROLLER ON/OFF push-
button (1).
The lay-on roller moves to its limit position. The
LED in the button goes dark. Wic_0345

X000302152

Values to be entered into the operator terminal
(1) Input fields Web tension
1. Enter the web tension values into the winder operator terminal (optional) or Procontrol.

X000302152
Taper tension control mode
(1) Initial tension

(2) Start diameter at which tension is ta-
pered
(3) End diameter at which tension is tapered
(4) Percentage amount of taper
(5) Web tension after tension has been ta-
pered
(6) Roll Rewind
The material roll (6) has a relatively hard wound

core. In order to avoid telescoping of the roll or that
the winding core is pressed together, web tension
is tapered as the roll diameter increases.
The web tension is continuously tapered from the
start diameter (2) entered into the operation termi-
nal to the end diameter (3) entered. The maximum
taper (4) can be 50 percent of the specified web
tension.

X000260843

Safety instructions
CAUTION
Inappropriate or defective lifting devices
Risk of severe injuries to persons and/or damage to machinery.
Be aware that unsuitable or defective chain hoists may lose their load and thus cause injury to persons
or damage to the machine. Chain hoists and load handling attachment must be in technically perfect
condition when used. Check the hoisting equipment for adequate carrying capacity. Check the hoist-
ing equipment and the load handling attachment for wear at regular intervals and replace whenever
necessary. Never stay or work beneath a suspended load!
CAUTION
There is a risk of severe injury to persons and/or damage to machinery.
When using the lifting gear, the manufacturer's instructions and safety regulations must be heeded.
The lifting gear is laid out for certain roll diameters and roll weights. The given limits must not be
exceeded. Staying beneath the lifting table is forbidden. The lifting table must be secured against
inadvertent mechanical lowering before starting any repair or maintenance works.
NOTE
The lifting gear is intended to load or unload a roll into or from the winder.
All use in excess thereof is forbidden.
Make sure that the winding shaft supports are open before loading or unloading the roll.

X000260843
Removing the roll
Lift table Up
The roll to be removed must be in its unloading position.

The winding shaft supports must be open.

The lift table raises and moves automatically
forward from a preset position.
Carefully move the lift table beneath the roll 1
and lift up the roll until the winding shaft is in
place above the winding shaft supports.
Wic_0419
Moving the lift table out of the winder
(1) LIFT TABLE FORWARD/BACK button
Hold down the LIFT TABLE FORWARD/

BACK button (1).
The lift table returns into its end position.
1
Wic_0421

X000260843
Depositing the roll
(1) LIFT TABLE UP/DOWN
Hold down the LIFT TABLE UP/DOWN button

(1).
Move the lift table into its end position.
1
Wic_0420
Close the winding shaft supports, fit the cordon and activate the safety light grid.
Inserting the winding core
Lift table Up
The winding station to be loaded should be in its loading position.

The winding shaft supports must be open.
A winding shaft fitted with a core must be available on the lift table.

Move the lift table upwards until the winding
shaft is in place above the winding shaft sup-
ports.
1
Wic_0419

X000260843
Moving the lift table into the winder
(1) LIFT TABLE FORWARD/BACK
Hold down the LIFT TABLE FORWARD/

BACK button (1).
The lift table moves forward until it stops auto-
matically above the winding shaft supports.
1
Wic_0421
Depositing the winding core
(1) LIFT TABLE DOWN
Hold down the LIFT TABLE DOWN button (1).

Lower the lift table until the winding shaft lies in
the winding shaft supports.
Check whether the three-corner part of the 1
winding shaft fits properly in the winding shaft
support.
Move the lift table downwards into its end po-
sition.
Wic_0420
Close the winding shaft supports, fit the cordon and activate the safety light grid.

X000239768

If the shafted rewind is provided with an additional automatic roll removal system, the chucks for roll
removal are opened and closed automatically.
This process is controlled by the roll removal system. When the printed roll in the rewind unit is in its
removal position, the roll removal system sends a command to the computer for the rewind to open
the chucks (1). The chucks (1) are opened pneumatically and the roll removal system removed the
roll. Depending on the request, a new winding shaft provided with a core and paste is loaded and the
chucks (1) are closed automatically.
(1) Automatic chucks

Z WINDMLLER & HLSCHER 5 Operation | Inking system
5.14 Inking system

5.14.1 Safety instructions for using the inking unit.......................................................................3
General information.......................................................................................................3
Instructions for handling the agitator..............................................................................4
Safety instructions for using ink containers...................................................................4
Safety instructions for using solvent containers.............................................................5

Design............................................................................................................................6
Function.........................................................................................................................7
5.14.3 Permitted solvents in the washing systems.......................................................................8
5.14.4 Conductivity of fluids.........................................................................................................9
5.14.5 Control elements on the pump and valve unit.................................................................13

Connections.................................................................................................................13
Front control elements.................................................................................................14
Rear control elements..................................................................................................14
5.14.6 Supply system for cleaning agents..................................................................................15

Design and function.....................................................................................................15
Notes...........................................................................................................................16
Function.......................................................................................................................17
5.14.7 Changeover when non-mixable inks are to be used.......................................................18
5.14.8 Control elements on the hand-held panel.......................................................................21

Hand-held panel..........................................................................................................21
Function keys...............................................................................................................22
5.14.9 Inking, wash-up and viscosity screen page.....................................................................24
5.14.10 Starting inking, wash-up, preconditioning or pump out programs...................................25

Color deck inking mode...............................................................................................25
Ink or solvent pump out...............................................................................................26
Preconditioning the ink................................................................................................27
Color deck wash-up.....................................................................................................28
Changing over from the inking mode to the wash-up mode for all color decks simulta-
neously........................................................................................................................29
Stopping the inking or cleaning programs...................................................................32
5.14.11 Inking programs...............................................................................................................33
5.14.12 Pump-out programs.........................................................................................................33
5.14.13 Wash-up programs..........................................................................................................34
5.14.14 Pre-conditioning programs..............................................................................................34
5.14.15 Error display on the hand-held panel..............................................................................35

Error display.................................................................................................................35
Error messages...........................................................................................................35

5 Operation | Inking system Z WINDMLLER & HLSCHER
5.14.16 Cleaning the connectors..................................................................................................36
5.14.17 Pivoting and removing the doctor blade chamber...........................................................37

Notes...........................................................................................................................37
Pivoting the doctor blade chamber in order to change the blades...............................37
Pivoting the doctor blade chamber to remove the drain boxes....................................38
Removing the doctor blade chambers.........................................................................39
5.14.18 Layout and assignment of the drain boxes......................................................................41

Drainbox design...........................................................................................................41
Assigning the drain boxes to the doctor blade chambers............................................43
Removing and mounting the drain box........................................................................45
5.14.19 Layout and arrangement of the doctor blade chambers..................................................46

Front side.....................................................................................................................46
Rear side.....................................................................................................................47
Arrangement of the doctor blade chambers in the printing unit (right-hand machine).....
48
Arrangement of the doctor blade chambers in the printing unit (left-hand machine)...49
5.14.20 Profiled element on doctor blade chamber - Blade change............................................50

Blade change...............................................................................................................50
5.14.21 Doctor blade chamber profile - Changing the seal in the machine..................................52
Seal change.................................................................................................................53
5.14.22 Profiled element on the doctor blade chamber - Cleaning..............................................55

Parts needing cleaning Profiled elements Doctor blade chamber...............................55
General........................................................................................................................56
Blade change...............................................................................................................56
Cleaning the doctor blade chamber.............................................................................57
Anilox rolls...................................................................................................................57
5.14.23 Additional doctor blades..................................................................................................58

Notes...........................................................................................................................58
Position of the additional doctor blades.......................................................................58
5.14.24 Fitting the additional doctor blade...................................................................................60

Clamping rail assembly at the additional doctor blade................................................60
Fitting the additional doctor blade................................................................................61
5.14.25 Fitting/removing the clamping rail....................................................................................62
5.14.26 Determining the doctor blade length...............................................................................62

X000161919

General information
DANGER
Electrostatic charging
The line can be electrostatically charged. There is a risk of personal injury from electric shocks caused
by electrostatic charging which may result in uncontrolled reactions.
Provide suitable earthing. Equipotential bonding cables must be connected. Keep the contact surfa-
ces clean.It is forbidden to operate the line unless the equipotential bonding cables are properly
connected. Always wear conductive shoes when working on the inking unit.
CAUTION
Liquids under high pressure
Risk of injury from liquid penetration or splash under high pressure. Thrashing of defective pressure
hoses.
Wear personal safety equipment, keep the lids of all ink containers closed and check the pressure
hoses regularly.
If the inking system is equipped with pneumatic ink pumps, the compressed air supplied must meet
the quality requirements specified in the sheet under the heading "General information on com-
pressed air supply". For this reason, it must only be used with the machine or a suitable compressed
air conditioner.
Ink hoses which are not connected to a doctor blade chamber must be connected to the ink hose
parking position of the respective color deck and locked in place.
Make sure to install and attach the ink hoses in a way that they are not energized in any of the selected
color deck positions. Check the ink hoses and the associated quick-acting couplings at regular inter-
vals (see maintenance instructions for the 'Inking unit').
When cleaning the color decks, the exit air fans at the respective color decks must be switched on.
If the machine is provided with anilox roll covers plates or splash guards, these must be mounted in
both the printing mode and in cleaning mode.
When operating the unit without a filling level monitoring system make sure that sufficient clean
cleaning agent is available and that the container for the dirty cleaning agent is sufficiently empty
before starting a cleaning or pump-out cycle. There is a risk that the discharge container spills over
during the wash-up process.

X000161919
Instructions for handling the agitator
Ink return pipe must be set up correctly and locked in place so that it does not get in contact with the
agitator shaft.
The minimum distance of the agitator shaft from the container bottom or from the ink pipes should be
more than 20 millimeters.
The agitator shaft must be attached to the motor shaft. The locking pin must be locked in place.
The agitator motor must be introduced into the cover flange and the locking screw must be tightened.
Check the agitator shaft for truth of rotation.
The regulating valve is used to set up the operating speed. The operating speed depends on the
viscosity. Low operating speeds result in good agitating effects.
An equipotential bonding conductor is available on the cover and on the ink container and the junc-
tions must be blank.
Agitator monitoring is required. Operating the agitator above ink level is not permitted.
The compressed air motor must be lubricated via oiled compressed air.
The compressed air motor must not be dipped in fluids. Use a solvent-soaked cloth for cleaning.
Safety instructions for using ink containers
DANGER
The line can be electrostatically charged. There is a risk of personal injury from electric shocks caused
by electrostatic charging which may result in uncontrolled reactions.
All equipotential bonding cables must be connected.Keep contact surfaces clean. Disconnect the
ground terminal last when removing the ink container and establish the connection to the ground
terminal first when refitting the ink container. Only ever use suitable, static dissipative ink containers
made of low-sparking material. Do not use containers made of aluminimum, titanium or magnesium.
Always keep the covers of the ink containers closed. Only ever open the ink containers for ink re-
plenishment. Always wear conductive shoes when working on the inking unit.
CAUTION
Ink container lid
The ink container lid may snap shut when controlling the ink and crush parts of your body.
Open the lid completely. Do not deposit any objects behind the lid.

X000161919
Safety instructions for using solvent containers
DANGER
The line can be electrocstatically charged. There is a risk of personal injury from electric shocks
caused by electrostatic charging which may result in uncontrolled reactions.
Only ever use suitable, conductive solvent containers made of low-sparking material. Do not use
containers made of aluminimum, titanium or magnesium. The individual solvent containers on the
color decks providing solvents to control the ink viscosity should only be topped up with the amount
of solvent required for one shift.The solvent containers should be topped up outside the machine.
Solvent containers on color decks not involved in the production process must not contain any sol-
vents. Put the solvent pumps out of service. Keep the lids of the solvent containers closed to prevent
volatilizing and thus interference effects of the ambient air from occurring. The equipotential bonding
cables for the solvent containers provided on the machine must be connected.To make filling safe,
the container to be emptied and the one to be filled must be connected to the equipotential bonding
cable.

X000126602

Design
(1) Air conditioning (2) Ink container

(3) Pipe bridge (4) Transport cart with Turboclean box
(5) Cleaning agent and discharge container (6) Hand-held panel
(7) Base frame with Turboclean box (8) Doctor blade chamber and anilox roll

X000126602
Function
NOTE
Only aerosol-free and particle-free fluids and gases or gas mixtures must be used.
The inking and wash-up system Turboclean serves to supply the individual color decks on the
machine with inks and to ensure even ink transfer to the anilox roll.
Moreover, it renders possible to automatically clean the entire ink supply system including the
anilox roll and the connecting elements from left-over inks.
The pump and valve unit is the central element. It comprises the necessary pumps and valves for
supplying and cleaning a color deck. A special air conditioner is used for cleaning the compressed
air required for the pump and valve unit.
All of the pump and valve units are supplied with compressed air and cleaning agents via a base
frame. A specially designed supply system provides the cleaning agent. The used agent is collected
in a discharge container.
Hose connectors connect the pump and valve unit to the doctor blade chamber of the respective
color deck. The doctor blade chamber ensures even inking of the anilox roll. For normal printing,
the ink pails supplied by the ink manufacturers can be used. As an option, there are ink containers
which can be moved towards the pump and valve unit via rollers. The ink is pumped out of the
pump and valve unit through the doctor blade chamber and back into the ink container in an en-
closed circuit.
In wash-up mode, the ink is first pumped out of the ink supply system back into the respective
container. The cleaning agent is flushed from the supply system through the entire hose and
chamber system in various sequences. The anilox roll is cleaned as well.
After washing, the dirty cleaning agent is pumped into the discharge container.
All functions of the pump and valve unit are carried out by use of the hand-held panel. The settings
required for operating the unit are made at Procontrol.

X000050408
Solvent type Note Percent

Alcohol in amounts up to 100 percent
Ethanol
Isopropanol
N-Propanol
Ester in amounts up to 30 percent
Ethyl acetate
n-butyl acetate
Glycol ether in amounts up to 40 percent
Ethoxypropanol
Methoxybutanol
Diacetone alcohol
Butyl glycol
Ketones in amounts up to 5 percent
Methyl ethyl keton
Acetone
Methyl iso butyl keton
Hydrocarbon must not be contained
Toluene
Cyclohexane
Benzine 80/10
Aluminum doctor blade chamber

Thinned acids and lyes PH value pH 4 - 9
CFRP doctor blade chamber

diluted lyes PH value pH 9 - 12
The solvent mixture should have an evaporation number similar to ethanol to ensure for a good
washing effect.

X000150591

The chart has been taken from 'Berufsgenossenschaftliche Regeln fr Sicherheit und Gesundheit bei
der Arbeit' , BGR 132.
The chart contains conductivities of fluids measured by various authors and is taken from Techniques
of Chemistry Volume II, Organic Solvents, Physikal Properties and Methods of Purification. John A.
Riddick und William B. Bunger, John Wiley & Sons, 4. Edition 1986.
The values given depend on impurities in fluids and are indicative. When pure liquids are used, lower
conductivity values may be assumed.
Hydrocarbons exclusively comprising atoms of C and H must always be regarded as insulating when
in pure form.
Fluid Formula Conductivity [m/s

(mesured at C)
Acetaldehyde CH3CHO 1.20 x 10-4 (0 C)
Acetamide CH3CONH2 8.8 x 10-5 (83.2 C)
Acetic ether CH3COCH2COOCH2CH3 4 x 10-6 (25 C)
Acetone CH3COCH3 4.9 x 10-7 (25 C)
Acetonitrile CH3CN 6 x 10-8 (25 C)
Acetophenone C6H5COCH3 3.1 x 10-7 (25 C)
Acrolein CH2 = CHCHO 1.55 x 10-5 (- C)
Allylamine CH2 = CHCH2NH2 5.7 x 103 (25 C)
Formic acid HCOOH 6.08 x 10-3 (- C)
Ethyl formate HCOOC2H5 1.45 x 10-7 (20 C)
Methyl ester of formic acid HCOOCH3 1.92 x 10-4 (17 C)
Propyl formate HCOOCH2CH2CH3 5.5 x 10-3 (17 C)
Ethanolamine HOCH2CH2NH2 11.0 x 10-4 (25 C)
Aniline C6H5NH2 2.4 x 10-6 (25 C)
Anisole C6H5OCH3 1 x 10-11 (25 C)
Benzine approx. 1 x 10-13 (20
C)
Ethyl benzoate C6H5COOCH2CH3 1 x 10-7 (25 C)
Benzonitrile C6H5CN 0.5 x 10-5 (25 C)
Succinic dinitrile NCCH2CH2CN 5.64 x 10-2 (- C)
Bromobenzene C6H5Br 1.2 x 10-9 (25 C)
1-bromonaphthalene C10H7Br 3.66 x 10-9 (25 C)
Bromoform CHBr3 < 2 x 10-6 (25 C)
Butanol-(1) CH3CH2CH2CH2OH 9.12 x 10-7 (- C)
2-Butanol CH3CH2CHOHCH3 < 1.0 x 10-5 (- C)
tert- butanol (CH3)3COH 2.66 x 10-6 (27 C)

X000150591

(mesured at C)
2-Buntanone CH3CH2COCH3 3.6 x 10-7 (- C)
2-Butoxyethanol CH3CH2CH2CH2OCH2CH2OH 4.32 x 10-5 (20 C)
Caprylic acid CH3(CH2)5CH2COOH < 3.7 x 10-11 (- C)
Quinoline C 9H 7N 2.2 x 10-6 (25 C)
Chloroethane CH3CH2CI < 3 x 10-7 (0 C)
Chlorobenzene C6H5 CI 7 x 10-9 (25 C)
1-Chlorobutane CH3CH2CH2CH2CI 1 x 10-8 (30 C)
2-Chlorobutane CH3CH2CHCICH3 1 x 10-8 (30 C)
1-Chloro-2-methylpropane (CH3)2CHCH2CI 1 x 10-8 (30 C)
2-Chloro-2-methylpropane (CH3)3CCI 1 x 10-8 (30 C)
Chloroform CHCI3 < 1 x 10-8 (25 C)
Ethyl cyanoacetate NCCH2COOCH2CH3 6.9 x 10-5 (25 C)
Methyl cyanoacetate NCCH2COOCH3 4.49 x 10-5 (25 C)
Cyclohexanone CH2CH2CH2CH2CH2CO 5 x10-16 (25 C)
Diethylene glycol HOCH2CH2OCH2CH2OH 5.86 x 10-5 (20 C)
1,2-Dibromethane CH2BrCH2Br < 2 x 10-8 (19 C)
1,1-Dichloroethane CH3CHCI2 2.0 x 10-7 (- C)
1,2-Dichloroethane CH2CICH2CI 4.0 x 10-9 (25 C)
Cis-,2-Dichloroethylene CHCICHCI 8.5 x 10-7 (25 C)
o-Dichlorobenzene O-C6H4CI2 3 x 10-9 (25 C)
Dichloromethane CH2CI2 4.3 x 10-9 (25 C)
Diesel oil (commercially pure) approx. 1 x 10-13 (20
C)
N,N-dimethylformamide HCON(CH3)2 6 x 10-6 (25 C)
Dimethyl sulfoxide (CH3)2SO 2 x 10-7 (25 C)
p-Dioxane C4H8O2 5 x 10-13 (25 C)
Epichlorhydrine (Molecular formula C3H5OCI) 3.4 x 10-6 (25 C)
Acetic acid CH3COOH 6 x 10-7 (25 C)
Ethyl acetate CH3COOCH2CH3 < 1 x 10-7 (- C)
Amyl acetate CH3COOCH2(CH2)3CH3 1.6 x 10-7 (25 C)
Isobutyl acetate CH3COOCH2CH(CH3)2 2.55 x 10-2 (19 C)
Methyl acetate CH3COOCH3 3.4 x 10-4 (20 C)
Propyl acetate CH3COOCH2CH2CH3 2.2 x 10-5 (17 C)
Ethanol CH3CH2OH 1.35 x 10-7 (25 C)
2-Ethoxy ethanol CH3CH2OCH2CH2OH 9.3 x 10-6 (- C)

X000150591

(mesured at C)
Ethyl bromide CH3CH2Br < 2 x 10-6 (25 C)
Ethyl chloride CH3CH2CI < 3 x 10-7 (0 C)
Ethylenediamine H2NCH2CH2NH2 9 x 10-6 (25 C)
Ethylene glycol (CH2OH)2 1.16 x 10-4 (25 C)
Ethylene imine (CH2CH2)NH 8 x 10-4 (25 C)
Formamide HCONH2 < 2 x 10-5 (- C)
Glycerin HOCH2CH(OH)CH2OH approx. 0.6 x 10-5 (25
C)
Isoamyl alcohol (CH3)2CHCH2 CH2OH 1.4 x 10-7 (25 C)
Isobutanol (CH3)2CHCH2OH 1.6 x 10-6 (25 C)
Isovaleric acid (CH3)2CHCH2COOH < 4 x 10-11 (0-80 C)
Ethylene carbonate (Molecular formula C3H4O3) < 1 x 10-5 (- C)
Diethyl carbonate (CH3CH2O)2CO 9.1 x 10-8 (25 C)
m-Cresol m-CH3C6H4OH 1.397 x 10-6 (25 C)
o-Cresol o-CH3C6H4OH 1.27 x 10-7 (25 C)
p-Cresol p-CH3C6H4OH 1,378 x 10-6 (25 C)
Metatoluidine m-CH3C6H4NH2 5.5 x 10-8 (25 C)
Methanol CH3OH 1.5 x 10-7 (25 C)
N-Methylacetamide CH3CONH(CH3) 2 x 10-5 (40 C)
N-Methylformamide HCONCH(CH3) 8 x 10-5 (25 C)
4-Methyl-2-pentanon (CH3)2CHCH2COCH3 < 5.2 x 10-6 (35 C)
N-Methyl-2-pyrrolidone (Molecular formula C5H9ON) 2 x 10-6 (25 C)
2-Methoxyethanol CH3OCH2CH2OH 1.09 x 10-4 (20 C)
Ethyl lactate CH3CH(OH)COOCH2CH3 1.0 x 10-4 (25 C)
Nitroethane CH3 . CH2 NO2 5 x 10-5 (30 C)
Nitrobenzene C6H5NO2 2.05 x 10-8 (25 C)
Nitromethane CH3NO2 5 x 10-7 (25 C)
1-Nitropropane CH3CH2CH2NO2 3.3 x 10-5 (35 C)
2-Nitropropane CH3CH(NO2)CH3 5 x 10-5 (30 C)
1-Octanol CH3(CH2)6CH2OH 1.39 x 10-5 (23,1 C)
Ethyl oxalate (COOCH2CH3)2 7.12 x 10-5 (25 C)
Phenetole C6H5OC2H5 < 1.7 x 10-6 (25 C)
Phenol C6H5OH (1-3) x 10-6 (50 C)
Dibutyl phthalate 1,2-C6H4(COOCH2CH2CH2CH3)2 1.8 x 10-7 (30 C)
1-propanol CH3CH2CH2OH 9.17 x 10-7 (18 C)

X000150591

(mesured at C)
2-propanol CH3CHOHCH3 5.8 x 10-6 (25 C)
Propionaldehyde CH3CH2CHO 1 x 10-2 (25 C)
Propionitrile CH3CH2CN 8.51 x 10-6 (25 C)
Propionic acid CH3CH2COOH < 1 x 10-7 (25 C)
Propionic acid ethyl ester CH3CH2COOCH2CH3 8.33 x 10-2 (17 C)
Pyridine C 5H 5N 4.0 x 10-6 (25 C)
Salicylaldehyde (Molecular formula C7H6O2) 1.64 x 10-5 (25 C)
Dibutyl sebacate C4H9OOC(CH2)8COOC4H9 1.7 x 10-9 (30 C)
Butyl stearate CH3(CH2)16COOCH2CH2CH2CH3 2.1 x 10-11 (30 C)
Sulfolane (Molecular formula C4H8O2S) < 2 x 10-6 (30 C)
Tetrachloroethylene CCI2 = CCI2 5.55 x 10-2 (20 C)
Carbon tetrachloride CCI4 4 x 10-16 (18 C)
1,1,2,2-Tetramethylurea (CH3)2NCON(CH3)2 < 6 x 10-6 (- C)
N, N, N, N-
o-Toluidine o-CH3C6H4NH2 3,792 x 10-5 (25 C)
p-Toluidine p-CH3C6H4NH2 6.2 x 10-6 (100 C)
o-Tolunitrile C6H5CH2CN < 0.5 x 10-5 (25 C)
Toluene C7H8CH3 8 x 10-14 (- C)
Triethylene glycol HOCH2CH2OCH2CH2OCH2CH2OH 8.4 x 10-6 (20 C)
Methylchloroform CH3CCI3 7.3 x 10-7 (- C)
Trichloroethylene CHCL = CCI2 8 x 10-10 (- C)
Pentanenitrile CH3CH2CH2CH2CN 1.2 x 10-6 (- C)
Cleaning solvent see benzine
(commercially pure)

X000126609

Connections
(1) Pump out hose

(2) Ink return hose connection
(3) Ink supply hose connection
(4) Air connections for the optional agitator
motor
(5) Equipotential bonding conductors for the
ink containers
The long dip pipe of the ink container is connected

to the ink supply hose connection (3) by use of a
coupling.
The Ecomixer of the ink container is connected to
the ink return hose connection (2) by use of a cou-
pling.
Make sure not to mix up the connection pipes since
otherwise the ink cannot mix.
For safety reasons, the pump and valve unit and
the ink container should be brought to the same
voltage potential. To do so, the ink container must
be connected to the equipotential bonding con-
ductor (5). Make sure that the connecting points of
the equipotential bonding conductors are bare
metal.
The left-over ink can be pumped out of the ink con-
tainer and into a separate container by use of the
pump out hose (1). If ink is to be pumped out of the
ink container, an equipotential bonding conductor
(5) must be connected to the pump out container
as well.
The optional agitator motor is connected to the air
connections (4)

X000126609
Front control elements
(1) CLEAN CONNECTOR button (optional)
If both CLEAN CONNECTOR (1) buttons are

pressed, the optional connector cleaning function
is carried out.
Rear control elements
(1) Changeover switch on the second dirt

container
(2) Changeover switch on the second sol-
vent
The changeover switch (1) marked with a black dot

is used to switch over to a second dirt container.
The changeover switch (2) marked with a trans-
parent dot is used to switch over to a second clean-
ing agent.

X000127624

Design and function
(1) Clean solvent container (2) Dirty solvent container

(3) Central distribution system

X000127624
Notes
Observe the instructions and details given in the manufacturer's installation and instruction manual
for the respective supply system.
The pertaining local safety instructions for the cleaning agents to be used must be adhered to.
Dispose of the dirty cleaning agents environmentally sound in accordance with the pertaining local
regulations.
If the line is not equipped with a filling level monitoring system, make sure that the dirt container is
sufficiently empty before starting any cleaning or pump out cycle. There is a risk that the container
spills over during the wash-up process.
The process fluid of the ink must not necessarily be used as the cleaning fluid, since during cleaning,
the fluid will be collected completely and thus does not get into the ink. (Condensate or solvent mix-
ture)
The manufacturer's instruction manual must be adhered to when filling or emptying the supply system.
The filling process must be monitored.
On a few lines, it may become necessary to switch on control voltage to the machine for filling the
cleaning agents as otherwise the valve in the supply line is locked.
If the dirty fluid container is provided with overfill protection, this unit blocks the supply line to the
container upon reaching the maximum filling quantity. All currently running cleaning and pump-out
programs are aborted. A error message appears on the hand-held panel.
If the cleaning fluid has been completely pumped out of the container, the current program will not
be aborted!
The connectors from the supply system to the central distribution system are described in more detail
in the technical specifications. Keep all connecting lines free from foreign substances.

X000127624
Function
Cleaning media are used for the wash-up process on all color decks. These cleaning media are
provided by a supply system which is laid out for this purpose. The supply system serves to provide
sufficient cleaning media and to collect the dirty medium.
Different types of the supply systems are available according to the inks used and the related safety
instructions.
Connection to the pump and valve system is provided via the central distribution system. According
to the requirements, up to three different cleaning media can be used. The distribution system and
the number of supply containers should be adjusted according to the number of cleaning media used.
Make sure that sufficient cleaning medium for the operation is available in the cleaning container.
The capacity in the dirty fluid container should be sufficient to collect the dirty fluids from the cleaning
process. To ensure this, the fluid filling level should be permanently monitored.
Solvent-based inks:
Filling level monitoring in the containers takes place automatically. The two liquid volumes are per-
manently checked against a corresponding minimum and maximum value. These threshold values
when reached are laid out so that the standard cleaning processes for approx. eight color decks can
still be carried out completely.
If the minimum filling level in the clean cleaning medium container drops below this level or if the filling
level in the dirty medium container is exceeded, the warnings "Dirty liquid container almost full" or
"Solvent container almost empty" appear on the hand-held panel. Cleaning cycles are still possible
if this warning appears. Before starting a cleaning program the operator should check the filling levels
to decide whether the desired program can still be run.
Generally, the dirty fluid container should be emptied and the cleaning container be filled when the
first warning appears.
The dirty fluid container of the supply system has overfill protection. If the container is full all current
cleaning programs are interrupted and the supply line to the container is blocked automatically. A
error message appears on the hand-held panel.If the reservoir is empty the cleaning program will not
be interrupted; cleaning is no longer possible.
Water-based inks:
Due to the low risk potential the fluids are kept in simple metal containers when cleaning with water.
The exact filling level is not recorded.
If the system has no filling level monitoring equipment, the fluid levels in the containers should be
checked prior to every cleaning cycle. Make sure that sufficient cleaning medium is available for the
selected program. Make sure that there is sufficient collecting capacity in the dirty fluid container to
prevent the container from spilling over.

X000135673

There are many ink types that do not mix. Therefore, the machine operator should check with the ink
manufacturer which solvent is to be used for optimum dissolving and washing of both inks.
Color deck wash-up
Wash up the selected color decks again using the cleaning medium.Run a special wash-up pro-
gram, if necessary.
(1) F4 key
WINDMLLER & HLSCHER
(2) Program selection display screen PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
3
2 PU2
e
MENU
(3) Color deck display screen

a b c e
F1 F2 F3 F4
(4) Keys from 1 to 10 ESC
Check whether an e is displayed in the function

key line. If necessary, use the arrow keys to go
to the Wash up sub-menu. 1 2 3 4 5
6 7 8 9 10
4
Select the desired color deck using the keys 1
to 10 (4).
A B
Tc__0383
An e is displayed below the selected color
deck. The prompt of the selected color deck
(3) is blinking in the display.
The wash-up program preselected at Procon-
trol is started.
Flushing the pump out hoses
Hold the pump out hose into a suitable container and open the ball valve.
(1) F3 key
WINDMLLER & HLSCHER
(2) Keys from 1 to 10 PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
aaaaaaaaaa
PU2 MENU
F1 F2 F3 F4
Use the keys 1 to 10 2(2) to select the required F1 F2 F3 F4
color deck. ESC
Press and hold the F3 (1) key until the pump

out hose is clean.
The pump's supply side and the cleaning hose 1 2 3 4 5
are flushed with solvent. 6 7 8 9 10

2
Close the ball valve on the pump out hose after A B
flushing.
Tc__0386

X000135673
Color deck inking using ethyl acetate
Use a T-fitting to interconnect the ink hoses on the color deck. Connect a container with ethyl
acetate to the pump and valve unit.
(1) F1 key
WINDMLLER & HLSCHER

. . . . . . . . . .
TC
3
2 PU2
a
MENU

a b c e
F1 F2 F3 F4
Check whether an a is displayed in the function

to the Inking sub-menu. 1 2 3 4 5
6 7 8 9 10
4
to 10 (4).
A B
Tc__0381
An a is displayed below the selected color
By use of ethyl acetate for inking, all left-over
dirt particles and deposits are removed.
Thoroughly clean or replace the doctor blade
chamber.
Thoroughly clean or replace the anilox roll (ul-
trasonic equipment, Recyl, Cobra).

X000135673
Cleaning the pump out hose with ethyl acetate
Hold the pump out hose into a suitable container.
(1) F1 key
WINDMLLER & HLSCHER

. . . . . . . . . .
TC
3
2 PU2
a
MENU

a b c e
F1 F2 F3 F4
Check whether an a is displayed in the function

to the Inking sub-menu. 1 2 3 4 5
6 7 8 9 10
4
to 10 (4).
A B
Tc__0381
An a is displayed below the selected color
Open the ball valve when program a is running
and press the F4 key on the hand-held panel.
Ethyl acetate is pumped through the pump out
hose.
Emptying the system
(1) F2 key
WINDMLLER & HLSCHER

. . . . . . . . . .
TC
3
2 PU2
b
MENU

a b c e
F1 F2 F3 F4
Check whether a b is displayed in the function

to the pump out submenu. 1 2 3 4 5
6 7 8 9 10
4
to 10 (4).
A B
Tc__0382
A b is displayed below the selected color deck.
The prompt of the selected color deck (3) is
blinking in the display.
The pump out program preselected at Procon-
trol is started.
Re-connect the ink hoses to the doctor blade chamber. In order to prevent contamination to the
system, one WASH-UP cycle should be carried out before INKING is started. This ensures that
the system is free of left-over ink and left-over solvents.

X000126616

Hand-held panel
Dw__0400
(1) Display (2) Function keys

X000126616
Function keys
TC, MENU, A and B buttons
(1) TC button
WINDMLLER & HLSCHER
(2) MENU button PU1 TC
PU2 MENU
(3) A button F1 F2 F3 F4
(4) B button ESC

2
Press the TC (1) button.

The pages for operating the Turboclean are
called in the display. 1 2 3 4 5
6 7 8 9 10
Press the MENU (2) button. 3 A B

4
The service menu for the control console is Tc__0376
called in the display.
Press button A (3).
The stop watch function is called.
Press button B (4).
The program running on the selected color
deck is stopped.
All boxes will be stopped if no color deck has
been selected.
Display-dependent keys
(1) F1 to F4 keys
WINDMLLER & HLSCHER
Press the required key (1). PU1
PU2 MENU
TC
The key functions F1 to F4 will be re-assigned F1 F2 F3 F4
according to the display. ESC
1 2 3 4 5
6 7 8 9 10
A B
Tc__0377

X000126616
ESC, Enter and arrow keys
(1) ESC key

WINDMLLER & HLSCHER
(2) ARROW UP key PU1 TC
PU2 MENU
(3) ARROW DOWN key F1 F2 F3 F4
(4) ENTER key ESC
Press the ESC (1) key.

The entry is canceled and the display returns
2
to the previous display. 1 2 3 4 5
6 7 8
3 9 10
Press the ARROW UP (2) key. A
4
B
The previous display is called. Tc__0378

If the key is pressed together with the MENU
button, the display gets brighter.
Press the ARROW DOWN (3) key.
The next display is called.
If the key is pressed together with the MENU
button, the display gets darker.
Press the ENTER (4) key.
The entries are acknowledged or applied to the
machine program.
Keys for selecting the color decks
Only the color decks associated to the printing unit can be selected. The other keys have no function.
(1) Keys from 1 to 10

WINDMLLER & HLSCHER
Press the required key (1). PU1
PU2 MENU
TC
The associated color deck is selected as per F1 F2 F3 F4
the key selection. ESC
Error messages can be deleted by pressing the

ESC key.
Each color deck selection can be canceled by
use of the ESC key provided no program has 1 2 3 4 5
been started before. A color deck selection will 6 7 8 9 10
also canceled if selecting another color deck. A B
The color deck selection is automatically can-

Tc__0379
celed if no entries have been made within a
preset period of time.

X000135688
(1) Inking programm (2) Pump out program

(3) Pre-conditioning (4) Wash-up program
(5) Standard programs
This screen page renders possible to select between various inking programs (1), pump out programs
(2), pre-conditioning (3) and wash-up programs (4). On this screen page, the respective program for
the required application is selected.
To make handling of this screen page easier, a standard program for all color decks will be selected
in the top line (5). Normally, this will be the program which is used most.
If another program is selected, the screen page returns to the standard program after the selected
program has ended.

X000126647

Color deck inking mode
Selecting the inking program on Procontrol
(1) Choice boxes for entering the inking pro-

grams
(2) Choice boxes for inking programs
Change to screen page.25

Press the choice box (1) for the desired color
deck.
A list pops up and the desired inking program
can be selected.
After the inking program is finished, the pro-
gram display in display field (2) returns to the
standard program.
Starting the inking mode by use of the hand-held panel
The respective ink supply system including the ink container is connected and the anilox roll drive is
ready for operation. The doctor blade chamber is prepared and the doctor blade swivel switch is set
to ON.
Before starting the inking program make sure that sufficient collecting capacity is available in the dirt
container.
(1) F1 key
WINDMLLER & HLSCHER
(2) Program selection display PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
3
2 PU2
a
MENU
(3) Color deck display

a b c e
F1 F2 F3 F4
Check whether an A is displayed in the function

to the inking submenu. 1 2 3 4 5
6 7 8 9 10
4
Use the keys from 1 to 10 (4) to select the re-
quired color deck.
A B
Tc__0381
The prompt of the selected color deck (3) in the
display is blinking.
An a (2) is displayed below the selected color
deck. The inking program preselected on Pro-
control is started.

X000126647
Ink or solvent pump out
Selecting the pump out program on Procontrol
(1) Choice boxes for pump out programs

(2) Display field for pump out program

deck.
A list pops up and the desired pump out pro-
gram can be selected.
After the pump out program is finished, the pro-
gram display in display field (2) returns to the
standard program.
Starting the pump-out mode by use of the hand-held panel
Before pumping the ink into the dirt container make sure that suffucient collecting capacity is available
in the dirt container.
(1) F2 key
WINDMLLER & HLSCHER

. . . . . . . . . .
TC
3
2 PU2
b
MENU

a b c e
F1 F2 F3 F4
Check whether a B is displayed in the function

to the pump out submenu. 1 2 3 4 5
6 7 8 9 10
4
quired color deck.
A B
Tc__0382
The prompt of the selected color deck (3) in the
display is blinking.
A b (2) is displayed below the selected color
deck. The pump out program preselected on
Procontrol is started.

X000126647
Preconditioning the ink
Selecting the program in Procontrol
(1) Choice boxes for the preconditioning

programs
(2) Program display field
Go to to screen page.25.
deck.
A list appears to select the desired program.
After setting up the viscosity and/or the tem-
perature, a message in Procontrol informs the
operator that the color deck can now be inked
up.
After the program has ended, the program in-
dicator in the display field (2) returns to the
standard program.
Starting the program by use of the hand-held panel
(1) F3 key
WINDMLLER & HLSCHER
(2) Program selection display PU1 1 2 3 4 5 6 7 8 9 10 TC

3
2
. . . . . . . . . .
c

PU2 MENU
A B C E
F1 F2 F3 F4
Check whether a C appears in the display of

the the function key line. If necessary, use the
arrow keys to go to the pre-conditioning sub- 1 2 3 4 5
menu. 6 7 8 9 10
4
A B
quired color deck. Tc__0429

The prompt of the selected color deck (3) is
blinking in the display.
A c (2) appears in the display below the select-
ed color deck. The program selected on Pro-
control is started.

X000126647
Color deck wash-up
Selecting the wash-up program on Procontrol
(1) Choice boxes for wash-up programs

(2) Wash-up program display field

deck.
A list pops up and the desired wash-up pro-
After the program is finished, the program dis-
play in display field (2) returns to the standard
program.
Wash-up by use of the hand-held panel
All guards are closed, the fan is switched on, the anilox roll drive is ready for operation, the doctor
blade is loaded and the color deck is selected.
Before starting the wash-up programs make sure that sufficient collecting capacity is available in the
ink and dirt containers.
(1) F4 key
WINDMLLER & HLSCHER

. . . . . . . . . .
TC
3
2 PU2
e
MENU

a b c e
F1 F2 F3 F4
Check whether an E is displayed in the function

to the wash-up submenu. 1 2 3 4 5
6 7 8 9 10
4
quired color deck.
A B
Tc__0383
The prompt for the selected color deck (3) in
the display is blinking.
An e (2) is displayed below the selected color
deck. The wash-up program preselected on
Procontrol is started.

X000126647
Changing over from the inking mode to the wash-up mode for all color decks simul-
taneously
This function allows for all color decks to simultaneously change over from the inking mode to the
wash-up mode.
Selecting the wash-up program on Procontrol
(1) Choice boxes for wash-up programs

(2) Display fiels for the standard wash-up
program

Press the choice boxes (1) for the inked up col-
or decks.
A list pops up and the desired wash-up pro-
After the program is finished, the program dis-
play in display field (2) returns to the standard
program.
Entries on the hand-held panel
(1) F2 key
WINDMLLER & HLSCHER
(2) Color deck display PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
2
aaaaaaaaaa
PU2 MENU
(3) ARROW KEY DOWN

a b c e
F1 F2 F3 F4
ESC
3
Check whether F1, F2, F3, F4 is displayed in
the control key line. If necessary, use the arrow
keys to go to the appropriate submenu.
Press the F2 (1) key. 1 2 3 4 5
The prompt of all highlighted color decks (2) is

6 7 8 9 10
blinking.
A B
Tc__0384
Press the ARROW DOWN (3) key.
Press the key several times until main menu 1
appears.

X000126647
Preparing the pump out
DANGER
Danger due to electrostatic charging.
All equipotential bonding conductors must be connected. It is forbidden to operate the line unless the
equipotential bonding conductors are properly connected.
Keep the contact surfaces clean.
Disconnect the ground terminal last when removing the ink container and establish the connection
to the ground terminal first when refitting the ink container.
(1) Equipotential bonding

(2) Ball valve on pump out hose
Connect the equipotential bonding conductor

(1) to the container.
Hold the pump out hose in the container and
open the ball valve (2).
Starting the pump out program
(1) F1 key
WINDMLLER & HLSCHER
(2) Keys 1 to 10 PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
aaaaaaaaaa
PU2 MENU
F1 F2 F3 F4
Check whether F1, F2, F3, F4 is displayed in F1 F2 F3 F4
the functional keys line. If necessary, use the ESC
arrow keys to go to the correct submenu.

Use the keys from 1 to 10 2(2) to select the
required color deck.
1 2 3 4 5
Press and hold the F1 (1) key until the con- 6 7 8 9 10

2
tainer is empty. A B
After the wash-up, the ink is pumped out of the Tc__0385

ink container via the pump out hose.

X000126647
Starting the flushing program
(1) F3 key
WINDMLLER & HLSCHER
(2) Keys 1 to 10 PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
aaaaaaaaaa
PU2 MENU
F1 F2 F3 F4

Use the keys from 1 to 10 2(2) to select the
required color deck.
1 2 3 4 5
Press and hold the F3 (1) key until the pump 6 7 8 9 10

2
out hose is clean. A B
The pump's supply side and the cleaning hose Tc__0386

are flushed with solvent.
Close the ball valve on the pump out hose after
flushing.
Starting the pump out program during inking
Via the pump out hose, the ink will not be pumped into the ink container but into a separate suitable
container. The 'Pump out during inking' mode serves to reduce the ink level in the ink container and
to replenish ink blend, for example.
(1) F4 key
WINDMLLER & HLSCHER
(2) Keys from 1 to 10 PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
aaaaaaaaaa
PU2 MENU
F1 F2 F3 F4

Hold the pump out hose into a suitable con-
tainer and open the ball valve.
1 2 3 4 5
Use the keys 1 to 10 2(2) to select the required 6 7 8 9 10

2
color deck. A B
Press and hold the F4 (1) key until the required Tc__0435
level in the ink container is reached.
Clean the ball valve after the pump out and re-
move the container.

X000126647
Stopping the inking or cleaning programs
If a cleaning program is canceled, the entire ink supply system must be emptied. The filling level for
the fluids in the system is undefined.
It is possible to stop running programs for all color decks simultaneously or individually for each color
deck.
(1) Keys from 1 to 10

WINDMLLER & HLSCHER
(2) B button PU1 1 2 3 4 5 6 7 8 9 10

. . . . . . . . . .
TC
aaaaaaaaaa
PU2 MENU
F1 F2 F3 F4
Press button B (2). F1 F2 F3 F4
ESC
Running programs on all active color decks are

stopped. The selection is acknowledged by the
program symbol and the selection bar alter-
nately appearing on the display of the hand-
held panel below the respective color deck 1 2 3 4 5
number.
6 7 8 9 10
When aborting the ink supply or a cleaning pro-

A B
2
gram, continuous rotation of the anilox rolls is Tc__0380
switched off as well.
Use the keys from 1 to 10 (1) to select the de-
sired color deck.
Press button B (2).
The program running on the selected color
deck is stopped. The selection is acknowl-
edged by the program symbol and the selec-
tion bar alternately appearing on the display of
the hand-held panel below the respective color
deck number.
When aborting the ink supply or a cleaning pro-
gram, continuous rotation of the anilox roll is
switched off as well.

X000126507

The amount of the ink/cleaning agent mixture which is either pumped into the dirty cleaning agent or
remains in the ink supply line makes the difference between the inking programs. A maximum of ten
inking programs are provided.
Inking programs
Inking Good compromise between ink loss and change in viscosity.
Inking Short A small amount of ink will be pumped into the dirty fluid container. The change
in viscosity is higher than when using inking mode.
Inking Long More ink will be pumped into the dirty fluid container. Minor changes in vis-
cosity. This program is used for example when changing from black to white
or when using water-based inks.
Direct inking No ink will be pumped into the dirty fluid container. Significant change in vis-
cosity.
Flush the heat ex- (only when heat exchanger is optional)
changer
The inking programs six to ten are optional and will be developed on request according to the cus-
tomer's specifications.

The difference between the pump-out programs is that the contents of the ink supply line are pumped
into different containers. A maximum of ten pump-out programs are provided.
1 Pump-out into the container

2 Pump-out from the ink container into the dirty ink container
3 Pump-out from the ink container into the dirt bucket
4 Pump-out into the dirt container (no standard)

X000126514

The amount of cleaning agent to be used for the wash-up makes the difference between the wash-
up programs. The wash-up program to be selected depends on the ink changeover to be performed.
Wash-up programs
Short wash-up Cleaning agent consumption of 8 liters
Long wash-up Cleaning agent consumption of 10 liters
Intensive wash-up Cleaning agent consumption of 14 liters
(Washing from
dark to bright)
Wash-up when in When changing the doctor blades
continuous run-
ning mode
Pump ink from ink Pump ink from the ink container into the collecting tray. Carry out the 'Short
container into the wash-up' program.
collecting tray and Cleaning agent consumption of 8 liters
carry out the
'Short wash-up'
program
Pump into dirty Pump ink from the ink container into the dirty fluid container. Carry out the
fluid container and 'Short wash-up' program.
carry out the Cleaning agent consumption of 8 liters
'Short wash-up'
program
'Short wash-up' The left-over ink is pumped out of the ink container and into the ink bucket.
program including The 'Short wash-up' program including pre-cleaning of the ink container is be-
pre-cleaning of ing carried out.
the ink container
'Short wash-up' The left-over ink is pumped out of the ink container and into the dirty fluid
program including container. The 'Short wash-up' program including pre-cleaning of the ink con-
pre-cleaning of tainer is being carried out.
the dirty fluid con-
tainer
Flush the heat ex-
changer
Pre-conditioning programs
Viscosity The ink viscosity is set.
Viscosity ynd tem- The ink viscosity and the ink temperature are set.
perature

X000126517

Error display
If inking, wash-up or pump-out programs cannot be carried out, an error symbol appears on the hand-
held panel instead of the program symbol. If the color deck error below which the error symbol appears
is selected by use of the keys from 1 to 10, the associated error message is displayed on the hand-
held panel.
(1) Error symbol

WINDMLLER & HLSCHER
(2) Keys from 1 to 10 PU1

1 2 3 4 5 6 7 8 9 10
. . . . . . . . . .
E
TC
PU2 MENU
A B E
The error symbol 'E' (1) appears instead of the F1 F2 F3 F4
program symbols 'a' (inking), 'b' (pump-out) or ESC
'e' (wash-up)
Select the color deck below which the error
symbol appears by use of the keys from 1 to
10 (2).
1 2 3 4 5
2 6 7 8 9 10
In the display field of the main control console A B
the associated error message will be dis-

Tc__0394
played.
Error messages
1. Unknown error
2. Supply pump frequency reduced
3. Wash-up enable missing
4. Continuous rotation enable missing
5. Anilox roll enable missing
6. Wash-up enable missing
7. Ready-for-operation status for anilox rolls missing
8. Doctor blade chamber not closed
9. Anilox roll drive not switched on
10. Undefined color deck position
11. Fan not switched on
12. Portalift not in garange position
13. Needle bearing not closed
14. Guard door grid open
15. Supply pump error
16. Return pump error
17. Solvent tank Input/Output error
18. Dirty solvent container full
19. No control voltage

X000135837
NOTE
The connectors need cleaning after every washing cycle and prior to longer shutdown times. This
ensures that the connectors are free from ink and dirt.
When using ink systems which show a tendency to react chemically with each other (e.g. solvent-
based and water-based inks) it becomes necessary to carry out the CLEAN CONNECTORS function
until the solvent used comes out of the connectors.
Pressing the CLEAN CONNECTORS pushbutton causes the supply and return connectors at the
pump and valve system to be cleaned additionally. The pushbutton must be pressed only after the
actual wash-up cycle of the color deck.
(1) Pushbuttons
(2) Ink return hose
(3) Pushbuttons
(4) Ink supply hose
(5) Ink container
Close the ink container lid before pressing the

pushbutton.
Simultaneously press the pushbuttons (1) and
(3) three times for 1-2 seconds.
Compressed air is used to empty the ink supply
hose (4) and the ink return hose (2).
Press the pushbutton (1) for approx. 5 sec-
onds.
Clean the ink return hose (2) using the process
fluid.
Press the pushbutton (3) for approx. 5 sec-
onds.
Use the process fluid to clean the ink return
hose (4).
Simultaneously press the pushbuttons (1) and
(3) three times for 1-2 seconds.
Compressed air is used to empty the ink supply
hose (4) and the ink return hose (2) once again.

X000220346

Notes
WARNING
Risk of cuts from knives and blades.
WARNING
Risk of crushing when turning down the doctor bar on changing the knives in the machine.
Use the turning handle to lock the doctor blade chamber horizontally in place.
NOTE
Be careful not to damage the impression cylinder when working on the doctor blade unit.
The doctor blade unit illustrated may not be the same as provided on the machine. This procedure
can be followed for all of the machines.
Swing the doctor bar away from the plate cylinder before starting any works on the equipment.
Pivoting the doctor blade chamber in order to change the blades
Releasing the support
(1) Rotary handle
Release the rotary handle (1).

The doctor bar is loose and can be turned.

X000220346
Swiveling the doctor blade chamber
(1) Handle
(2) Turning handle
Use both handles (1) to hold the doctor blade

chamber and swivel it in the direction of the ar-
row.
Tighten the turning handle (2).
The doctor bar is fixed in place and the blades
can be replaced.
After completion of the works, swivel the doctor bar back forward and lock in place using the turning
handle.
Pivoting the doctor blade chamber to remove the drain boxes
Repositioning the stop
(1) Locking pin
Pull the locking pin (1) and then turn the doctor
bar stop upwards.
Lock the stop in its new position by releasing
the locking pin (1).

X000220346
Pivoting the doctor blade chamber
Hold the doctor bar by the handles when loosening the rotary handle. The doctor bar flips over.
(1) Handle
(2) Rotary handle
Hold the doctor blade chamber by the handles

(1).
Release the rotary handle (2).
The doctor bar can be pivoted downwards us-
ing the handles.
Once finished pivot the doctor bar back upwards again, reposition the doctor bar stop and lock the
doctor bar in place using the rotary handle.
Removing the doctor blade chambers
Pivoting the doctor blade chamber
(1) Rotary handle

(2) Handle
Loosen the rotary handle (1) and use the han-

dles (2) to pivot the doctor blade bar in the di-
rection indicated by the arrow.
Retighten the rotary handle (1).

X000220346
Removing the doctor blade chambers
Depending on the machine type, there are different ways to remove the doctor blade chambers.
DANGER
Risk of personal injury from slipping, tripping or falling when stepping on the climbing aids
and carrying the doctor blade chambers.
Climb up to the top color deck and ensure stable standing. Two persons are needed to remove the
doctor blade chamber. Hand down the removed doctor blade chamber. Only ever step on the ladders
without carrying any loads.
WARNING
Risk of gashes from knives and blades.
Remove the doctor blades before dismantling the doctor blade chamber. Wear cut-resistant gloves
as per anti-cut class 5 according to European standard EN 388. Only ever transport the doctor blade
chamber without doctor blades.
(1) Locking lever

(2) Screws
Depending on the machine type, either push

the locking lever (1) towards the impression
cylinder or slacken the screws (2) for removing
the doctor blade chamber.

X000217598

Drainbox design
(1) Terminal strip (2) Intermediate layer

(3) Seal with hole (4) Support plate with bolt
(5) Barrier (6) Rope seal
(7) Ink return hose connection (8) Vent pipe
(9) Barrier hole (10) Marking ring
In order to make it easier to assign the doctor bars to the respective color decks, the drain boxes are
provided with variegated intermediate layers 2 and marking rings 10 and the doctor bars with varie-
gated limit stops.
Doctor bars provided with black intermediate layers, marking rings and limit stops on the chamber
are installed in the inner color decks 1-4 (1-5).
Doctor bars provided with white intermediate layers, marking rings and limit stops on the doctor blade
chamber are installed in the outer color decks 5-8 (6-10).

X000217598
When replacing the rope seal (1) a thin coat of sil-

icone grease should be applied to the inner and
outer side of the rope seal. Greasing makes it eas-
ier to insert the rope seal.

X000217598
Assigning the drain boxes to the doctor blade chambers
Drain boxes for color decks 1-4 (1-5)
(1) Drain box Drive side Color decks 1-4 (2) Drain box Operator side Color decks 1-4
(1-5) (1-5)
(3) Barrier hole (4) Intermediate layer black
(5) Marking ring black

X000217598
Drain boxes for color decks 5-8 (6-10)
(1) Drain box Operator side color decks 5-8 (2) Drain box Drive side color decks 5-8
(6-10) (6-10)
(3) Barrier hole (4) Intermediate layer white
(5) Marking ring white

X000217598
Removing and mounting the drain box
Remove the drain box from the doctor blade chamber
(1) Locking lever

(2) Drain box
Insert the key into the locking lever (1) and turn
the locking lever to the center of the chamber.
Remove the key after turning the locking lever.
Pull the drain box (2) out of the doctor blade
chamber in the direction of the arrow.
Fit the drain box into the doctor blade chamber
NOTE
The sealing cord inserted in the drain box should not be damaged when fitting the drain box in the
doctor blade chamber.
The drain box will be fitted without seal.
(1) Drain box

(2) Locking lever
Push the drain box (1) into the doctor blade

chamber in the direction of the arrow.
Insert the key into the locking lever (2) and
press the locking lever towards the ends of the
chamber.
Remove the key after turning the locking lever.

X000042670

Front side
(1) Clamping strip for the doctor blade (2) Doctor blade
(3) Ink return hose connection (4) Ink supply connection

X000042670
Rear side
(1) Handles (2) Clamping lever for clamping the doctor

blade in place
(3) Drain boxes (4) Vent pipes
(5) Colored limit stop and colored marking
rings
In order to make it easier to assign the doctor bars to the respective color decks, the drain boxes are
provided with variegated marking rings (5) and the doctor bars with differently colored limit stops
(5).
Doctor bars provided with black marking rings and limit stops on the chamber are installed in the inner
color decks 1-4 (1-5).
Doctor bars provided with white marking rings and limit stops on the doctor blade chamber are in-
stalled in the outer color decks 5-8 (6-10).

X000042670
Arrangement of the doctor blade chambers in the printing unit (right-hand machine)
(1) Doctor blade chamber for the outer color (2) Doctor blade chamber for the inner color
decks 5-8 (6-10). decks 1-4 (1-5).
(3) Barrier hole at the service doctor blade (4) Doctor blade chamber with white mark-
ings on the ink return and supply hoses
(5) Doctor blade chamber with black mark-
Doctor blade chambers with black markings on the ink return and supply hoses are installed in color
decks 1-4 (1-5).
Doctor blade chambers with white markings on the ink return and supply hoses are installed in color
decks 5-8 (6-10).

X000042670
Arrangement of the doctor blade chambers in the printing unit (left-hand machine)
(1) Doctor blade chamber for the inner color (2) Doctor blade chamber for the outer color
decks 1-4 (1-5). decks 5-8 (6-10).
(3) Barrier hole in the service doctor blade (4) Doctor blade chamber with black mark-
(5) Doctor blade chamber with white mark-
Doctor blade chambers with black markings on the ink return and supply hoses are installed in color
decks 1-4 (1-5).
Doctor blade chambers with white markings on the ink return and supply hoses are installed in color
decks 5-8 (6-10).

X000184358

Safety instructions
CAUTION
Risk of crushing your fingers. Make sure to switch off the continuous rotation before working on the
doctor blade unit.
NOTE
DANGER
Press the lateral clamping plates and the sealing plate on the seals of the doctor blade cham-
ber until they hit the limit stop. The clamping plates or sealing plates must not rub against the
anilox roll.
Blade change
Preparing the locking lever
(1) Key
(2) Locking lever
Fit the key (1) on the locking lever (2) and hold
it.

X000184358
Removing the blade
(1) Locking lever

(2) Clamping bar
(3) Knife
(4) Seal
Pull the locking lever (1) in the direction of the

arrow.
The clamping bar (2) is released.
Withdraw the key from the locking lever.
Carefully remove the blade (3).
Remove the seal (4) (see the description of a
seal change)
Replacing the blades in the machine
RISK OF GASHES FROM BLADES.

Your hands and arms might get hurt.
Wear cut-proof gloves. Only fit the key for releasing the rear slide rail on the locking lever from below.
Do not reach over the swiveled doctor blade chamber.
(1) Doctor blade chamber

(2) Key and locking lever
Fit the key on the locking lever (2) and hold it.
Push the locking lever backwards.
The clamping bar (2) is released.
Carefully take the blade out of the doctor blade
chamber (1).

X000184358
Mounting the blades
Mount the blade first, then insert the seals. (see the description of a seal change)
(1) Blade
(2) Locking lever
(3) Clamping bar
Push the blade (1) under the clamping bar (3)

and align.
The blade should laterally be in proper align-
ment with the clamping bar. If the blade pro-
trudes laterally, the seal clamp cannot be
moved anymore.
Fit the key on the locking lever (2) again and
move the locking lever in the direction of the
arrow.
The clamping bar (3) clamps the blade in place.
Safety instructions
CAUTION
Risk of crushing your fingers. Make sure to switch off the continuous rotation mode before working
on the doctor blade unit.
NOTE
DANGER
Fire and explosion hazard
Press the lateral clamping plates and the sealing plate on the profiled seals of the doctor blade
chamber until they hit the limit stop. The clamping plates or sealing plates must not rub against the
anilox roll.

X000043108
Seal change
Open the clamping plate
(1) Clamping plate

(2) Intermediate layer
Swivel the clamping piece (1) in the direction of

the arrow until the intermediate layer and the
seal are freely accessible.
The clamping piece can be removed if neces-
sary.
Removing the intermediate layer
(1) Intermediate layer
Pull off the intermediate layer (1) upwards.
Removing the seal
(1) Seal
Pull the seal (1) from the support plate.

X000043108
Fitting the seal
DANGER
Fire and explosion hazard due to improper mounting of the clamping and sealing plates.
Fire and explosion may hurt persons and cause damage to the machine.Press the lateral clamping
plates and the sealing plate on the seals of the doctor blade chamber downwards until they hit the
limit stop. The clamping plates or sealing plates must not rub against the anilox roll.
(1) Seal
(2) Doctor blade
(3) Bolt in the support plate
(4) Locking bolt for clamping plate
Fit the new seal (1).

Push the seal diagonally beneath the doctor
blade (2) at the top first.
Pay attention that the bolt (3) in the support
plate engages in the seal's hole. Then, properly
push the seal in place at the bottom.
Install the intermediate layer and pivot the
clamping plate in the direction of the arrow until
it firmly rests on the locking bolt (4).

X000043171

Parts needing cleaning Profiled elements Doctor blade chamber
(1) Doctor blade chamber (2) Tie rods

(3) Terminal strips (4) Drain boxes with vent pipes

X000043171
General
Swap all drain boxes every other week for thorough cleaning (e.g. 1 doctor blade chamber every
other day). Make sure that the barrier area is perfectly clean!
When cleaning the doctor blade chamber in the machine special care must be taken to prevent solid
bodies such as dried up ink residues or knife abrasion particles from getting into the ink return hose.
Disconnect the ink return hoses, if necessary.
Venting
Replace both vent pipes contained in the used color decks for cleaning every other day.
Lower anilox roll cover
Also replace the lower cover in the respective color deck when replacing a doctor blade chamber.
Pay attention to the splash guards when cleaning.
Upper anilox roll cover
When inserting an anilox roll into a color deck be sure that the respective upper cover is perfectly
clean.
Blade change
CAUTION
The following actions should be taken when doctor blades or seals are worn down:
Remove the doctor blades and seals.
Remove the clamping bars and tie rods for cleaning.
Clean the doctor blade support.
Clean the outlets prior to the barriers.Prevent solid bodies from getting into the ink return hose
during cleaning. Disconnect the ink return hose, if necessary.
Refit the cleaned clamping bars and tie rods.
Fit new doctor blades and seals.
Inspect barriers for damage.

X000043171
Cleaning the doctor blade chamber
NOTE
Prevent damage to the doctor blade chamber from occurring when placing it into the washing ma-
chine.
When cleaning the doctor blade chamber in a washing machine, the doctor blade chamber must be
prepared as follows:
The doctor blade and the clamping device (clamping bars and tie rods) have been removed.
The drain boxes have been removed.
the sealing plate and the intermediate layer have been removed from the drain boxes.
The vent pipes are removed.
All parts need to be cleaned.

Take note of the following after cleaning is finished:
The doctor blade holder must be clean and level.
The vent pipes must be free of ink residues.
The drainage in front of the barriers must not be blocked.
The barriers must not be damaged.
Anilox rolls
General cleaning of the anilox roll is required after approx. 200 hours. The anilox roll must be replaced
or thoroughly cleaned when changing the ink system (for example, from NC to PVB).
You must always abide by the general safety and accident prevention regulations.

X000068312

Notes
An additional high-speed doctor blade can be fitted to avoid trapped air when running the machine
at high speeds.
To avoid ghosting, an additional antighosting doctor blade may be fitted.
A steel or plastic doctor blade may be fitted as necessary and according to the application.
The additional clamping rail equipped with the third blade can only be fitted when both the ink supply
lines are open. Where necessary, the doctor blade chamber need to be modified.
Only one of the two additional doctor blades can be fitted.
If a plastic doctor blade is fitted, the contact pressure of the doctor blade unit remains unchanged.
If a steel doctor blade is fitted, the contact pressure of the doctor blade unit needs to be increased to
1.8 bar.
An additional doctor blade should only be fitted if the working and closing doctor blades are removed
from the doctor blade chamber.
CAUTION
Risk of crushing your fingers. Make sure to switch off the continuous rotation before working on the
doctor blade unit.
Position of the additional doctor blades
High-speed doctor blades
(1) Closing doctor blade

(2) Working doctor blade
(3) High-speed doctor blade
Fit the high-speed doctor blade (3) whenever

necessary.

X000068312
Antighosting doctor blade
(1) Closing doctor blade

(2) Working doctor blade
(3) Antighosting doctor blade
Fit the antighosting doctor blade (3) whenever

necessary.
When inks showing a tendency of ghosting are
to be used, the printing result may be improved
by inserting a blade which is considered to be
a high-speed doctor blade .

X000068337

Clamping rail assembly at the additional doctor blade
(1) Clamping rail at the additional doctor (2) Clamping elements

blade
(3) Clamping rod (4) Doctor blade
(5) Key
View of the key
(1) Flute for clamping and undoing the

clamping rod
(2) Flute for undoing the clamping rail at the
additional doctor blade
(3) Hole for clamping and undoing the
clamping rod at the doctor blade cham-
ber

X000068337
Fitting the additional doctor blade
Inserting the clamping elements
(1) Clamping elements
Insert the clamping elements (1) into the

clamping rail of the additional doctor blade.
Pay attention to the shape of and properly fit
the clamping elements.
The pin at the clamping elements must engage
with the central groove of the clamping rail.
Inserting the tensioning rod for the doctor blade
(1) Doctor blade

(2) Clamping rod
Place the clamping rod (2) between the clamp-

ing elements.
The clamping rod surfaces point towards the
clamping elements.
The end of the clamping rod should be in prop-
er alignment with the nose at the clamping rail
(A).
Push the doctor blade (1) between the clamp-
ing element and the clamping rail and align in
the center.
Clamping the doctor blade in place
(1) Key
(2) Clamping rod
Push the keyway (1) onto the clamping rod.

Turn the key (1) by 90 degrees.
The clamping elements are properly clamped
if the milled, straight surface of the clamping
rod points upwards.

X000068341

Fitting the clamping rail
1 Mounting on the closing doctor blade

side
2 Mounting on the working doctor blade
side
Align the clamping rail in the middle of the doc-

tor blade chamber.
The nose (A) at the clamping rail should point
towards the closing doctor blade side.
Tip the clamping rail and push the mounting of
the closing doctor blade side (1) beneath the
edge of the doctor blade chamber.
Press the clamping rail at the working doctor
blade side down until you hear it snapping in.
Check whether all of the mountings have snap-
ped in.
Removing the clamping rail
(1) Key
(2) Mounting on the working doctor blade
side
Fit the key (1) onto the mounting on the working

doctor blade side (2).
Push the key (1) in the arrow direction, then
slightly pull the clamping rail upwards and out
of its mounting.
This procedure is to be followed for all of the
mountings, then remove the clamping rail.

The blade length corresponds with the respective working width plus 60 millimeters.
Working width 820 1000 1270 1450

Blade length 880 1060 1330 1510

Z WINDMLLER & HLSCHER 5 Operation | Viscosity control system

5.15.1 Viscosity controller and solvent pump...............................................................................2
Layout and function.......................................................................................................2
Equipotential bonding....................................................................................................3
5.15.2 Viscosity control................................................................................................................4

Viscosity screen page Part 1.........................................................................................4
Viscosity screen page Part 2.........................................................................................5
5.15.3 Conversion........................................................................................................................6
Screen page Conversion...............................................................................................6
Entries in the screen page Conversion..........................................................................7
Stopwatch in the Turboclean hand-held panel..............................................................9

5 Operation | Viscosity control system Z WINDMLLER & HLSCHER
X000011930

Layout and function
(1) Terminal compartment and evaluation (2) Ink chamber with rod for generating vi-
unit brations
(3) Cable gland (4) Ink inlet
(5) Ink outlet to doctor blade chamber (6) Equipotential bonding cable
NOTE
A sealed clip connects the terminal compartment and the ink chamber. When opening the clip and
separating the connection, the viscosity controller becomes defective and must not be used any more.
A viscosity controller is required to keep the ink viscosity specified for the job constant. The sensor
is integrated in the supply line to the doctor blade chamber.
The rod in the ink chamber is set vibrating and the vibrations are transmitted to the ink. The resulting
ink vibrations are measured and evaluated. This value along with the conversion to be carried out
allow conclusions regarding the ink viscosity.
Conversion is to be carried out on every ink change. As to that, the stop watch mode of the hand-
held panel is explained in this chapter.

X000011930
Equipotential bonding
DANGER
It is forbidden to operate the system without the viscosity controller being grounded! The risk
of an explosion being caused by an electrostatic charge exists.
It is forbidden to operate the system without the solvent pump being grounded. The risk of an
explosion being caused by an electrostatic charge exists.
All of the screw connections must be tightened up carefully. It is important that the contact
surfaces are kept clean at all times.
Equipotential bonding cable (1) on the viscosity

controller
Connecting position for connecting the equipo-
tential bonding cable on the viscosity controller
with the frame of the machine (2).
Connecting position (1) for the equipotential

bonding cable

X000307892

Viscosity screen page Part 1

(1) Input field Color or hue to be used in the color deck
Color
(2) Choice box Control mode selection
Controller Off = measurement Off, control Off
Man = measurement On, control Off
Auto = measurement On, control On
(3) Input field Used to set up the viscosity value.
Set
(4) Input field Used to set up the viscosity value or the input field is auto-
Act matically assigned during conversion.
(5) Button The actual value is applied as the set value.
Act -> Set

X000307892
Viscosity screen page Part 2

(1) Display field The display shows the current status of the viscosity controller.
Status When the viscosity controller is On and in automatic mode:
Green = viscosity okay
Yellow = viscosity too high or too low
Red = viscosity outside the tolerance range
Further status messages:
Waiting for the measurement result = is being displayed for
300 seconds if inking is carried out after the wash-up
Waiting for the measurement result = is being displayed for
180 seconds when inking is carried out once more
Cleaning progress = is being displayed when a wash-up pro-
gram has been started
(2) Display field The display shows the currently selected Turboclean pro-
TC program gram.
(3) Display field Shows the solvent valve measuring cycle
MeasCycle Arrow upwards = dropping element is raised.
Arrow downwards = dropping element is dropped.
(4) Display field Shows the solvent valve status
Solv. valve Asterisk or plus sign = solvent valve open

X000307892

(5) Input field Time to open the solvent valve manually to be entered in sec-
Solv. valve onds
5.15.3 Conversion
Screen page Conversion
The service pages can only be accessed by entering a password. Entries in these pages can
only be made after the customer's password has been entered.
(1) Measuring cup input field (2) Conversion factor

(3) Conversion offset (4) Control tolerance
(5) Alarm limit (6) Alarm limit
(7) Max. viscosity (8) Pump strokes return pump
(9) Pump strokes return pump

X000011574
Entries in the screen page Conversion
Measuring cup and conversion input fields
(1) Measuring cup selection button

(2) Conversion factor display field
(3) Conversion offset display field
(4) Max. viscosity display field
Press the cutton (1) .

Select appropriate measuring cup from those
available for selection.
Conversion factor (2) for the individual color
decks
The conversion factor is ascertained automat-
ically. No entry is required. The factor should
be between three and seven.
Offset display (3) of the conversion factor.
The offset is automatically entered when the
measurement cup is selected.
Display (4) of max. viscosity.
The max. viscosity is automatically entered
when the measurement cup is selected.

X000011574
Tolerance and alarm input fields
(1) Control tolerance input

(2) Alarm limit input
(3) Alarm limit input
Manual entry of control tolerance (1). The

range should be between 1 - 3%.
The status field on screen page Viscosity Con-
troller shows VISCOSITY OK .
Manual entry of alarm limit (2). The range
should be between 15 - 30% .
troller shows VISCOSITY TOO HIGH or VIS-
COSITY TOO LOW .
Manual entry of alarm limit (3). The range
should be between 25 - 50% .
troller shows VISCOSITY OUTSIDE TOLER-
ANCE .
The tolerance and alarm limits should be matched to customer needs.
Pump stroke displays
(1) Pump stroke display for supply pump

(2) Pump stroke display for return pump
The pump strokes are automatically updated.

After pump maintenance (changing of dia-
phragms) the counters must be reset to "0".

X000011574
Stopwatch in the Turboclean hand-held panel
Selecting the stopwatch
A stopwatch has been integrated into the hand-held panel for converting the viscosity controller.
Change from Main menu screens 1, 2 or 3 to the viscosity measurement screen.
(1) Stopwatch selection field

(2) Turboclean boxes selection field
Select the stopwatch start screen by pressing

key A (1) .
Select the desired Turboclean box by pressing
the relevant selection keys (2) .

X000011574
Measuring viscosity
To enable conversion, the viscosity controller fitted in the Procontrol column must be switched to
AUTO (automatic) and must have ascertained a valid measurement.
(1) Start key

(2) Stop key
(3) Enter key
(4) Escape key
Start the stopwatch function by pressing F1

(1).
Stop the stopwatch function by pressing F2
(2).
Transfer the measurements to the computer by
pressing ENTER (3)
Press the ESCAPE (4) key to exit the stop-
watch function.
Submerge the measuring cup until it is beneath the ink surface.

Use the F1 key to start the stopwatch as soon as the edge of the cup breaks through the surface
of the ink when it is being removed.
Record the time until the net of ink flowing out of the cup brakes off for the first time. Stop the watch
using the F2 key.
ENTER TO SEND appears in the display of the hand-held panel.
Press the ENTER (3) key. The measurement is transferred to the host computer. It is displayed in
the selected box beneath the actual value.
Press the ESCAPE (4) key to exit the stopwatch function.

Z WINDMLLER & HLSCHER 5 Operation | Production make-ready

5.16.1 Switching the machine to ready for operation...................................................................2
Water and compressed air connections........................................................................2
Main switch....................................................................................................................3
Status of the LED in the pushbutton..............................................................................3
Control voltage...............................................................................................................3
5.16.2 Selecting the winding direction..........................................................................................4

Unwind mode.................................................................................................................4
Rewind mode.................................................................................................................6
5.16.3 Threading up the web........................................................................................................8

Switching off the web break detector.............................................................................8
Control elements Web thread-up...................................................................................8
Web thread-up at the unwind.......................................................................................10
Web thread-up at the printing unit...............................................................................12
Web thread-up at the rewind unit.................................................................................15
5.16.4 Changing the web paths towards the web inspection unit..............................................16
Converting the front and reverse side inspection unit..................................................16
Converting the web inspection unit from reverse side to front side inspection............18
5.16.5 Instructions for the correct printing plate assembly.........................................................19
5.16.6 Web tension reference values.........................................................................................20

Material: PET...............................................................................................................20
Material: PE-HD...........................................................................................................21
Material: PE-LD...........................................................................................................22
Material: BOPP............................................................................................................23
Material: ALUMINIUM..................................................................................................24
Material: PAPER..........................................................................................................25
5.16.7 Roller covers...................................................................................................................26

General........................................................................................................................26
Storing.........................................................................................................................26
Cleaning.......................................................................................................................26
Operation.....................................................................................................................26
Change on printing presses.........................................................................................26

5 Operation | Production make-ready Z WINDMLLER & HLSCHER
X000288146

Water and compressed air connections
Energy connection point
DANGER
Machine starting automatically
Depending on the production, various parts of the line may start automatically. Parts of your body,
clothes, hair and objects may be caught and crushed.
The main switch must be turned off and padlocked before carrying out any maintenance work. Ob-
serve the instructions next to the main switch. Visual and acoustic warning signals. Keep a safe
distance.
NOTE
Never change the maximum or minimum pneumatic working pressures! The compressed air supply
from the on-site system must satisfy the quality requirements defined for the utilities.
(1) ENERGY CONNECTION POINT
For the energy supply to the machine, open the

ball valves of the energy supply lines at the
ENERGY CONNECTION POINT.
Compressed air supply to the machine
(1) COMPRESSED AIR CONDITIONER
Move the ball valve of the COMPRESSED AIR

CONDITIONER (1) to open or close the com-
pressed air supply line to the machine.
The operating pressure is shown on the man-
ometer of the compressed air conditioner when
compressed air supply is switched on.

X000288146
Main switch
The entire electrical power supply to the machine is provided via a main switch. The power element
of the main switch is integrated in the Eltainer. The operating element located outside the Eltainer
switches the power element on or off by means of an electric drive.
(1) OPERATING ELEMENT
Switch on the OPERATING ELEMENT (1).

The power element of the main switch is
switched on to activate the electrical power
supply to the machine.
Status of the LED in the pushbutton

the
push-
button
Flashing green: Control voltage On
Blinking green: The mode is in the shutoff process.
Control voltage
The control voltage can only be switched on if no Emergency-Stop pushbutton has been actuated.
The CONTROL VOLTAGE ON pushbutton is integrated in the main operator panel of the machine.
(1) CONTROL VOLTAGE ON/OFF
Press the CONTROL VOLTAGE ON/OFF (1)

pushbutton.
The control voltage to the machine is switched
on.
1
Press the CONTROL VOLTAGE ON/OFF (1)
pushbutton once more.
The control voltage to the machine is switched
off.
Dw__1183

X000270644

Unwind mode
The unwind mode to be selected depends on the provided roll. Normally, the web is treated on one
side and printing takes place on the treated web side. The treated side of the web may either be the
front or reverse side and the roll must be loaded into the winder accordingly. ' Overwind ' or ' Under-
wind ' mode is selected in PROCONTROL or an optional winder terminal.
Determining the side to be printed
(1) Front side of the web

(2) Reverse side of the web
Use testing ink to check whether the front side

of the web (1) or the reverse side of the web
web (2) has been treated.
If the front side of the web (1) has been treated,
select OVERWIND mode in PROCONTROL
and load the roll into the winder accordingly.
If the reverse side of the web (2) has been
treated, select UNDERWIND mode in PRO-
CONTROL and load the roll into the winder ac-
cordingly.
Settings in Procontrol
(1) UNWIND MODE choice box

Press choice box (1) and select the desired
unwind mode.

X000270644
Loading the roll
(1) ' Overwind ' mode

(2) ' Underwind ' mode
Load the roll into the winder paying attention to

the unwind mode selected in Procontrol.
' Overwind ' mode means that the web tail is lo-
cated at the top of the roll (1) .
' Underwind ' mode means that the web tail is
located at the bottom of the roll (2) .

X000270644
Threading up the web

Swivel the roll into the winding position.

Thread the web through the winder into the
machine paying attention to the winding direc-
tion selected before.
Observe the web travel plan. Thread the web
through the machine up to the rewind.
Rewind mode
Defining the position of the print subject on the roll
(1) Front side of the web

(2) Reverse side of the web
Determine how to wind up the printed web.

If the print subject shall be located at the top of
the roll (1), select OVERWIND mode in PRO-
CONTROL.
If the print subject shall be located at the bottom
of the roll (2), select UNDERWIND mode in
PROCONTROL.

X000270644
Settings in Procontrol
(1) REWIND MODE

Press choice box (1) and select the desired re-
wind mode.
Threading up the web

Swivel the winding shaft for rewinding forwards

into the loading position.
Insert an appropriate core for the web width to
be processed.
Thread the web through the winder paying at-
tention to the rewind mode selected before.
Observe the web travel plan. Splice the web to
the core.
Switch on the respective winding motor and
swivel the winding shaft back into its winding
position.

X000288157

Safety instructions
DANGER
Always switch off the compressed air supply to the winder and withdraw the key from the
compressed air conditioner before entering the winder. There is an increased risk of injury.
CAUTION
Risk of injury from rotating chains, belts and rotating gears
Parts of your body, clothes, hairs and objects can be pulled in and crushed. Do not open or remove
safety devices. Wear tight-fitting clothes and a hairnet. Work without gloves. Keep a safe distance.
Switching off the web break detector
(1) WEB BREAK DETECTOR button
Actuate the WEB BREAK DETECTOR button

in screen page 22.
The web break detectors are out of operation.
The display in the button flashes. The machine
speed is reduced to threading speed.
Actuate the button once more.
The display in the button is dark. The web
break detectors are ready for operation again.
Control elements Web thread-up
Manual web thread-up
(1) Crank handle
Turn the crank handle (1) to feed the attached

web through the machine.
The first part of the threading chain ends at the
web infeed of the impression cylinder. The sec-
ond part of the threading chain begins at the
web outfeed of the impression cylinder and
ends at the step behind the rear frame.
Once the web has passed the impression cyl-
inder the web transport can be supported by
the Jog mode.

X000288157
Motorized web thread-up
CAUTION
Rotating rollers and running threading chain
Wear tight-fitting clothing. Work without gloves. Keep your hands away from the nip. Keep a safe
distance.
CAUTION
Sharp edges
Risk of cutting your body on sharp-edged webs.
Web thread-up can only be realized at reduced speed. Wear protective equipment.
(-) THREADING CHAIN pushbutton
Press and hold down the pushbutton.

The threading chain with the attached web is
fed through the machine.
The first part of the threading chain ends at the
1
web infeed of the impression cylinder. The sec-
ond part of the threading chain begins at the
web outfeed of the impression cylinder and
ends at the step behind the rear frame.
Once the web has passed the impression cyl-
inder the web transport can be supported by Wic_0467
the Jog mode.
Manual web thread-up for reverse printing
(1) Crank handle
Turn the crank handle (1) to feed the attached

web through the rear frame.
When using the reverse printing mode, the web
must be separated from the standard threading
chain and attached to the threading chain for
reverse printing. After that, the web can be
threaded through the rear frame for reverse
printing by using the threading chain for re-
verse printing.

X000288157
Web thread-up at the unwind
Inserting and swinging in a the roll
Swing all nip rolls away before threading in the web.
(1) Roll
Insert the roll (1) as described.

Swing the roll into the winding position accord-
ing to the selected winding direction.
Switching off the compressed air supply

(2) Key switch
Switch off the compressed air supply to the

winder at the compressed air conditioner (1).
Remove the key from the key switch.
The compressed air supply to the winder can
be switched on no more.

X000288157
Roll make-ready
(1) Web section

(2) Adhesive tape
Apply an adhesive type (2) in the longitudinal

direction to the web on the running side of the
threading chain.
Cut off the web (1) at an angle of approx. 45
degrees.
The cut edge on the roll can be reinforced by
an adhesive tape .
Pulling the web as far as the threading chain
The threading chain ends at the step behind the rear frame. According to the machine design the
threading chain is separated at the impression cylinder or passed around the impression cylinder.
If no threading chain is available the web must be threaded up manually according to the instructions
in the web travel plan.
(1) Web
Open the lateral guard door at the winder and

enter the clear spacing.
Thread the web via the idler rollers as far as the
first follower of the threading chain according
to the web travel plan.

X000288157
Attaching the web to the threading chain
(1) Follower of the threading chain

(2) Adhesive tape
Use an adhesive tape (2) to attach the web to

the follower (1) of the threading chain.
Use the threading chain to draw the web behind the rear frame.
Web thread-up at the printing unit
Printing unit make-ready
CAUTION
Risk of injury from rotating machine parts.
Clean color decks One and Ten and switch off the anilox roll drive.
(1) Ladder
(2) Safety guide
Open the sliding door on the web infeed side of

the printing unit.
Put up the ladder (1) in front of the printing unit
and hook it in accordingly.
Enter the upper area of the printing unit to at-
tach the web to the impression cylinder.
To do so, push the safety gate (2) upwards.
After the operator has entered the upper area
of the printing unit and lets the safety gate go,
the safety gate automatically swivels back in its
home position.

X000288157
Attaching the web to the impression cylinder
(1) Nip roll

(2) Splice
Pull the web behind the nip roll (1) of the print-
ing unit according to the web travel plan.
Splice the web onto the impression cylinder
(2).

X000288157
Feeding the web through the printing unit
Only the sliding door on the web infeed side of the printing unit must be open. All other guard doors
must be closed.
(1) Control element

(2) Safety guide
(3) Ladder
Plug the control element (1) into the socket

provided for this purpose and perform the
SAFE JOG MODE .
End the mode once the web has reached the
lower color deck.
Retract the control element (1), remove the
ladder out of the printing unit and close the slid-
ing door.
Open the sliding door at the web outfeed side
of the printing unit, fit the ladder (3) to the lo-
cations provided for this purpose, enter the up-
per area of the printing unit, plug the control el-
ement into the socket provided for this purpose
and perform the SAFE JOGGING function.
Push the safety gate (2) upwards for entering
the upper areas of the printing unit.
After the operator has entered the upper area
of the printing unit and lets the safety gate go,
the safety gate automatically returns to its
home position.
End the SAFE JOG MODE when the splice be-
hind the last color deck is visible, separate the
web from the impression cylinder and attach it
to the threading chain again.
Retract the control element, remove the ladder
out of the printing unit and close the sliding
door.

X000288157
Web thread-up at the rewind unit
Switching off the compressed air supply

(2) Key switch
Switch off the compressed air supply to the

winder at the compressed air conditioner (1).
Remove the key from the key switch.
The compressed air supply to the winder can
be switched on no more.
Web thread-up at the rewind unit
No threading chain is available in the rewind machine module so that the web must be threaded up
manually.
Pay attention to the selected winding direction when threading up the web in the cut-off assembly of
the rewind.
(1) Guard door
Open the guard door (1) on the rewind.

Thread up the web from the web tension frame
to the desired winding shaft in the rewind as
shown in the web travel plan and provisionally
splice it onto the sleeve.
Close all guard doors, establish readiness for operation and switch on the machine.
Feed the web carefully through the machine until it lies wrinkle-free on all rollers and cylinders.
Then, loosen the provisionally fixed web from the rewind, remove the old winding roll and fix the
web to the sleeve correctly.

X000267740
Converting the front and reverse side inspection unit
(1) Threading chain follower Drive side (2) Idler roller

(3) Web
1. Separates and fixes the web (3) prior to the idler roller (2).
2. Draw back the separated web (3) up to the first cooling roller.
3. Attach the web (3) to the threading chain follower on the drive side (1). The web forms a loop.

X000267740
(1) Web (2) Removal position Support
1. Actuate the crank handle: At first, the web (1) is misdirected deliberately. Then, the web (1) is
fed towards the rear frame as desired.
2. Actuate the crank handle until the web running upwards through the rear frame reaches the
removal position Support (2).
3. Remove the web from the threding chain follower on the drive side (2) and feed it further through
the machine by hand.

X000267740
Converting the web inspection unit from reverse side to front side inspection
(1) Threading chain follower Operator side (2) Separate web

(3) Web
1. Separate the web (3) after the last color deck and attach it to the threading chain follower on the
operator side (1).
2. Remove the separated web (2) after the last color deck up to the support from the machine.
3. Use the threading thain to thread in the web on the operator side through the drying box and
the rear frame.
4. Remove the web from the threading chain follower on the operator side and thread it further
through the machine by hand.

X000041546

Preparation:
Thoroughly clean the surface of the sleeve with ethanol.
Thoroughly clean the rear side and edges of the printing plate with ethanol.
Always cut printing plates from the rear side of the plate.
Remove any ripples and bends in the area of the printing plate edge as far as possible.
Assembly:
Use assembly belts with high adhesive force.
Mount the adhesive tape free from bubbles with increased hand pressure.
Lay the impact edge of the adhesive tape under the printing plate when possible.
Use reinforced adhesive primer of the respective adhesive tape manufacturer.
Fix the printing plate with nip roll applying medium force.
Mask-off:
allow 0.5 to 1 cm of adhesive tape to protrude.
Fold-free taping of the printing plate edges using one-sided adhesive tape. The adhesive tape should
have a strong bonding to the plate as well as the sleeve.
Integrating the printing plate with a commercially available LDPE (Low Density Polyethylene), approx.
thickness 80 m and width of 15 cm.

X000198620

Material: PET

X000198620
Material: PE-HD

X000198620
Material: PE-LD

X000198620
Material: BOPP

X000198620
Material: ALUMINIUM

X000198620
Material: PAPER

X000011192

General
Improper storage conditions have an adverse effect on the properties of the roller covers and leads
to a reduction in the service life of a roller cover.
In order to ensure that the covers have a long service life, please observe the following instructions
on storage, cleaning and operation. Please refer to DIN 7716 (ISO 8331) for other requirements
regarding the storage and cleaning of the roller covers.
Storing
Rollers Should be stored in their transport case and supported on studs. Do

not apply or fit coverings. Turn rollers through 180 degrees, turning
'soft' qualities more frequently than 'hard' ones.
Room heating Screen rollers from heating elements.
Temperature 5C - 20C
Humidity Max. 65% relative humidity.
Lighting Protect from direct sunlight and strong artificial light with high UV
content.
Ozone Storage areas must be absolutely free of ozonic equipment (e.g. pre-
treater, electric motors).
Other Solvents, fuels and other chemicals must not be stored in the same
area as rollers.
Cleaning
Coated rollers Use solvents which are also contained in the inks, adhesives etc. in
use.
Clean the roller covers with a little bit of solvent keeping the cleaning
time to a minimum, then wipe dry with a clean cloth.
Never use hard objects for cleaning.
Rubberized rollers Only ever use soap, warm water and a lint-free cloth when cleaning
rubberized rollers.
The manufacturer recommends the use of effective and gentle clean-
ing agents.
Counter rollers Remove deposits or contaminations, if any.
Operation
Relieve pressure immediately when roller covers running under pressure come to a standstill. Dry
running of the rollers must be avoided. Regular maintenance of the roller coverings prevents major
damage and downtimes.
Change on printing presses
Pay attention to the electric conductivity of the surfaces. The surface resistance is defined as < 109
Ohm and must not be exceeded.

Z WINDMLLER & HLSCHER 6 Maintenance
6 Maintenance

6.2 Cleaning
6.2.1 Rewind
6.2.2 Unwind
6.2.3 Unwinder
6.2.4 Rewind
6.2.5 Rewind
6.2.6 Printing unit
6.2.7 Printing unit
6.2.8 Printing unit
6.2.9 Printing unit
6.2.13 Drying
6.2.14 Rear frame
6.2.15 Film slitter
6.2.16 Film slitter
6.2.17 Procontrol
6.2.18 Eltainer
6.2.19 Easy-Col
6.2.20 Easy-Set
6.2.21 Easy-Reg

6 Maintenance Z WINDMLLER & HLSCHER

Z WINDMLLER & HLSCHER 6 Maintenance | ATEX-relevant greasing points

6.1.1 Important information on 'ATEX-relevant greasing points'................................................2
Quick reference guide....................................................................................................2
Alarm overview screen page.........................................................................................3
Identification of the lubrication points and execution of the works.................................4
Acknowledging a safety-relevant alarm message at the visual display unit..................5
6.1.2 ATEX-relevant greasing points on the printing unit...........................................................6

Color decks (drive side).................................................................................................6
Color decks (operator side).........................................................................................11
Sleeve-type nip roll......................................................................................................13
Impression cylinder drive.............................................................................................13

6 Maintenance | ATEX-relevant greasing points Z WINDMLLER & HLSCHER
X000164477

Quick reference guide
DANGER
Fire/explosion hazard
Lubricating the ATEX-relevant lubrication points is safety-relevant in terms of a fire/explosion hazard
in the machine.
(1) Sequence number in the alarm overview (2) Date and time of alarm activation
(3) Yellow field = Highlighting of the safety- (4) Text of the safety-relevant alarm
relevant alarm message
(5) 60-hours time block indicating the re- (6) Specification of the lubrication intervals
maining time concerned
A safety-relevant message (4) appears in the 'Alarm list' 60 operating hours before the greasing
interval (6) expires. At the same time, the system-integrated running time meter (5) starts a COUNT-
DOWN (countdown of the 60-hour time block). If no lubrication is carried out within this COUNTD-
OW period and the alarm message is acknowledged by safety acknowledgement, the machine will
be stopped at the end of the COUNTDOWN.
The safety acknowledgement resets the safety-relevant alarm message in the alarm overview. The
associated interval for all ATEX-relevant lubrication points will be re-started until the '60 hours until
end of interval' limit is reached next time.

X000164477
Alarm overview screen page
Messages appearing in the alarm overview in the visual display unit of Procontrol activate a virtual
signal lamp (2) in the visual display unit. The signal lamp will also be visible if the 'Alarm overview'
screen page is not displayed.
To have the alarm message(s) displayed, go to the ' Alarm overview ' screen page via the ALARM
OVERVIEW button in the menu bar of the virtual display unit.
A safety-relevant alarm message when received is highlighted in a yellow field (1) in the relevant line.
When the alarm message appears the COUNTDOWN of the system-integrated running time meter
(3) is started beginning with 60 hours (timespan until the end of the lubrication interval).
Touch the Procontrol touch screen with your finger to select the line with the safety-relevant alarm
message (yellow field). The line is highlighted in gray. At the same time, two virtual buttons, namely
SAFETY ACKNOWLEDGEMENT (4) and LUBRICATION (5), become visible.
(1) Yellow field = Highlighting of a safety-rel- (2) Visual signal on activating an alarm
evant alarm message
(3) Running time meter of 60 hours with au- (4) Virtual SAFETY ACKNOWLEDGE-
tomatic updating MENT button
(5) Virtual LUBRICATION button

X000164477
Identification of the lubrication points and execution of the works
(1) Depiction of the chart containing the (2) 'Signature' acknowledgement line
ATEX-relevant lubrication points
(3) Example of a safety-relevant message
When acknowledging the virtual LUBRICATION button in the menu bar of the visual display unit, the
lubrication chart containing the ATEX-relevant lubrication points appears in the visual display unit.
The safety-relevant message in the alarm overview (3) informs you of the points needing lubricating.
Print out the chart to have the required information at hand on the ground (at the lubrication point).
After greasing the lubrication point, the operator must acknowledge this by signature in the associated
"Signature" line (2) of the paper printout.
After all of the lubrication points specified in the safety-relevant message have been lubricated, the
complete paper list is being filed centrally.
Delete the safety-relevant message in the alarm overview by safety acknowledgement to complete
the entire procedure.

X000164477
Acknowledging a safety-relevant alarm message at the visual display unit
Press the SAFETY ACKNOWLEDGEMENT button in the menu bar of the ' Alarm overview ' screen
page.
The ' Safety acknowledgement ' window pops up in the visual display unit (1).
Touching the SERVICE PASSWORD (2) line makes an alphanumeric keypad available for entering
the customer password.
After the entry, press the virtual ACKNOWLEDGE (3) button in the pop-up window.
(1) ' Safety acknowledgement ' pop-up win- (2) SERVICE PASSWORD entry line
dow
(3) Virtual ACKNOWLEDGE button
Sequence of the safety acknowledgement

The ' Safety acknowledgement ' pop-up window is closed
The safety-relevant alarm message is deleted
Blinking of the virtual signal lamp is switched off
The virtual SAFETY ACKNOWLEDGEMENT button is hidden
The virtual LUBRICATION button is hidden
The associated interval for all ATEX-relevant lubrication points will be re-started until reaching the
'60 hours until end of interval' limit next time.

X000175254

Color decks (drive side)
Greasing the anilox roll bearings on color decks 1-5 on the drive side
(1) Grease nipples on the anilox roll bear-

ings of color decks 1-5
Grease the anilox roll bearings using a grease

gun.
Interval: 400 hours
Use: Klber Polylub WH 2 grease
The grease nipples are arranged on a central
plate and located on the drive side behind the
guard door of color decks 1-5.
Signature:
Greasing the anilox roll bearings on color decks 6-10 on the drive side
(1) Grease nipples on the anilox roll bear-

ings of color decks 6-10
Grease the anilox roll bearings using a grease

gun.
Interval: 400 hours
Signature:

X000175254
Greasing the anilox roll spindle bearings on color decks 1-5 on the drive side
(1) Grease nipples on the anilox roll spindle

bearings of color decks 1-5
Grease the anilox roll spindle bearings using a

grease gun.
Interval: 400 hours
Signature:
Greasing the anilox roll spindle bearings on color decks 6-10 on the drive side
(1) Grease nipples on the anilox roll spindle


grease gun.
Interval: 400 hours
Signature:

X000175254
Greasing the plate cylinder bearings on color decks 1-5 on the drive side
(1) Grease nipples on the plate cylinder

Grease the plate cylinder bearings using a

grease gun.
Interval: 400 hours
Signature:
Greasing the plate cylinder bearings on color decks 6-10 on the drive side

Grease the plate cylinder bearings using a

grease gun.
Interval: 400 hours
Signature:

X000175254
Greasing the plate cylinder spindle bearings on color decks 1-5 on the drive side

spindle bearings of color decks 1-5
Grease the plate cylinder spindle bearings us-

ing a grease gun.
Interval: 400 hours
Signature:
Greasing the plate cylinder spindle bearings on color decks 6-10 on the drive side

Grease the plate cylinder spindle bearings us-

ing a grease gun.
Interval: 400 hours
Signature:

X000175254
Greasing the sidelay register spindle bearings of color decks 1-5 on the drive side
(1) Grease nipples on the sidelay register

Grease the sidelay register spindle bearings

using a grease gun.
Interval: 4000 hours
Signature:
Greasing the sidelay register spindle bearings of color decks 6-10 on the drive side
(1) Grease nipples on the sidelay register

Grease the sidelay register spindle bearings

using a grease gun.
Signature:

X000175254
Color decks (operator side)
Greasing the anilox roll bearings on the operator side
(1) Grease nipple on the anilox roll bearing
Grease the anilox roll bearing using a grease

gun.
Interval: 400 hours
The grease nipples are located behind the
guard doors on the operator side.
color decks.
Signature:
Greasing the plate cylinder bearings on the operator side
(1) Grease nipple on the plate cylinder bear-

ing
Grease the plate cylinder bearing using a

grease gun.
Interval: 400 hours
color decks.
Signature:

X000175254
Greasing the anilox roll spindle bearings on the operator side
(1) Grease nipple Spindle bearing

grease gun.
Interval: 400 hours
color decks.
Signature:
Greasing the plate cylinder spindle bearing on the operator side
(1) Grease nipple Spindle bearing
Grease the plate cylinder spindle bearing using

a grease gun.
Interval: 400 hours
color decks.
Signature:

X000175254
Sleeve-type nip roll
Greasing the bearing
Remove excessive grease after lubrication.
(1) Grease nipple Bearing
Grease the bearings (1) on the sleeve-type nip

rolls using a grease gun.
Interval: 400 hours
Signature:
Impression cylinder drive
Greasing the impression cylinder bearing on the drive side
Grease the impression cylinder bearings (1)

using a grease gun.
Use: KP2K-20 grease
The grease nipple is located on the drive side
behind the guard doors.
Grease until grease leaks from the bearing.
Signature:

X000175254
Greasing the impression cylinder bearing on the operator side
Grease the impression cylinder bearings (1)

using a grease gun.
Use: KP2K-20 grease
The grease nipple is located on the operator
side behind the guard doors.
Grease until grease leaks from the bearing.
Signature:

Z WINDMLLER & HLSCHER 6 Maintenance | Cleaning
6.2 Cleaning
6.2.1 Rewind..............................................................................................................................3
Turret.............................................................................................................................3
Winding stations............................................................................................................3
Cut-off assembly............................................................................................................4
Computer.......................................................................................................................4
6.2.2 Unwind..............................................................................................................................5
Turret.............................................................................................................................5
Winding stations............................................................................................................5
Separating assembly.....................................................................................................6
Computer.......................................................................................................................7
6.2.3 Unwinder...........................................................................................................................7
6.2.4 Rewind..............................................................................................................................8
6.2.5 Rewind..............................................................................................................................8
6.2.6 Printing unit.......................................................................................................................9
6.2.7 Printing unit.......................................................................................................................9
6.2.8 Printing unit.....................................................................................................................10
6.2.9 Printing unit.....................................................................................................................11
6.2.10 Printing unit.....................................................................................................................12
6.2.11 Overhead structure..........................................................................................................12
6.2.12 Drying system..................................................................................................................13

Between-color drying system.......................................................................................13
Tunnel drying...............................................................................................................14
Fan...............................................................................................................................15
6.2.13 Drying..............................................................................................................................16
6.2.14 Rear frame......................................................................................................................17
6.2.15 Film slitter........................................................................................................................17
6.2.16 Film slitter........................................................................................................................18
6.2.17 Procontrol........................................................................................................................18
6.2.18 Eltainer............................................................................................................................19
Climate control unit......................................................................................................19
Computer.....................................................................................................................20
6.2.19 Easy-Col..........................................................................................................................20
6.2.20 Easy-Set..........................................................................................................................21

6 Maintenance | Cleaning Z WINDMLLER & HLSCHER
6.2.21 Easy-Reg.........................................................................................................................24

X000050971
6.2.1 Rewind
Turret
Cleaning the turret drive
(1) Turret drive
Clean the turret drive (1)

Use: vacuum cleaner (the regulations for ex-
plosion protection must be heeded)
The cleaning point is located behind the guard
door on the drive side.
Please heed the manufacturer's cleaning in-
structions.
Winding stations
Cleaning the winding station drive
(1) Winding station drive
Clean the winding station drive (1).

The cleaning points are located behind the
guard doors on both the drive and operator
sides.
The manufacturer's cleaning instructions must
be adhered to.
This procedure is to be followed for all winding
station drives.

X000050971
Cut-off assembly
Cleaning the cut-off assembly drive
(1) Cut-off assembly drive
Clean the cut-off assembly drive (1) .

Use: vacuum cleaner (Tthe explosion protec-
tion regulations must be adhered to.)
structions.
Cleaning the cut-off knife guide shaft
(1) Cut-off knife guide shaft
Clean all of the cut-off knife guide shafts (1).

Interval: 800 hours
Use: soft cloth
The cleaning points are located at the upper
and lower cut-off assembly.
The cleaning points are located on both the
drive and operator side.
This procedure is to be followed for all cut-off
knife guide shafts.
Computer
Cleaning the computer
(1) Computer
Clean the air ventilation of the computer (1) and

the optional machine operator terminal.
The computers are integrated in terminal box
+N90.
The optional machine operator terminal is in-
tegrated in the winder enclosure.
structions.

X000110316
6.2.2 Unwind
Turret
Cleaning the turret drive
(1) Turret drive
Clean the turret drive (1)

plosion protection must be adhered to)
The cleaning point is located behind the guard
door on the drive side.
structions.
Winding stations
Cleaning the winding station drive
(1) Winding station drive
Clean the winding station drive (1).

plosion protection must be adhereed to)
sides.
structions.
This procedure is to be followed for all winding
station drives.

X000110316
Cleaning the center shaft drive
(1) Center shaft drive
Clean the center shaft drive (1).

sides.
be adhered to.
This procedure is to be followed for all center
shaft drives.
Separating assembly
Cleaning the cut-off assembly drive
(1) Cut-off assembly drive
Clean the cut-off assembly drive (1) .

be adhered to.
Clean the light barriers
(1) Light barriers
Clean the light barriers (1).

Interval: 400 hours
Means: Soft cloth
The cleaning points are located on the upper
and lower separating assembly.
The cleaning points are located on the drive
side and the operator side.
Carry out the same process for all light barriers.

X000110316
Cleaning the cut-off knife guide shaft
(1) Cut-off knife guide shaft
Clean the cut-off knife guide shaft (1).

Interval: 800 hours
Use: soft cloth
The cleaning points are located at the upper
and lower cut-off assembly.
and operator side.
cut-off knife guide shafts.
Computer
(1) Computer
Clean the air ventilation of the computer (1) and

the optional machine operator terminal.
The computers are integrated in terminal box
+N10.
The optional machine operator terminal is in-
tegrated in the winder enclosure.
structions.
6.2.3 Unwinder
Cleaning the lenses
(1) Lenses
Clean the lenses at the winder safety arrange-

ment.
Interval: 800 hours
Use: soft cloth
and operator side.
This procedure is to be followed for all lenses.

X000054983
6.2.4 Rewind
Cleaning the lenses
(1) Lenses
Clean the lenses at the winder safety arrange-

ment.
Interval: 800 hours
Use: soft cloth
and operator side.
This procedure is to be followed for all lenses.
6.2.5 Rewind
Clean the sensor
(1) Sensor
Clean the sensor (1).

Use: Soft cloth
Carry out the same process for all sensors.
Clean the guide rails
(1) Guide rails
Clean the guide rails (1).

Use: Soft cloth

X000109893
6.2.6 Printing unit

Clean the plate cylinder drive
(1) Plate cylinder drive
Clean the drive (1) of the plate cylinder.

Use: Vacuum cleaner
guard doors on the drive side.
Follow the manufacturer's cleaning instruc-
tions.
Carry out the same process for all plate cylin-
der drives.
Clean the anilox roll drive
(1) Anilox roll drive
Clean the drive (1) of the anilox roll.

Use: Vacuum cleaner
tions.
Carry out the same process for all anilox roll
drives.
6.2.7 Printing unit

Clean the impression cylinder drive
(1) Impression cylinder drive
Clean the drive (1) of the impression cylinder.

Use: Vacuum cleaner
tions.

X000074730
6.2.8 Printing unit

Cleaning the roll up doors
(1) Roll up doors
Clean the roll up doors (1).

Use: damp cloth
Cleaning the light barrier
(1) Lenses
Clean the light barrier lenses.

Interval: 800 hours
Use: soft cloth
The cleaning points are located on the color
deck side 1-4 (1-5) on the operator side behind
the roll up doors.
Cleaning the reflector
(1) Reflector
Clean the light barrier reflector.

Interval: 800 hours
Use: soft cloth
The cleaning points are located on the color
deck side 5-8 (6-10) on the operator side be-
hind the roll up doors.

X000055887
6.2.9 Printing unit

Cleaning the sensor
(1) Sensor
Clean the sensor (1).

sensors.
Cleaning the guide rail
(1) Guide rail
Clean the guide rails (1).

Use: soft cloth

X000056159

Cleaning the filter inserts
The temperature control unit is located on the tunnel.
(1) Filter inserts
Clean the strainer inserts (1).

structions.
The procedure should be followed for all of the
filter inserts.

Cleaning the discharge electrode
WARNING
Electrical current
Risk of severe injuries when getting in touch with live components.
Disconnect the main power supply and secure it against unintentional reactivation. Verify the safe
isolation from supply. Ground and short-circuit the machine part. Any adjacent parts that are still live
must be covered. Only electrically skilled personnel should carry out work on the unit.Keep a safe
distance.
(1) Discharge electrode
Clean the discharge electrode (1).

Interval: 200 hours
Use: Metal-free brush
be adhered to.
The procedure should be followed for all of the
discharge electrodes.

X000147794

Between-color drying system
Cleaning the slot blowers in the between-color drying
CAUTION
Surfaces may be hot.
The blowers need to be removed for cleaning when very dirty.
(1) Slot blower
Clean the slot blowers in the between-color

drying
Interval: 800 hours
Use: Cleaning cloth with ethyl alcohol and a
spatula, if necessary
slot blowers.
Cleaning the filter in the between-color drying system
CAUTION
(1) Filter
Use the handle to pull the filter out of the air

duct.
Clean the filter (1).
Interval: 800 hours
The cleaning point is located on the printing
unit's drive side.

X000147794
Tunnel drying
Cleaning the idler roller drive
CAUTION
(1) Drive
Remove dust and dirt from the drive (1) of the

idler rollers in the drying tunnel. In addition, the
drive manufacturer's instructions must be ad-
hered to (see SIS-CD 'Sub-vendor documen-
tation').
Identification of records: Rating plate on the
drive.
Cleaning the slot nozzles in the tunnel drying
CAUTION
Pivot the nozzles in the cleaning position.
(1) Slot nozzles
Clean the slot nozzles in the tunnel drying

Interval: 800 hours
Use: Cleaning cloth with solvent
slot nozzles.

X000147794
Cleaning the screen in the tunnel drying
CAUTION
(1) Screen
Clean the screen (1).

Interval: 800 hours
Push the hood of the tunnel drying open to gain
access to the cleaning points.
Fan
Cleaning the drive of the make-up air fan
CAUTION
(1) Drive
Remove dust and dirt from the drive of the

make-up air fan (1). In addition, the drive man-
ufacturer's instructions must be adhered to
(SIS-CD 'Sub-vendor documentation').
drive.

X000147794
Cleaning the drive of the exit air fan
CAUTION
(1) Drive
Remove dust and dirt from the drive of the exit

air fan (1). In addition, the drive manufacturer's
instructions must be adhered to (SIS-CD 'Sub-
vendor documentation').
drive.
6.2.13 Drying
Cleaning the fine-mesh filter
CAUTION
Hot surfaces
Leave the machine to cool down before starting any works on the machine. Wear safety gloves, safety
shoes and long-sleeved clothing. Keep a safe distance. Keep away substances with low ignition
temperatures.
(1) Fine-mesh filter
Clean the fine-mesh filter (1) or replace when-

ever necessary.

X000147811
6.2.14 Rear frame

Cleaning the drive
(1) Drive
Remove dust and dirt from the chill roll drive

(1). In addition, the drive manufacturer's in-
structions must be adhered to (SIS-CD 'Sub-
vendor documentation').
drive.
6.2.15 Film slitter

Cleaning the drive
(1) Drive
Clean the spreader roller drive (1) .

structions.

X000111049
6.2.16 Film slitter

Cleaning the drive
(1) Drive
Clean the edge trim removal drive (1) .

structions.
6.2.17 Procontrol
Cleaning the filters
(1) Filter
Remove dust and dirt from the filters. In addi-

tion, the operator panel manufacturer's instruc-
tions (SIS-CD 'Sub-vendor documentation')
must be adhered to.
filters.
Identification of records: Control console rating
plate.

X000147827
(1) Computer
Clean the ventilation or air conditioning of the

computer. In addition, the computer manufac-
turer's instructions (SIS-CD 'Sub-vendor docu-
mentation') must be adhered to.
The computer is integrated in the operator pan-
el.
Identification of records: Computer rating plate.
6.2.18 Eltainer
Climate control unit
Cleaning the filters
(1) Filters
Clean the filters (1) of the climate control units.

Interval: 800 hours
Use: vacuum cleaner (The explosion protec-

X000055710
Computer
(1) Computer
Clean the ventilating and air circulating fan (1)

of the computer.
Use: vacuum cleaner (Tthe explosion protec-
This procedure is to be followed for all comput-
ers in the Eltainer.
6.2.19 Easy-Col
Cleaning the ink weighing system
Clean the ink weighing system (1) .

Interval: 400 hours
ink weighing systems.

X000057496
6.2.20 Easy-Set
Removing leftover film from the camera module
(1) Camera module (ICM)
Remove leftover film from the camera module

(1).
Interval: 200 hours
Do not enter the Easy-Set unit during cleaning.
The interval may be shortened, whenever nec-
essary.
Cleaning the camera module
(1) Camera module (ICM)
Clean the camera module (1)

Interval: 400 hours
Use: Micro-fiber cloth for the lenses
Do not stand on the Easy-Set unit when clean-
ing.
Do not scratch the acrylic lens when cleaning.
The interval may be shortened if required.
Removing leftover film from the lighting
(1) Lighting
Remove leftover film from the lighting (1).

Interval: 200 hours
essary.

X000057496
Cleaning the lighting
(1) Lighting
Clean the lighting (1)

Interval: 400 hours
Use: Micro-fiber cloth for lenses
ing.
Clean using a clean and moist cloth and then
rub dry using a dry micro-fiber cloth.
Removing leftover film from the background lighting
The background lighting is located beneath the camera.

For cleaning the background lighting, the cover can be swung away.
Remove leftover film from the background

lighting (1).
Interval: 200 hours
essary.

X000057496
Cleaning the background lighting
The background lighting is located underneath the camera.

The cover can be swung-out for the purpose of cleaning the background lighting.
Clean the background lighting (1)

Interval: 400 hours
ing.
Cleaning the transparent panel
(1) Transparent panel
Clean the transparent panel (1)

Interval: 200 hours
ing.
Do not scratch the transparent panel when
cleaning.

X000057496
Cleaning the encoder on the idler roller
Only moisten the cloth a little.
(1) Encoder on the idler roller
Clean the Encoder on the idler roller (1)

Interval: 400 hours
ing.
6.2.21 Easy-Reg
Cleaning the sensor glass
1 Swivel arm
2 Sensor glass
Pivot the swivel arm (1) from the parking posi-

tion manually.
Clean the sensor glass (2).
Interval: 400 hours
Use: lint-free cloth
Ethyl alcohol should preferably be used for
cleaning the sensor glass. Acetate should only
be used for the removal of tenacious dirt.

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Z WINDMLLER & HLSCHER

Overall table of contents

4 Control elements and screen pages

13.07.2016 - Eq.59468 Training manual OP 1

4.5.2 Operator panel +R52

2 13.07.2016 - Eq.59468 Training manual OP

5.3.8 Plate cylinder sleeve change

13.07.2016 - Eq.59468 Training manual OP 3

5.10 Drying system

4 13.07.2016 - Eq.59468 Training manual OP

5.14.13 Wash-up programs

13.07.2016 - Eq.59468 Training manual OP 5

6 13.07.2016 - Eq.59468 Training manual OP

13.07.2016 - Eq.59468 Training manual OP 1

2 13.07.2016 - Eq.59468 Training manual OP

1.2 Instructions for training......................................................................................................3

13.07.2016 - Eq.59468 Training manual OP 1

1.1 Information on the training manual

2 13.07.2016 - Eq.59468 Training manual OP

1.2 Instructions for training

Qualification of the training participants

13.07.2016 - Eq.59468 Training manual OP 3

4 13.07.2016 - Eq.59468 Training manual OP

2.1 Machine data

13.07.2016 - Eq.59468 Training manual OP 1

2 13.07.2016 - Eq.59468 Training manual OP

2.1 Machine data

2.1.2 Technical specifications....................................................................................................3

13.07.2016 - Eq.59468 Training manual OP 1

2.1.1 Manufacturer's address and name plate

WINDMLLER & HLSCHER KG

Windmller & Hlscher KG

(1) Machine model (2) Machine type

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2.1.2 Technical specifications

General specifications for the entire machine

Cooling water requirements

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Drying system (gas-heated)

Emission sound pressure level

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2.2.1 Overview of the workstations

(1) Workstation Unwind (2) Workstation Main operator column PRO-

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2.3 Safety devices: Description

2.3.4 Printing unit.......................................................................................................................7

2.3.5 Drying system..................................................................................................................11

2.3.6 Central warning device....................................................................................................18

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Press the EMERGENCY-STOP pushbutton

The machine can now be restarted.

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(1) Operating element

Turn the switch in the operating element (1) to

(1) Power pack

Use the operating element attached outside the

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(1) Warning light

The flashing warning light (1) attached to the op-

Emergency trip wire

Pulling the emergency trip wire

(1) Emergency trip wire

Pull the emergency trip wire (1).