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Specifications CD 102
Sheet size:
Max. sheet size 720 x 1020 mm
Min. sheet size in straight printing 340 x 480 mm
In perfecting -
Max. print format 710 x 1020 mm
Gripper bite 10 –12 mm
Printing material 0.03 to 1.0 mm
Printing plates:Autoplate printing plates
Length x width (Autoplate) 790 x 1030 mm
Thickness 0.24 – 0.3 mm
Plate cylinder undercut 0.15 mm
Distance from the lead edge of plate to start of printing 43/52 mm
Speed:
Maximum 15,000 iph
Minimum 3,000 iph
Blankets:
Length x width (metal-backed) 840 x 1052 mm
Thickness 1.95 mm
Blanket cylinder undercut 2.3 mm
Packing sheet 735x1030
Coating unit:
Length x width of the coating plate 780x1030 mm
Clamping thickness 0.2 – 0.6 mm
Distance from the lead edge of plate to start of printing 43 mm
Length x width of the blanket (metal-backed) 800 x 1048 mm
Thickness 1.95 mm
Coating blanket cylinder undercut 3.2 mm

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In order to change the sheet size on the feeder, the pile support plate must be fully lowered until the
chain of the pile support plate is completely free of tension.
After entering the sheet size in the CP 2000 Center in the Job menu under Printing material,
the feeder automatically moves to each desired sheet size between min. 340 x 480 mm
and max. 720 x 1040 mm.

On the delivery, both joggers must be moved forward until the limit switch is actuated. To do this,
slacken both Allen screws from below on the jogger (size 8 Allen key, approximately half a
revolution) and tighten them again in the end position to avoid a skewed position.
Lower the pile support plate until the chain is completely free of tension.
Now the joggers can automatically be moved to each desired sheet size from min. 340 x 480 mm
to max. 720 x 1040 mm.

To avoid a collision with the pile, the pile support plate (and thereby also the pile) must be fully
lowered in order to set a smaller sheet size. This is not necessary for increasing the sheet size

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Error messages in the MID

01 – 20 Printing units
21 – 25 Coating units
26 – 30 Intermediate units
41 – 45 Perfector, die-cutting unit
60 Feeder
61 Sheeter
70 Delivery
90 Central equipment (main drive, air supply, dryers, etc.)
91 Central control cabinet
92 Central control console
95 Logistics

In addition, the red light appears on all consoles and,

in the event of faults in the printing units, the blue light flashes here.

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Checking the functionality:

• Inch the press forward until the front lays are in the upper end position.
• Set the deflection of the front lays to zero.
• Insert sheets with a width of approximately 100 cm at the front lays (the sheet alignment
monitor is displayed)
• Position the sheets laterally at a distance of approximately 5 mm from the sheet stop.
• Inch the press forward until the sheet touches the sheet stop.
• When the pull lay monitor is set, the control bar appears in the display
(at the bottom for O.S. and at the top for D.S.).

Setting:

• Turn the knurled screw (1) to the left until the control bar appears in the MID.
• Turn to the right until the latter is extinguished, then turn to the left again until it just starts to
appear. Now go on turning for another 10 fine divisions (every fine division corresponds to
0.03 mm).
• Recognition works 0.3 mm within the paper in order to avoid misrecognition (inaccurately cut
paper edge, incorrect angle)
• If there are still problems in the paper travel, check the suction power of the pull lay and the
pull lay cover.

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Setting the feed drum

• Put the feeder on safe and inch the press forward until the locking screws are accessible.
• Open all three locking screws and keep on inching until both scale handwheels are
accessible.
• Each number on the scale corresponds to 0.1 mm printing material thickness.

Examples: For papers up to 0.1 mm
Position 1

For papers up to 0.2 mm
Position 2 etc.

• The basic position for the scale setting is 2. A deviation in the printing material thickness of up
to 0.1 mm at the respective scale position is within the tolerance value; as such, a
readjustment at the feed drums must only be made for more pronounced material changes.
• In order to compensate for any backlash of threads, both scales should be set in a clockwise
direction.
• After making the change, continue to inch the press until the locking screws are accessible.
• Tighten the locking screws and release the safety device on the feeder.

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The ultrasonic double sheet detection monitors the supply of sheets at the feeder. It detects double
sheets at the front lay and thereby prevents breakdowns.

Note
The electro-mechanical double sheet detection and the ultrasonic double sheet detection monitor the
supply of sheets together. The ultrasonic double sheet detection consists of a transmitter and a receiver
with an integrated signal processing unit and an LED. The transmitter generates an ultrasonic signal
whose strength is not dependent on the paper thickness. There is no "teaching-in" of the paper
thickness. The receiver recognizes the ultrasonic signal with a single sheet and evaluates it. In the
event of a double sheet, the ultrasonic signal loses so much energy on the paper-air connection that the
receiver does not receive a sufficiently strong signal. The sensor recognizes a double sheet during the
measurement process. The control system queries the output signal of the ultrasonic double sheet
detection shortly before the sheet is transferred to the first printing unit. The query of the output signal
takes place at a press angle of 336°(SM 102) or 313°(CD 102).
The control system evaluates the signals from the double sheet detection. In the event of a double
sheet, the LED lights up "red" on the receiver of the double sheet detection.

The control system

• activates the pneumatic valve for the ratchet pawl,
• activates the pneumatic valve for the sheet stop finger,
• switches off the feeder,
• reduces the press speed to 3,000 iph,
• issues an error message on the CP 2000 display and on the MID.

The double sheet detection is always switched on as long as the main switch of the press is in the "ON"
position. The ultrasonic double sheet detector can be deactivated via the control console (press
service).

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Block 1:
Function buttons for the feed table and
the sheet infeed

Block 2:
Press display (MID)
with press control system

Block 3:
Feeder sheet size / control system

Block 4:
Pile control / functions

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1 Blowing/suction nozzle: Increases the volume of blast air of the blowing/suction
nozzle
2 Minus button: Reduces the volume of blast air of the blowing/suction nozzle
The blowing/suction nozzle holds the sheet stable on the front lay and thus aids
paper travel at high speeds.

3 Traction roll: Increases the suction air volume of the traction roll
4 Minus button: Reduces the suction air volume of the traction roll
The traction roll "drives" the incoming sheet to the front lay and stabilizes the
sheet at the front edge.

5 Pull plate: Increases the suction air volume of the pull plate
6 Minus button: Reduces the suction air volume of the pull plate
The suction air of the pull plate holds the sheet and transports it with the pull
plate up to the stop of the pull lay.

7 Suction tape: Increases the suction air volume of the suction tape
8 Minus button: Reduces the suction air volume of the suction tape
The center chamber of the suction tape is controlled. The suction tape
transports the sheet over the feed table to the front lay.

9 Clear feed table

Transports all sheets on the feed table to the ratchet pawl.
This pushbutton replaces the handwheel of the Preset feeder. 9
10 Press display (MID) shows the current press data 16 Control panel selection
(totalizer reading, degree), sheet feed monitoring, reporting of Press button 2 x (double-click) > LED on > press
general malfunctions, etc. can now only be moved in inching mode at this control panel.
Remove by double-clicking again
11 Production
Press in operation: Press automatically goes into production 17 Operation
Press not in operation: The start-up warning signal sounds; The start-up warning signal sounds. When pressed again,
when pressed again > automatic production the machine starts at minimum speed (3,000 iph)
12 Stop 18 Compressor
Slow stop > switches off all functions for production (except the Switches the compressor on (LED on) and off
compressor). Press immediately slows to 3,000 iph. 19 Feeder on
Press runs empty and then goes to press idle.
Switches the feeder on (LED on) and off automatically
13 Increase printing speed 20 Dampening rollers on/off
Increases the speed of the press steplessly
Throws all selected dampening form rollers on (LED on) and
14 Reduce printing speed off manually
Reduces the speed of the press steplessly 21 Paper travel
15 Inch forward Switches the paper travel (LED on) and off
The start-up warning signal sounds, then inch the press forward 22 Emergency stop
Requirement: The Control panel selection button on the feeder must
Press stops immediately – palm button locked
be activated
Release the lock by turning

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23 Fault button red
Press cannot be put into operation due to a fault
24 Fault button blue
Press cannot be put into operation due to a fault
25 Pull distance correction D.S.
26 Pull distance correction O.S.
Note: If both buttons are pressed at the same
time, the pull distance value currently set appears
in the MID
27 Increase lateral sheet
separation blowers
Moves the lateral sheet separation blowers
opposite the pull side away from the pile
28 Reduce lateral sheet
separation blowers
Moves the lateral sheet separation blowers
opposite the pull side toward the pile
29 Pile toward D.S.
Moves the active pile toward D.S.
30 Pile toward O.S.
Moves the active pile toward O.S.
31 Pile alignment
Activates the pile alignment
LED on: Pile controlled automatically
LED off: Pile controlled manually
Each toward the pull lay
32 Suction head up
Manual mode: moves the suction head upward
Automatic mode: increases the setpoint
33 Suction head down
Manual mode: moves the suction head downward
Automatic mode: reduces the setpoint
34 Pile height sensor
LED on: Pile height controlled automatically
LED off: Pile height controlled manually
35 Increase suction head format
Moves the suction head away from the forwarding
rollers
36 Reduce suction head format
Moves the suction head toward the forwarding
rollers
37 Blast air compensation +
Increases the volume of blast air for the
compensation
38 Blast air compensation –
Reduces the volume of blast air for the
00 Automatic misaligned
compensation
sheet correction
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39 Auxiliary pile up
Moves the auxiliary pile upward for as 43 Pile STOP
long as the button is pressed Interrupts the movement of the
40 Auxiliary pile down auxiliary and main piles

Moves the auxiliary pile downward for as

long as the button is pressed

41 Main pile up
44 Pile toward D.S.
Moves the main pile upward for as long
Manual operating mode: Moves
as the button is pressed
the active pile toward D.S.
From "pile centering" onward, the pile is
taken over automatically 45 Pile toward O.S.
42 Main pile down Manual operating mode: Moves
the active pile toward O.S.
Moves the main pile downward.
The downward movement ends
approximately 12 cm above the ground.
Holding the button down again moves
the pile support plate to approximately 1
cm above the ground. The pile support
plate and frame are centered and set
down on the ground

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1 Forwarding sucker O.S.
Adjusts the height of the forwarding sucker O.S.
2 Forwarding sucker D.S. 1 Corner blower D.S.
Adjusts the height of the forwarding sucker D.S. Adjusts the volume of blast air for the corner blower D.S.
3 Rear edge blower 2 Corner blower O.S.
Adjusts the volume of blast air for the rear edge blower Adjusts the volume of blast air for the corner blower O.S.
4 Inner carrier air blower
Adjusts the volume of blast air for the inner carrier air blower 3 Diagonal blower D.S.
Adjusts the volume of blast air for the diagonal blower
5 Outer carrier air blower
D.S.
Adjusts the volume of blast air for the outer carrier air blower
6 Sheet separation blower 4 Diagonal blower O.S.
Adjusts the volume of blast air for the diagonal blower
Adjusts the volume of blast air for the sheet separation blower
O.S.
7 Inclination of lifting sucker
Adjusts the inclination of the lifting sucker
5 Guide plate
8 Travel of lifting sucker Adjusts the height of the guide plate
Adjusts the size of the lifting movement
9 Suction head up 6 Pre-separation air
Automatic mode: increases the setpoint of the height adjustment Adjusts the volume of pre-separation air for the carrier air
Manual mode: moves the suction head upward and sheet separation blowers. The pre-separation air is
blown into the pile before paper travel is activated
10 Suction head down
Automatic mode: reduces the setpoint of the height adjustment
Manual mode: moves the suction head downward
In addition, the buttons for the intercom system,
11 Blast air compensation + microphone and volume control are located on the
Increases the volume of blast air for the blast air compensation control panel.
12 Blast air compensation –
Reduces the volume of blast air for the blast air compensation 13
 The ultrasonic double sheet detector detects all
standard printing materials with the exception of multi-
The multiple sheet detector is adjusted
layer printing materials or thick films.
automatically according to the printing material
thickness.
If the ultrasonic double sheet detector detects double
The multiple sheet detector can be switched off -
sheets, the feeder switches off immediately.
however, it is automatically switched on again after
To remove the double sheet, press the button for the
a pile change and after 5,000 impressions.
ratchet pawl and remove the sheets.
Note:
Switching off the ultrasonic double sheet detector
From a printing material thickness of at least
On the CP 2000 Center in the Service menu under
0.4 mm upward, the device differentiates between
Basic adjustment/Paper travel, press the button with
multiple sheets and double sheets.
the Ultrasonic double sheet detector icon.
Under 0.4 mm, only multiple sheets are detected
A warning message appears!
12345
Job
Name

Double sheet 1
Basic settings / paper travel

The double sheet is 2

Ultrasonic double sheet detector
•stopped by the sheet stop finger before the printing unit Basic adjustment
5
3
•The ratchet pawl moves upward
•The feeder is switched off 4

-20 mm

Multiple sheets
The feeder is switched off as soon as multiple
sheets are detected.

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Pull lay double sheet detector
The double sheet detector in the pull lay is
adjusted automatically according to the printing
material thickness.
The measurement is made by a sensor in the pull
lay during the pull procedure.
The average value is determined from the last 5
sheets and this is then used as the reference value
for the following sheets.
Switching off the pull lay
double sheet detector
The procedure is the same as for the ultrasonic
double sheet detector - however it is only possible
to deactivate either the ultrasonic or the pull lay
double sheet detector.
It is not possible to switch them off simultaneously.
Stream control
The double sheet detector above the suction tape
driving roller consists of a cross bar that can be
fitted with a maximum of 24 feeler rollers.
(delivery condition = 4 feeler rollers)
The rollers detect
•double sheets
•multiple sheets
•accordingly large paper shavings, depending on
their number and position
The cross bar is adjusted via the control knob;
screen division = 1/100 mm
Adjusting to the printing material thickness
1. Switch on the feeder and paper travel
2. Turn the control knob clockwise until the double
sheet detector just triggers.
3. Use the following formula to determine the
setting value for the current printing material:
Printing material thickness ÷ 2 x100
Example:
Printing material thickness 0.1 mm
0.1 ÷ 2 = 0.05 / 0.05 x 100 = 5
= 5 screen divisions to the left
Printing material thickness 0.4 mm
0.4 ÷ 2 = 0.2 / 0.2 x 100 = 20
= 20 screen divisions to the left
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The separator rolls guide the sheets under the cover guides. They ensure that the
sheets are fed into the press smoothly and with little marking.
With printing materials that are thicker than 0.4 mm, the separator rolls automatically
move into the cardboard position. Individual separator rolls can be thrown off.

Setting the separator rolls

Paper = 3 strips of paper, cardboard = 2 strips of cardboard
The height of the separator rolls is to be set using the knurled screw so that 3 strips of paper (2
strips of cardboard) can be moved between the separator rolls and the feed table with a slight
degree of resistance (do not clamp!)

The maximum distance between the separator rolls and the feed table is 10.4 mm
The minimum distance between the separator rolls and the feed table is
• 0.2 mm in the paper position
• 0.4 mm in the cardboard position

Note
The same procedure must be used when covering the pull lay.
D.S. and O.S. and the separator rolls; this gives a total of three settings when changing the printing
material and an accordingly large difference.
To throw off individual separator rolls, move the lever on the separator roll in
question clockwise – toward O.S. - throwing off is recommended for sensitive
materials or materials of different thicknesses.
Image 2
Position 1 = on / Position 2 = off
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The CP2000 Center design
The new CP2000 Center convinces due to its appealing and ergonomic design. Its main feature
is the flat screen with touch-sensitive color display, the inclination and height of which are
adjustable. The control panel is equipped with operator-friendly key pads in the same design as
those on the feeder, delivery and printing units. The control panel is screened against external
light sources by means of a pin board at the rear and is roofed with a standard daylight lamp.

Operation and display

The menu guides the operator to the individual functions by means of an easily understandable
system of text, symbols, graphics and colors. The familiar icons from the CPTronic control
system are used as symbols. The header, from which the main functions are selected, is visible
at all times. Country-specific plain text displays enable quick and simple operation. Status
displays make the press process (for example washup) visible.

Functions
The expanded job and press control system includes:
Preparation and saving of job data, control of paper travel, print functions, remote ink control,
water distribution, remote register control, wash programs and service functions and much
more.

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There are several ways in which the ink zone values can be transferred to the ink zone motors of the Speedmaster.
Convenient and fast transfer is ensured by the network connection with the CP2000 PresetLink module on the
CP2000 Center. The PrepressInterface can feed the data directly into the network; this can be done from the Plate
Image Reader by means of the Plate Image Reader Online Kit. Alternatively, the DataControl software module
"PrepressInterface Connection" can be used for the transfer of color data from the Plate Image Reader or
PrepressInterface to the CP2000 Center. In addition, the data can be stored on the job memory card and
transferred directly from the card to the CP2000 Center.

The CP2000 console

For each of the 32 ink zones, the ink zone console has a coarse display which is divided into 25 bars, as well as a
fine display with 20 additional adjusting steps. A gradation can be made in 4% steps (coarse) and 0.2% steps (fine)
respectively. The bars of the coarse display represent an ink profile that is easy to ascertain visually. The opening
of the ink zones can be selected manually here using the light pen and +/– buttons.
The preinking programs saturate the inking unit before the print start and thus reduce start-up waste. In the event
of ink changes during printing, the Color Booster function overmodulates the opening and closing of the ink zone
for a short time depending on the area coverage. This accelerates the reaction of the inking unit and the change of
the color on the printed sheet is achieved more rapidly. A "green light" in the ink display continuously informs the
operator of the current status of the printing unit during production. This signal shows when the adjustment
changes are complete. A pre- and post dampening program greatly increases the fast color attainment after
interruptions in production. The automatic follow-up dampening ensures that the ink-water balance is adjusted
accordingly after changes in speed and ink volume and thus helps to achieve stable inking. In addition, the
consumption volume of ink and varnish is automatically adjusted in the event of changes in the printing speed. The
customer can adapt the characteristic curves for the speed compensation that are preset in the factory individually
to suit his particular press and ambient conditions. Following a successful first proof, the inking can be changed not
only by direct follow-up of the ink zones on the CP2000 Center: a correction can also be controlled via the
QualityControl and ImageControl color measuring devices. They record the deviations of the color from setpoints.
The correction values calculated from these can be transferred online to the CP2000 Center.

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CPC ink fountain
With the SM/CD 102, the CPC ink fountain and thus remote ink control are included
as standard. Instead of an ink fountain blade for ink zone adjustment, the CPC ink
fountain has ink metering cylinders which lie on the ink fountain roller. They are
controlled remotely from the CP2000 Center via motors: Their position is shown by
means of light-emitting diodes and can be adjusted at the push of a button or with
the light pen. 500 adjustment steps allow the finest of gradations in the ink film
thickness. A plastic foil lies between the ink and the ink metering cylinders. This
ensures that the mechanical part of the ink fountain does not come into contact
with ink, which minimizes the maintenance required and drastically cuts down the
cleaning time during ink change. The ink fountain foil has another advantage. Its
position can be changed several times to compensate for wear. Thus it is
guaranteed that the metering in the ink fountain is always precise. Together, remote
control and the ink metering cylinders ensure reproducible ink profiles with the
finest of layer thicknesses. The setting of the ink zones with no side effects enables
an exact setting of the ink profile.

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• Operating the Stop button (2)

• In no-load operation
Press reduces speed until it reaches press idle

• In production
Impression off in all units. Simultaneous reduction of the speed to 3,000
iph. All sheets are transported to the delivery; once the last sheet is laid on the pile, the
speed is reduced until it reaches press idle.

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21
Gray background color:
All actions refer to the current job and all changes made directly affect the press setting.

Purple background color:

All changes made are written to the job preparation memory. The "Confirm job" function
transfers the data to the press and they become the current settings.

Green background color:

By pressing the Heidelberg button, the online help is activated; additional information is
shown on the monitor, as is access to the spare parts list and operating manual. No changes
are made to the current settings. Pressing the Heidelberg button again takes you back to
press operation.

Color mark at the top:

The button opens a submenu which contains further functions of a press group.

Purple color mark at the top:

This button takes you to job preparation. After pressing this button, the screen background
turns purple (see purple background color).

Function button:
By pressing the function button, a function is triggered on the press or a setting is changed.
With functions, the activated symbol turns white and the function is switched on at the press
at the optimum point in time. When settings are changed, the number turns white during the
adjustment; once the settings are reached, the number turns black again.
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In all adjustments, the contact is increased in the clockwise direction and decreased
in the counterclockwise direction. The cylinder gap is outside the adjustment range.

Installation and adjustment:

1st step: Install rollers 1-12, then apply ink (yellow) and allow it to be distributed.
2nd step: Adjust 1 to C = 4 mm, 2 to D = 4 mm.
Install rollers 13 and 14 and adjust 13 to D = 4 mm, 14 to C = 4 mm.

Note: Rollers 3 - 8 require no adjustment.

Tighten the Allen screws after installing roller 4.

Attention: Roller 12 to 11
6 mm contact area

3rd step: Adjust 10 to 9 = 4-5 mm and 9 to B = 4 mm, then adjust 12 to 11 = 6 mm.

4th step: Install the ink vibrator (15) and adjust 15 to the ink fountain roller = 4 mm,
then 15 to A = 4 mm (adjust spring pressure if necessary).
Thus: 1st vibrator roller
ink fountain roller - 2nd vibrator roller

distributor roller
5th step: Set the inking form rollers down onto the plate.
Distance between dampening form rollers and plate = 4 mm.
(Diagonal register at 0.00 mm)

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Inking unit surface
An assessment measure for the surface of an inking unit is the comparison between the
largest print format and the inking unit surface. It is calculated from the sum of the surfaces of
all rollers and distributor rollers, from the vibrator roller to the inking form rollers. A good inking
unit should have a large storage capacity, while also being able to react as fast as possible to
corrections.

Ink flow
Another important factor is the roller arrangement. It determines the ink flow and directly
effects the inking of the plate. Heidelberg sheet-fed offset presses have front-heavy inking
units. The main ink stream is directed at the first form rollers. Depending on the press model,
they apply up to 90% of the required ink volume to the printing form. The last two inking form
rollers mainly have the task of smoothing the ink layer on the plate.

Inking
The number and circumference of the inking form rollers have a major influence on the even
inking of the printing plate. We know from experience that it is simpler to apply a thin ink layer
to the plate from several inking form rollers in succession and then to smooth it, than to apply
the same ink volume with fewer rollers. Different diameters of the inking form rollers ensure
even inking, even for difficult forms. If all inking form rollers had the same diameter, the ink
consumption of the printed image would coincide exactly due to the same cylinder rolling,
manifesting itself as an ink transfer error (ghosting). With 4 inking form rollers in correctly
graded roller diameters, Heidelberg sheet-fed offset presses guarantee good inking.
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Preconditions
- Inking form rollers have been adjusted - Connection has been selected
- Plate is mounted - Vario is switched off
- Diagonal register is set to 0.00 mm - Note the gap position
Alcolor is adjusted using strips of paper. Two strips each are used for D.S. and O.S. (a broader one toward the rubber
roller, a narrower one for feeling). The total thickness of the two paper strips should be 0.10 mm. All adjusting screws
for compensating for a backlash of threads must be turned clockwise only (clockwise more contact, counterclockwise
less contact).

1st step: Install A. Adjust A to R using the strips of paper on D.S. and O.S. until parallel with light
contact + 1 1/2 revolutions; check the contact area later with ink.
A to R = 6 mm (frequent use of Vario = 7 mm)

2nd step: Adjust A to the plate with paper strips until contact is established; check later with ink.
A to the plate = 6 mm

3rd step: Bring F and A into contact with the plate, then insert Z. Adjust Z to A using the paper strips
until light contact is established + 1/2 revolution (3-4 mm) and lock.

4th step: F and A are in contact with the plate, turn the knurled screws up to the stop + 1/2 revolution
and lock (approximately 3-4 mm). Disengage F and A from the plate.

5th step: Install D and T and the dampening solution pan. Adjust D to T until light contact is
established + 1/2 revolution (metering) and lock (may require slight correction during first
proofprint).

6th step: Connect D to A, adjust D to A until light contact is established + 1 1/2 revolutions
(check with ink = 6 mm).
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7th step: Dampening form roller and inking form rollers to plate,
Alcolor Vario continuous-type dampening system

The dampening system can be ordered with Vario function as an option.

On the Alcolor Vario continuous-type dampening system, the dampening distributor of
the Alcolor dampening system is connected with a gear which enables the distributor
roller to be switched to a 12% lower speed. In Vario operation, the lower surface speed
on the distributor roller slows down the dampening form roller. This creates a certain
slippage between the dampening form roller and the printing plate, which effectively
prevents the formation of hickeys. Hickeys are removed from the plate and washed
away with the dampening solution.

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Distributor roller zero option

1. Ink profile from ink fountain roller 1

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 26 27 28 29 30 31 32

2. Current ink profile on the inking

2
form roller during production
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 26 27 28 29 30 31 32

3. Ink profile too thinly distributed on

inking form rollers after press stop, for 3
example due to pile change or blanket
washup procedure 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 26 27 28 29 30 31 32

4. Because distribution is thrown off

during the press stop, the current 4
production ink profile on the inking
form rollers is retained 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 26 27 28 29 30 31 32

Benefit: less start-up waste

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Lateral distribution
In addition to ink distribution in the circumferential direction, the ink is also distributed
laterally by traversing distributor rollers. This is necessary for the following reasons:
Lateral distribution ensures that the ink is evenly distributed toward the sides, plus the
ink remains smoother. It breaks down ink accumulations that reach the inking unit as a
result of uneven ink acceptance of the printed image. Furthermore, lateral distribution
helps to set the ink zones, as these are not always arranged in accordance with the
motif. Finally, lateral distribution makes it even easier and quicker to wash the inking unit.
On Speedmaster SM/CD 102, the travel of the lateral distribution can be adjusted. The
basic adjustment of the distributor travel is 35 mm, which can be changed steplessly if
necessary. To do this, inch the hinge bolt downward, then open the lock nut and move
the hinge bolt toward the center until the desired position is reached. The lock nut is then
tightened. The advantage of this setting option is that the printer can exert influence in
problem cases, for example: fine font next to a large area or rainbow printing from a
divided ink fountain.

Starting point of the lateral distribution

Adjustment via CP 2000 > Print functions

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Heidelberg print quality begins with the good interaction of the inking and dampening
systems. A stable ink/water balance is an important prerequisite for consistently good
print results – without compromises in quality. And the inking and dampening systems
of the Speedmaster SM/CD 102 fulfill precisely this prerequisite. The tried and tested
Heidelberg Alcolor continuous-type dampening system ensures a thin and evenly
distributed dampening solution film on the printing plate. As such, the quality of the
printed product and brilliance of the colors are always of the highest level. The low
dampening solution distribution reduces the drying time of the print sheets so that
they can be further processed more quickly.

In the event of press stops (washup, stopper, etc.), the dampening form roller swings
away from the plate. Before production continues, the dampening form roller swings
back to the plate – the duration of this predampening can be adjusted in the menu

Malfunction
Service
Basic adjustment
Setting ink/dampening. Good
adjustment aids print start after an interruption or generally at print start.

29
Setting the pre- and postdampening phases

Adjustment Adjustment
Mode Standard
Revolutions range for max. range for min.
settings
revolutions revolutions

Predampening
phase 1 3 3 18 0
.

Predampening
phase 2
2 2 18 0

Postdampen-
ing phase 1
15 15 50 0

Postdampen-
ing phase 2 45 45 100 0

30
2-roller system (water pan roller coating unit)
The water pan roller rotates in the coating pan and the varnish transfer takes place via the
smooth distributor roller onto the blanket. The volume of varnish is controlled by squeezing the
water pan roller and metering roller.
Advantages Disadvantages
 Transfer volume can be determined by - Volume of varnish is variable at different
squeezing the water pan roller and speeds
metering roller
- No homogeneous application
 Simple handling during cleaning
- Reproducibility not possible

Chambered blade coating unit

The varnish transfer takes place via the screen roller with a defined volume
Advantages Disadvantages
 Homogeneous varnish application - Screen roller must be changed for
different application volumes
 Constant application weight
 Reproducibility guaranteed

 Easy varnish change

 Cleaning possible by rinsing

31
Be careful when handling the chambered blade!
The blades are very sharp and are sharpened even more by the screen roller when the
doctor blade is used. Only well-trained staff should handle the doctor blade (installation,
removal, cleaning, etc.). Touching the blades can lead to cutting injuries; precautions should
therefore be taken, such as wearing special gloves (ceramic, metal) and/or removing the
blades before cleaning.
If the chambered blade is not needed, place the doctor blade on a soft surface (for example
polystyrene from the ink fountain foil) with the blades pointing downward.

Risk of injury!
Doctor blade chamber with
eccentric clamping
of the doctor blade

32
Flexokit is a closed chambered blade system.
The different components, such as the evenly circulating hose pump and the closed
circuit, ensure that the formation of air bubbles is almost completely prevented. This
is a great advantage and often a prerequisite when processing metallic materials or
similar, such as gold coatings or iriodin varnishes.

33
Before changing the screen roller, the return flow trough of the coating unit needs to be
removed. To do this, remove the drainage hose on D.S. and fit the cover. Press the
locking device downward on both sides of the trough, lift the back of the trough and
remove it in the direction of the feeder; now pull the trough to O.S. and set it down here.
Insert the carriage. Insert the plastic mounting under the screen roller so that the carriage
rests in the position of the drainage trough. Release the locking device at the rear end,
move out the extension under the guard and lock again. Turn the marking on the screen
roller to the "3 o'clock position". Now slacken the two size 17 screws on D.S. and O.S.
(open completely, they cannot fall out). Now reach under the white plastic mounting and
pull it out together with the screen roller. Insert the hooks into the ears between the size
17 screws and use them to remove the screen roller and position it on the coating unit on
the supports provided. Afterwards install the screen roller in the reverse sequence.

Attention:
When removing the screen roller, ensure that it does not come into contact with
tools or other objects (coating pan). Jewellery, such as rings, etc. should also be
removed.
Hard objects can cause damage to the screen roller, which is then visible on the
print sheet.

34
Measuring procedure for blanket and plate cylinders
Measuring the end heights on blanket and plate cylinders
To measure the packing thickness of the blanket and plate cylinders exactly, it is best to use a special
measuring device which is available as a special accessory under the following part number:
Measuring device 09.465.000/1 K1 (metric setting)
Measuring device 09.465.100/1 K1 (imperial setting)

Measuring procedure for the blanket

After mounting the blanket, allow the press to turn several times under pressure so that the blanket
can settle, then retension the blanket. To enable the measuring device to be moved more easily on
the blanket, a sheet is placed on the blanket so that it also covers the bearer. The measuring device,
which is equipped with three dial indicators, is positioned parallel to the cylinder shaft; the feeler pin of
the outer dial indicator should rest on the bearer. Now adjust the three dial indicators so that they all
show the value "0". Move the entire measuring device until the feeler pin of the outer dial indicator
rests on the blanket. Ensure that the values of the other two dial indicators do not change, as an exact
measuring result cannot be read off if the measuring device is tilted. The scale of the outer dial
indicator shows how the blanket lies in relation to the bearers.
After several hundred impressions, the blanket must be retensioned. This can mean that the
measuring result differs from the previous result. It may be necessary to use packing sheets.

Measuring procedure for the plate cylinder

The measuring procedure for determining the packing thickness of the plate cylinder is the same as
the procedure for the blanket cylinder. You should also place a sheet on the plate cylinder here to
prevent any damage to the plate. In order to fix the sheet more easily, place it on the plate cylinder so
that it is positioned beneath the last inking form roller. Once the inking rollers are engaged, the paper
can no longer be moved.

35
Perform the following steps in order
to remove the blanket washup device:
Use a size 6 Allen key to slacken screw 1 on D.S. and O.S. and remove the guard.
Open latch no. 2 so that you can pull out the washup tray.
Remove the piping before pulling out the tray.
With WashStar: Open the door on the operator's side and use a size 5 Allen key to
open the safety door; then remove the hoses.
Without WashStar: Remove the piping on the drive side.

Again, use a size 6 Allen key to slacken 2 screws each (no. 1) on D.S. and O.S. of
the pneumatic cylinders.
Attention: Once the screws are slackened, one person should hold the washup
device in place in the center while a colleague pulls the washup device out by 1 cm
on the appropriate side so that the pneumatic cylinder can be removed. If the
washup device is not held in place, there is a danger that the device may slip out of
the guide and tip downward.

Then press the latch fastenings and remove the water and washing fluid
lines on the BWD. Place the pneumatic cylinder on the cross bar above the
BWD. It is recommended that you position the hoses so that the BWD can
be pulled out with no further effort, i.e. without having to hold the hoses out
of the way.

36
 When installing and removing the BWD, it is essential that those
involved discuss all steps beforehand and then perform them in
parallel. (It is better to spend an extra minute discussing the steps
than talk about it in the press). When pulling out the BWD, the first
roller (no. 2) comes out of the guide rail and the BWD can therefore
be tilted downward by almost 90 degrees.
Accordingly, roller 1 must be inserted into the guide first during
installation – once again, it is vital to work in parallel here. Once roller
1 is in the guide on D.S. and O.S., what is almost the entire weight of
the BWD is no longer being supported by the persons performing the
work …

Before work is performed on
the BWD, the brush gasket on
the underside needs to be
removed to protect it from
damage.
To remove the cover of the
BWD, slacken 2 screws each
on D.S. and O.S. It is
recommended that you
slacken the upper screw first –
and when reassembling,
tighten the lower screw first.
To remove the brush (4) you
need to slacken the screws (1 +
2). Now lift the plate (3) and
swing it by 180°. You can now
remove the brush.

37
38
Air Transfer System on the CD 102
As already tried and tested with sheet control in deliveries patented by Heidelberg, venturi nozzles are now also
responsible for smoothing and guiding the sheets at the sheet guide plates below the transfer drums. Instead of
being supported by the SuperBlue net on sheet-metal jackets, the sheets follow the curve of the air baffles, are
sucked onto them by the vacuum, and are carried by a thin air cushion generated by the venturi nozzles. In
comparison with the guide plates used previously, the distance between the new air baffles and the transfer
drums has been reduced, which aids sheet travel yet does not disadvantage the processing of cardboard. The
constant volume of blast air required for supplying the venturi nozzles is generated by radial fans that are
mounted directly on the rear of the double-walled air baffles. Regardless of whether small or large sheets, airmail
paper or label paper, long grain or short grain: neither the air volume nor individual nozzles need to be adjusted or
sealed off. Each individual sheet is smoothed by the laterally escaping blast air, adapted to the round form of the
guide plate and, at the same time, carried free of wrinkles on an air cushion. This means that when working-and-
turning or working-and-tumbling small pressruns, sheets that are already printed on one side run scratch-free,
while, at the same time, the freshly printed side of the sheet is at a considerable distance from the air baffles of
the transfer drum. All that remains for the printer to do with regard to sheet control is to adjust the volume of blast
air on the printing nip between the impression roller and the blanket cylinder, if necessary, so that the sheet does
not come into contact with the inked up blanket and cause a contact slur. Manometers show the selected air
volume and enable reproducible, fast settings. The air volume depends upon parameters such as the press
speed, paper thickness, direction of paper travel and paper surface, the tack of the blanket surface and the ink,
and the motif of the printing plate. In most cases however, you can generally work with a basic adjustment that
needs to be set just once. Once the sheets are transferred to the next impression cylinder, the blast air takes over
sheet control into the printing nip and up to the blanket cylinder. The blowing devices for sheet control on the
impression cylinders are supplied with compressed air from the central air supply system. The air pressure can
be finely adjusted and read by manometers.

39
 Press control system
1 2 3  1 Production
 2 Job counter
4 5
 3 Printing speed +
 4 Slow stop
 5 Printing speed -
1 2 3  1 Operation
 2 Feeder on
4 5
 3 Paper on
 4 Compressor
 5 Dampening system
Air control for the pile area
1 Longitudinal blast tube 50

Stepless change of the volume of blast air for the longitudinal blast tube.
Used for heavily rolled paper on the lead edge of sheet. 0 100

2 Fans 50 50

4 movable rows, each with 6 fans (adjustable)

0 100 0 100

Row 4 (rear edge of sheet) = 1 potentiometer for 6 fans

Row 3 = 2 potentiometers (2 + 4 fans) 50 50 50 1 50

Row 2 = 3 potentiometers (2 + 2 + 2 fans)

Row 1 = 5 potentiometers (1 + 1 + 2 + 1 + 1 fans) 0 100 0 100 0 100 0 100

The rear edge of sheet is still located on the sheet slow-down device,
50 50 50 50 50

while the front edge has already left the gripper bar and is therefore
hovering freely. It is therefore necessary to control the front edge of the 0 100 0 100 0 100 0 100 0 100

sheet using the fans in order to lay the sheet virtually hovering onto the
pile. 2

40
 1000 x 700
Sheet slow-down
device menu
455 227 1 227 455 Each of the 5 sheet slow-
down devices can be freely
positioned by pushing the
button – regardless of
whether the press is running
or at a standstill.
Additional equipment
menu
The sheet decurler and
powder spray device can be
switched on and off in this
menu; the parameters can
also be changed. Dryers
and anti-static units can only
be switched on and off.
1000 x 700 Sheet stops menu
The sheet size can be
increased or decreased at
any time by pushing the
button.
The lateral stops can also
be thrown off - separately -
and the tilting motion of the
front flap can be locked,
too.
Malfunction menu
The number next to the
"Malfunction" symbol gives
the position of any
malfunction (for example 3
for PU 3 or 70 for the
delivery). You can also set
the contrast for the display
here.
41
When you enter the printing material thickness for the job on the CP 2000 Center, the parameters of all zones of
the sheet guide plate change – from the transfer drum to the sheet slow-down device.
Area A: Transfer up to the sheet decurler
Area B: Sheet ascent ramp
Area C: Extension module
Area D: Extension module
Area E: Extension module
Area X: Sheet slow-down device
In area A, 6 zones over the entire width of the sheet guide plate can be adjusted. In area B, there are 8 zones,
and for an extended delivery there are an additional 4 zones for each extension module. Area X can be adjusted
via the KID.
In unfavorable conditions, such as wave formation or similar during sheet transport over the sheet guide plate, it
makes sense to change the parameters on the local operating panel and thereby positively influence sheet
travel.
All air settings that affect sheet transport in the delivery are preset values;
sheet guide plate, X-plate in front of the sheet slow-down device and the entire
delivery air system above the delivery pile.
These values can, of course, be adjusted manually and can all be saved with
the corresponding job so that they can be called up again for repeat jobs.

42
43