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1. Maintenance and replacement 33 Clean air filter in sound damper SUCTION side 22a22000000nnnnunnunnnnn ann 33 Clean powder channels uu uuuuuuuan0nun0nn 34 Disassemble reassemble solenoid valve uunuusnnaaannunnunnnnnnnnnnnnnnnnnnnn 35 Disassemble reassemble valves 37 Clearance of malfunctions 39 VAG EPE E RER RFE SRBRFSERFERSBERERFEEG 40 25 Please note Warning notice Warning lt general danger gt Caution notice Caution lt brief description of the danger gt General notice gt Note Test instruction control instruction chapter note or note regarding supplementary documents Handling instruction Execute instruction 26 MEDIPRINT 3 Please note 3 1 User notes on the documentation Important notes which must be complied with are emphasised in the instructions as follows This safety note warns you about potentially dangerous situations Non compliance could lead to severe injuries In extreme circumstances to loss of life In addition machines and auxiliary equipment could be severely damaged This safety note warns you about potentially dangerous situations Non compliance could lead to damage to machines and auxiliary equipment This note gives you additional information and tips regarding use when operating the printing machines and their auxiliary equipment Supplementary explanation of the necessary operating steps MEDI
2. powder sprayer must be made Fig 9 Disassemble solenoid valve Do not undo the screws on the rear side of the solenoid valve Only disassemble the solenoid valve together with the base Undo the screws at the base of the solenoid valve and completely take off the solenoid valve Reassemble in the reverse order of disassembly 35 MEDIPRINT Maintenance and replacement S Axx KR Y Fig 10 Disassemble and reassemble valves 36 MEDIPRINT Warning danger of injury from whirled up solid particles Ensure responsible handling of the compressed air pistol There is a considerable danger of injury if the compressed air pistol is improperly handled When blowing out with compressed air detached solid bodies or whirled up powder dust can cause eye injuries Always wear protective goggles when cleaning the powder hoses Warning danger to health by inhaling powder dust The inhalation of airborne particles can endanger your health When cleaning the powder hoses always wear a dust protection mask powder channels by oily or fat containing Caution clogging of powder nozzles and substances When using oily compressed air lumping of the powder can occur and in this way can lead to clogging of the powder nozzles and powder channels in the unit If the end of a powder hose comes into contact with fatty substances powder deposits can lead to clogging of
3. rear side of the distributor with compressed air Blow out powder hoses ey with compressed air Replace defective powder hoses Only clean powder nozzle slot with plastic or wood stick then blow out with compressed air Fit back powder hoses blower air hose and powder glass gt Note Powder hoses must be laid free of kinks and safe from contact with moving parts gt Note The markings of powder nozzle 3 powder hose 7 and nozzle valve head must match MEDIPRINT Maintenance and replacement 5 3 Disassemble reassemble solenoid valve Warning live connections When working on live connections there is an increased danger to life from electric shock When working on the electrical parts the unit and all live components of the printing machine must be switched free from electric current and protected against inadvertent switching on Set the master switch on the switch cabinet to position 0 Switch the installation free of current Dismantle the sheet metal covering 69 Mark the connection lines to the timed control and to the master switch and separate at the lustre terminals on the solenoid valve 3 Draw off the air hose from the distributor 2 to the base of the solenoid valve only be positioned on the base by the Caution the solenoid valve can manufacturer If the solenoid valve is disassembled without base then the manufacturer s installation positioning of the
4. the hose Therefore for blowing out powder channels always use compressed air from oil free systems When hose ends are contaminated by fat containing substances shorten them by 10 15 mm a gt 8 Maintenance and replacement Disassemble reassemble valves Disassemble control unit see Page 30 Disassemble sheet metal cover 9 Draw off plug connection at the switch Lever off the cover caps of the rotary knobs and 9 Undo locking screws and draw off rotary knobs 9 Unscrew hexagonal nut remove washer and draw off rotary knob 0 Dismount front plate 0 Mark the position and arrangement of the valve head 1 gt Note The valve heads must not be reinstalled rotated by 180 The valve heads must be installed again in the same seating as they were disassembled from Unscrew the threaded connection 5 and draw out the valve heads together with washers 2 and the springs 9 gt Note When reinstalling pay attention to the markings made Draw out mixture control valve 7 together with spring 8 and washers 9 9n Take off powder glass Blow out all components with compressed air and blow out all holes For reassembly repeat working steps to Q in reverse order Bring the holes in the valve heads into line with the holes in the underside of the distributor in order that a bit 3 mm sticks in gt Note From the underside of the distributor look into
5. the holes and turn the valve head until the holes align Working steps to amp on the next page 37 Maintenance and replacement Fig 11 Adjustment of mixture control valve 38 MEDIPRINT Continued 5 4 Disassemble reassemble valves Push the rotary knobs 6 on the outlined valve ee 6 head 1 into the maximum position and screw tight 0 5 mm distance to the front plate see Fig 10 Page 36 Take out bit Draw off the air hose from the connection piece of the mixture control valve Turn the mixture control valve in such a way that the start of the curve is approx 1 mm from left edge of the hole in the distributor see Fig 11 gt Note Illuminate the hole in the distributor with a torch Fit rotary knob 9 in position 1 put on washer and tighten the hexagonal nut 0 5 mm distance to the front plate gt Note Check once again the position of the mixture control valve Execute working steps to in the reverse order see Page 37 Insert powder glass Check the correct setting of the mixture control valve N by a test run MEDIPRINT Clearance of malfunctions 6 Clearance of malfunctions Possible cause Fault clearance Note 1 Blower motor does not run 1 1 Unit fuse 9 defective Change unit fuse check Page 32 electrical connections 1 2 Motor protection switch 7 Check electrical connections Service manual of the printing tr
6. 3 Disassembly and reassembly of blower 29 Disassembly reassembly and electrical connection Fig 4 Disassemble reassemble control unit 30 MEDIPRINT 4 1 3 Disassemble reassemble control unit Warning live connections When working on live connections there is an increased danger to life from electric shock When working on the electrical parts the unit must be switched free from electric current and protected against inadvertent switching on Disassemble sheet metal cover 9 Draw off the powder hoses from the connection pieces at the rear of the distributor gt Note When reassembling the markings of powder nozzle 3 powder hose and nozzle valve head 6 must match see Fig 1 Page 23 Take off powder glass Open hose clamp 3 and draw off blower air hose 62 from the connecting piece Undo the wires of the cable connections to the blower motor to the timing control and to the power supply in the control unit gt Note When reassembling pay attention to the circuit diagram on page 32 Mark the arrangement of the cable and the cable conduits on the rear side of the control unit Open the cable conduits on the rear side of the control unit and draw out the released cables Dismantle distributor from the retaining plate Reassemble in reverse order of disassembly MEDIPRINT Disassembly reassembly and electrical connection 4 1 4 Disassemble reassemble no
7. MEDIPRINT paratevau cmbH Glonner Stra e 31 85567 Grafing Germany Powder Sprayer Service manual 22 41 HDM Nr A1 164 9102 1 edition 03 00 Technical Data Manufacturer Type Type plate Electrical connection Total weight Noise emission Maximum filling quantity powder We reserve the right to make changes without notice 22 MEDIPRINT MEDIPRINT Apparatebau GmbH Glonner StraBe 31 D 85567 Grafing Germany Tel 49 0 80 92 46 69 Fax 49 0 80 92 3 14 30 E mail info mediprint com Internet http www mediprint com AS 30 MEDIPRINT Ire AS 30 HDM NO A1 164 1701 M NO 94 05 XXXX U 1 230V 50 60Hz 24VDC 1 5 1 0A 0 3A ce ha month i mois year of construction ann e de construction 230 V 24 VDC 1 5 1 0 A 290 mA 50 60 Hz 13 kg 55 dB A 225 ml Overview MEDIPRINT Overview 1 Overview Fig 1 23 Replacement parts MEDIPRINT 2 Replacement parts No Designation _________ Mediprint no HDM no 1 Bracket AS BS 4854 Jat isa zee 1 Machineplate CBG O945FSA A1164 1781_ 1 G Platecover CBG TFS instruction manua A 164 9101 gt Note Example For machine AS 952 118 1 Powder glass complete In order to ensure the correct replacement part ordering and supply the following information must be provided HDM no 22 164 1761 e Machine no of the affected printing machine for pow
8. PRINT 3 2 Use in accordance with the regulations e The powder unit is supplied ready assembled for use as auxiliary equipment to the Heidelberg printing machine Quickmaster QM46 The attachment of the powder unit to another type of printing machine is not permitted It serves 1 for powdering of the printed paper sheets in order to prevent their adhesion 2 as a stacking aid for the printed sheets e The unit may only be used in accordance with the specifications of these instructions Any other type of use can lead to personal injury and damage to property 3 3 Safety notes 3 3 1 General notes e The operating instructions must be completely read and all notes taken into consideration before the installation and commissioning of the unit 3 3 2 Storage and transport e Inthe event of temporary storage before installation the machine components must be protected against wet and damp 3 3 3 Attachment and installation e Electric shock from touching live parts e Fundamentally work on the electrical parts of the equipment may only be undertaken by qualified electricians e Before working on the electrical parts disconnect the unit from the mains or switch off the master switch and secure it against being switched on e Check protective conductor connections regularly for faultless fastening especially after repair work 3 3 4 Modifications on the unit e Only execute reconstruction or retrofit changes to the un
9. der sprayer AS 30 e Part designation with HDM number Mediaprint machine no 9405 3542 e The type designation the make and the machine see type plate no of the powder sprayer 24 MEDIPRINT 3 1 3 2 3 3 3 3 1 3 3 2 3 3 3 3 3 4 3 3 5 3 3 6 3 3 7 3 3 8 4 1 4 1 1 4 1 2 4 1 3 4 1 4 4 2 4 2 1 5 2 5 3 5 4 Contents Service manual AS 30 Technical Data ccccccccccceecseseeeesseeeenenees 22 Overview 23 Replacement parts nuuu0u00000n 24 Please notel nn 26 User notes on the documentation 26 Use in accordance with the regulations 27 Safety nofes 1 2 1 27 General notes uuuunensnsnennnnnnnnnnnnnnnnnnn 27 Storage and transport 27 Attachment and installation 27 Modifications on the unit 27 Familiarisation notes 27 Safe working visacie aaraa nnnnnnnennn nennen 27 Action in the event of danger 27 Stipulations and regulations 27 Disassembly reassembly and electrical connection 00000 28 Disassembly reassembly unnuunnnnnnnnn 28 Arrangement of the components 28 Disassemble reassemble blower 29 Disassemble reassemble control unit 30 Disassemble reassemble nozzle AIVANGEMEN ccccsssenceceesesecenesestenccsoeseceesss 31 Electrical connection a2u22u200 32 Circuit diagramin anrea iii 32
10. iggered on printing machine Press motor protection switch machine 1 3 Cable break Check electrical connections Page 32 1 4 Blower motor defective Replace blower Page 29 2 1 Solenoid valve 3 defective Replace solenoid valve Page 35 2 2 Cable break e Check electrical connections Page 32 2 3 Cycle control of printing e Check cycle control Service manual of the printing machine defective machine 3 1 Powder channels blocked e Clean powder channels 3 2 Powder hoses amp defective e Replace defective powder hoses 3 3 Valves blocked e Dismantle and blow out valves zm 1 Air filter blocked Clean replace air filter 4 2 Powder channels blocked Clean powder channels 4 3 Blower air hose 6D powder Clear leakages replace hoses leaky or defective defective hoses 4 4 Valves blocked Dismantle and blow out valves gt Note The part designations given here refer to fig 1 page 23 39 Index 7 Index Clean air filter grill 4444444 HH RHHBn nen nenne nennen 33 Clean powder channels ususss44 seen 34 Disassemble reassemble blower u002222222000 29 Disassemble reassemble control unit 30 Disassemble reassemble nozzle arrangement 31 Disassemble reassemble solenoid valve 35 Disassemble reassemble valves ccccceseseeceeeees 37 Fitting and installation 4444e4 rennen 27 Malfunctions sesioni a a 39 Replacement part
11. ine and protect it against being switched on by others Caution danger of damage to improperly laid powder hoses When powder hoses are improperly laid kinking can lead to interruption of powder delivery If powder hoses touch moving parts of the printing machine then it can lead to chafing of the hose wall or tearing of the hose For this reason always lay powder hoses free of kinks and at a suitable distance from moving parts of the printing machine 4 1 1 Arrangement of the components Blower Control unit Nozzle arrangement Drive side BS Operating side AL Starting position p O O MEDIPRINT Disassembly reassembly and electrical connection 4 1 2 Disassemble blower A and reassemble Warning live connections When working on live connections there is an increased danger to life from electric shock When working on the electrical parts the unit must be switched free from electric current and protected against inadvertent switching on Open connection socket on the blower motor Undo wires of the cable connection to the control unit Open the cable clamp at the connection socket and draw out the released wires gt Note When reassembling pay attention to the circuit diagram on page 32 Open hose clamp 3 and draw off blower air hose 2 from the connection piece Dismantle blower motor 8 from the retaining plate Reassemble in reverse order of disassembly Fig
12. it after approval of the manufacturer 3 3 5 Familiarisation notes e The unit may only be operated by trained persons Unless expressly otherwise described maintenance and repair work may only be undertaken by qualified service technicians Please note 3 3 6 Safe working e The unit may only be operated with closed control unit housing e Disconnect the installation from the mains supply or switch off the master switch before opening the housing e When working with expendable supplies or auxiliary agents you must observe the relevant instructions for handling dangerous substances 3 3 7 Action in the event of danger e Stop the machine and secure it against being switched on 3 3 8 Stipulations and regulations e You must comply with the relevant national ordinances as well as safety accident and environmental protection regulations In addition you must observe the safety instructions of the manufacturer of the printing machine 27 Disassembly reassembly and electrical connection Fig 2 28 Arrangement of the components MEDIPRINT 4 Disassembly reassembly and electrical connection 4 1 Disassembly reassembly Warning prevent inadvertent starting up of the printing machine When mechanical work on the machine is taking place the unwanted starting up of the printing machine can lead to severe injuries to those working on it Switch off the master switch of the printing mach
13. nents of the printing machine must be switched free from electric current and protected gt Note against inadvertent switching on See also the service manual of the printing machine X15 pin 1 X15 pin 2 Should be marked Or Switch cabinet A1 Control unit housing M1 Blower motor 230 V AC F1 Fine wire fuse 6 3 A 500 V AC 50 60 Hz 1 5 A Y Solenoid 24 V DC 290 mA S1 Master switch 4 A 250 V AC 2 Motor protection switch 1 5 A 250 V AC AS Drive side Fig 7 Circuit diagram 32 MEDIPRINT Maintenance and replacement 5 Maintenance and replacement 5 1 Clean the air filter grill in the sound damper on the suction side 89 every month Clean the protective grill if there is diminished powder output or visible contamination Caution danger of damage from sucked in parts When operating the unit without air filter parts can be sucked in and damage the blower wheel or the blower motor Never operate the unit without air filter Unscrew sound damper 69 Blow out the sound damper from the air outlet by means of compressed air See arrow Fig 8 Screw on sound damper again Fig 8 Clean air filter grill 33 Maintenance and replacement Warning danger of injury when handling compressed air Ensure responsible handling of the compressed air pistol There is a considerable danger of injury if the compres
14. s ccccceeeeeeeeeeeeeeeneeeeeeeeeeees 24 Replacement parts Ordering seeceseeeeeeeeeeees 24 Rotation direction of the blower motor 32 Safe working siririn ieaie aaen narri ia iA 27 Stipulations and regulations nsssursssnnnnnnnn nenn 27 Storage and transpott uneesesnnenssnennnnnnnnnnnnnnnnn nenn 27 Technical Data 2444s44 rn aneha ARKETA NEN AE FINESA 22 40 MEDIPRINT MEDIPRINT Notes S 41
15. sed air pistol is improperly handled When blowing out with compressed air detached solid bodies or whirled up powder dust can cause eye injuries Always wear protective goggles when cleaning the powder hoses Warning danger to health by inhaling powder dust The inhalation of airborne particles can endanger your health When cleaning the powder hoses always wear a dust protection mask 34 powder channels by oily or fat containing Caution clogging of powder nozzles and substances When using oily compressed air lumping of the powder can occur and in this way can lead to clogging of the powder nozzles and powder channels in the unit If the end of a powder hose comes into contact with fatty substances powder deposits can lead to clogging of the hose Therefore for blowing out powder channels always use compressed air from oil free systems When hose ends are contaminated by fat containing substances shorten them by 10 15 mm 5 2 MEDIPRINT Clean powder channels weekly When there is irregular powder output clean the powder channels In the case of frequent use blow out the powder hoses weekly gt Note All part designations on this page refer to Fig 1 Page 23 Draw off powder hoses and blower air hose 2 at the distributor Fully open the nozzle valve heads 16 and mixture control unit Take off powder glass Blow out the holes on the underside and hose connection on the
16. zzle arrangement C Warning prevent inadvertent starting up of the printing machine When mechanical work on the machine is taking place the unwanted starting up of the printing machine can lead to severe injuries to those working on it Switch off the master switch of the printing machine and protect it against being switched on by others Draw off the powder hoses from the connection pieces at the rear of the control unit gt Note When reassembling the markings of powder nozzle 3 powder hose and nozzle valve head must match see Fig 1 Page 23 Unscrew the four screws M6x16 on the brackets of the nozzle arrangement 2 and completely take off the nozzle assembly Reassemble in the reverse order Fig 6 Reassemble disassemble nozzle arrangement 31 Disassembly reassembly and MEDIPRINT electrical connection blower motor 4 2 Electrical connection Caution wrong rotation direction of the 4 2 1 Circuit diagram Warning live connections g The blower motor turns anticlockwise If the connections to the power supply are transposed the rotation direction of the motor changes When disconnecting the terminals on the blower motor mark them appropriately and do not When working on live connections there is an a transpose them when fitting again increased danger to life from electric shock When working on the electrical parts the unit and all live compo

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