Industrie-Automation Vertriebs-GmbH

Hans-Böckler-Straße 5g • 63110 Rodgau

Tel.: +49 6106/851530 • Fax: +49 6106/851550

Operating manual 80.95AEN-D253

Coating supply machine

I.LV.0030/I.LV.0034

Version 01.11.10
IAV GmbH I.LV.0030
I.LV.0034

1 Contents
1 Contents 1

2 Contact addresses 3
Manufacturer of printing machine and coating unit 3
Manufacturer of the coating supply machine 3
Manufacturer of hose pumps 3
3 Notes about this operating manual 4
Reading and storing the operating manual 4
Contents and accompanying documents 4
Target groups 4
Symbols used 4
4 Description of the machine 5
Intended usage 5
Layout of I.LV.0030 5
Electrical connections 6
Layout of I.LV.0034 7
Electrical connections 8
Function description 9
Safety features I.LV.0030 9
Burst tube sensor 10
Peristaltic pump 10
Hose assemblies 10
Technical data 11
5 Basic safety and environmental regulations 12
Intended use 12
Requirements of personnel 12
Requirements of the location 12
Electromagnetic compatibility 13
Components and spare parts 13
Modifications to the machine 13
Danger areas on device, warning signs 13
Safety features 14
Leakages 14
Disposal of flushing agent with coating residue 14
6 Connecting (see construction on page 5) 15
Safety and environmental regulations 15
Preparation 15
Instructions 15
7 Operation 17
Safety and environmental regulations 17
Operating 17

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8 Maintenance and service 18

Safety regulations for servicing 18
Safety specifications for working on electrical technology 18
Switching off the machine and disconnecting power 18
Maintenance schedule 19
Replace protective switch on the peristaltic pump cover (only I.LV.0030) 20
Replace burst tube sensor 20
9 Troubleshooting 21
Faults of the coating supply machine 21
10 Spare parts and wearing parts 22
Coating supply machine 22
11 Index 24

Appendix (separate documents):

Peristaltic pump Type 701 (Watson Marlow)

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2 Contact addresses
Manufacturer of printing machine and coating unit
manroland AG
Mühlheimer Straße 341
63075 Offenbach am Main
Germany
Tel.: +49 (0) 69 / 83 05 - 0
Fax: +49 (0) 69 / 83 05 - 1440

Manufacturer of the coating supply machine

IAV GmbH
Hans-Böckler-Straße 5g
63110 Rodgau
Germany
Tel.: +49 (0) 61 06 / 8515 - 30
Fax: +49 (0) 61 06 / 8515 - 50

Manufacturer of hose pumps

Watson Marlow GmbH
Mühlenweg 7
41569 Rommerskirchen
Germany
Tel.: +49 (0) 21 83 / 42 04 0
Fax: +49 (0) 21 83 / 82 59 2

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3 Notes about this operating manual

Reading and storing the operating manual
All persons who deal with the machine must have read and understood these operating
instructions and the accompanying documents before beginning work of any kind.
These operating instructions must always be available at the place where the machine
is operated.

Contents and accompanying documents

These operating instructions contain the information about the coating supply machine
for the manroland Coating Machine

The following other documents belong to this document:

Document Location
Operating Instructions for the manroland Coating Printing machine documentation
Machine
Operating Instructions for the Type 701 Appendix to this document
Peristaltic pump (Watson Marlow)

Target groups
These operating instructions are intended for the following target groups:
• Assembly and start-up personnel
• Operating personnel
• Service and maintenance personnel

Symbols used
Symbol Meaning
Warning of danger of electric shock

Warning of a hazardous area

Reference to the operating instructions for the manroland Coating Machine

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4 Description of the machine

Intended usage
The I.LV.0030/I.LV.0034 are coating supply machines for coating in manroland sheet-
fed offset machines, and are connected to the coating machine. The machines pumps
coating to and from a storage vessel.

Layout of I.LV.0030

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Item Designation
1 Paint package
2 Electronically regulated peristaltic pump – forward flow
3 Electronically regulated peristaltic pump – return flow
4 Base frame
5 Burst hose sensor
6 Protection switch on peristaltic pump cover for forward flow peristaltic pump
7 Protection switch on peristaltic pump cover for return flow peristaltic pump
8 Coating collection trough
9 Coating collection trough lock plunger
10 Adjustable foot with rubber covering
11 Block roller

Abbreviation Connections
VL Paint flow connection
RL Coating return
VM Machine flow connection
RM Machine return connection

Electrical connections
Plug Connections
-B238 Plug - electr. connection burst hose sensor (5)
-B453 Plug - electr. connection for protection switch on the peristaltic pump cover (6)
-B454 Plug - electr. connection for protection switch on the peristaltic pump cover (7)
X1-M204 Plug - flow pump electr. connection
X1-M205 Plug - return pump electr. connection

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Layout of I.LV.0034

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Item Designation
1 Paint package
2 Electronically regulated peristaltic pump – forward flow
3 Electronically controlled double-head peristaltic pump – return
4 Base frame
5 Burst hose sensor
6 Coating collection trough
7 Coating collection trough lock plunger
8 Adjustable foot with rubber covering
9 Block roller

Abbreviation Connections
VL Paint flow connection
RL Coating return
VM Machine flow connection
RM Machine return connection

Electrical connections
Plug Connections
-B238 Plug - electr. connection burst hose sensor (5)
X1-M204 Plug - flow pump electr. connection
X1-M205 Plug - return pump electr. connection

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Function description
The coating supply machines comprise two peristaltic pumps on a base frame. A
coating collection trough is situated below the peristaltic pumps. The forward flow pump
pumps coating from a container to the coating machine. The return flow pump pumps
coating back into the container.

The entire control of the coating supply machines is performed by the

manroland printing machine.
See operating instructions for manroland coating machine.

Safety features I.LV.0030

Safety feature Peristaltic pump cover over the Guard plate over the drive shaft.
moving parts of the tube pump.
Fuse-protected switch on the cover
of the peristaltic pump.
Location Peristaltic pump Drive shaft between the motor and
the peristaltic pump
Function Protects against danger of crushing Protects against danger of crushing
when the pump is running. when drive shaft is rotating.
The pump switches off, or cannot
start if the pump cover is opened.
Picture

Protective switch on the peristaltic pump cover (only I.LV.0030)

The protection switches are located on the covers of the peristaltic pumps. If the pump
cover is opened, a signal is given and the pump switches off. This ensures that there
can be no injury from rotating parts of the tube pump.

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Burst tube sensor

The coating collection trough is situated below the peristaltic pumps. In case of a burst
pumping tube, the escaped coating is collected here. The burst hose sensor detects
liquid in the coating collection trough and can report a burst of the pumping tube. The
pumps are stopped automatically.

The signal from the burst tube sensor is further processed by the printing
machine control unit.
See operating instructions for manroland coating machine

Peristaltic pump
The type 701 FB/R Watson Marlow pump used in the forward and return flow is a self-
priming, sealless peristaltic pump of very compact construction with an inlaid pumping
tube. It is driven by a frequency-regulated electric motor with attached gearbox.

Function
• Four rollers in the rotor group alternately press a thick-walled pump hose against
a hose bed and convey the contents of the hose (coating, flushing medium) from
the suction to the pressure side by means of rotation.
• Due to the subsequent opening of the pump hose, a reduced pressure results on
the suction side, which causes a continuous suction.
• The medium conveyed passes through the pump hose without contacting any
mechanical parts. The smooth flow ensures gentle pumping. There is no
emulsification or turbulence.
• The pump can safely be run dry and is self-priming from dry.
• The direction of rotation and therefore the pumping direction of the flow pump is
reversible. Because of this it is possible to clean the pumping tube without
dismantling it.

For further information: see the Watson Marlow operating manual (Appendix).

Hose assemblies
For the supply of coating or connection to the machine (VM and RM) pre-assembled
tube groups are available, which are to be assembled in the pump heads according to
the Watson Marlow operating instructions.

The forward or return flow tube groups consist of the following parts:
• Forward flow lance or return flow lance
• Pump hose
• Conveyor hose
• Adapter for connection to the machine

The spare pumping tubes are described in the Chapter "Spare parts and wearing parts".

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Technical data

Burst tube sensor

Operating mode: Ultrasonic sensor
Operating voltage: 12 – 30 V/DC
No-load/standby current: < 25 mA
Output function: Open, NPN
Sound frequency < 33 Hz
Temperature range: -20°C to +60°C

Protection switch on peristaltic pump cover.

Operating mode: Solenoid valve
Protection type: IP 67 (IEC 529)
Temperature range: -25°C to +75°C
Air-gap for reliable switching function: Max: 6 mm
Min: 17 mm
Minimum air-gap: 0.5 mm

Type 701 Peristaltic pump

See Watson Marlow operating instructions

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5 Basic safety and environmental regulations

Intended use
The machine is only intended for the purpose described in the Chapter entitled
"Description of the machine".
In particular, no other media than coatings and flushing agents used in offset printing
machines may be pumped with the machine. No coatings or flushing agents containing
solvents may be used. This can cause danger of explosion!
The technical limiting values stated for the individual components must not be
exceeded.
The manufacture does not accept liability for damage caused by incorrect use.

Requirements of personnel
For all work on and with the machine, the following requirements regarding personnel
apply:
• Operation: The machine may only be operated by trained printers.
• Work on the electrical equipment may only be carried out by qualified
electricians.
• Service of the mechanism: Work on the mechanical parts of the machine may
only be carried out by a trained mechanic.

Please ensure observance of all pertinent regulations for the prevention of accidents, as
well as the generally recognized regulations concerning safety and industrial medicine.

All persons who deal with the machine must have read and understood these operating
instructions and the accompanying documents before beginning work of any kind.

Requirements of the location

The following requirements of the location are to be adhered to:

• The machine should be installed on the drive side of the manroland sheet-fed
offset machine, in the immediate vicinity of the coating machine (see
configuration plan).
• The prescribed escape routes are to be kept clear.
• The machine must stand securely and horizontally.
• Hoses and electrical feeder cables must be laid safely so that they are protected
and do not present a risk to staff.
• Ambient operating temperature: 10°C to 40°C
• Ambient temperature for transportation -10°C to 60°C when fully emptied
• Atmospheric humidity 45% to 60%.
• Please observe the currently applicable technical and building regulations.

Deviations from these requirements must be authorized by manroland.

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Electromagnetic compatibility
The machine is designed for use in industrial areas. Use in living areas makes special
measures necessary.
Before assembly of the machine, possible electromagnetic problems in the area must
be assessed

Components and spare parts

Only components and spare parts supplied and authorized by IAV and Watson Marlow
may be used. IAV accepts no liability for damage caused by the use of other
components.

Modifications to the machine

Alterations or modifications to the machine are only permissible on consultation with the
manufacturer. In particular, no modifications may be made to the safety features. IAV
accepts no liability for damage caused by unauthorized alterations or modifications.

Danger areas on device, warning signs

The hazardous areas are marked by warning signs on the machine. The signs must
remain legible during the entire lifetime of the machine. Replacement signs can be
ordered from IAV.

Warning sign on the machine Meaning

Peristaltic pump Danger of crushing!
There are moving parts inside peristaltic pumps,
which can cause severe crushing.

The covers of the peristaltic pumps

may only be removed when the
pump drive motor is switched off.

Drive shaft between the motor and the Danger of crushing!

peristaltic pump The drive shafts between the motor and the
peristaltic pumps turn when the machine is
operating, and can cause severe crushing.

The guard plate over the drive shaft

may only be removed when the
motor is switched off.

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Safety features
The safety features of the machine are listed in the Chapter "Description of the
machine".

The following regulations are to be observed for the safety features:

• The machine may only be operated if all safety features are complete and
operational.
• If dismantling of the safety features is necessary, these are to be replaced
immediately when the work is completed.

Leakages
Leakages must be drained so that they do not present a risk to persons or the
environment.

Disposal of flushing agent with coating residue

Washing water contaminated with coating is hazardous waste and must be disposed of
according to the specific national regulations! Under no circumstances may it be poured
into the sewage system!

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6 Connecting (see construction on page 5)

Safety and environmental regulations
All the rules in the Chapter "Basic Safety and Environmental regulations" apply.

Above all, observe the "Requirements of the location"!

Compare the mains voltage with the machine identification

plate; observe local regulations.
Install the necessary mains fuses according to the power
rating on the machine identification plate

To avoid damage, all electrical wiring must be laid in pipes,

cable ducts or via cable racks.

Data and control cables are segregated from motor cables

within the machine.

Preparation
• The hose lengths should be selected as short as possible to avoid large residual
quantities.

Instructions
To connect the coating supply machine, proceed as follows:
• Remove transportation and packaging material

• Erect the coating supply machine

• Fit the pump tubes

See the Watson Marlow operating instructions

• Fit the hoses

• Lay the hoses with a continuous gradient to the coating machine.

• Connecting the peristaltic pumps to the coating machine

• Connect the return flow connection RM (machine end) to the coating machine
• Connect the forward flow connection VM (machine end) to the coating
machine

• Connect the peristaltic pumps to the coating drum

• Connect the coating forward flow connection (VL) to the forward flow lance
• Connect the coating return flow (RL) to the coating return flow lance

• Stand the coating container in a separate collection trough so that it cannot tip
over

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• Insert the forward flow and return flow lances into the prepared coating container

• Check that all hoses for fluids are firmly attached

• Connect the protection switch on peristaltic pump cover.

• Plug –B453
• Plug –B454

• Connect the burst hose sensor

• Plug –B238

• Complete all the necessary electrical connections.

• Connect plug X1 to the electrical connection of the forward flow pump
(-M204)
• Connect plug X1 to the electrical connection of the return flow pump (-M205)

• Check the function of the protective switch (only l.LV.0030)

• Open the cover of the peristaltic pump
• The pump switches off

• Check the function of the burst tube sensor

• Hold an object under the burst tube sensor at a maximum distance of 100 mm
• The pumps switch off

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7 Operation
Safety and environmental regulations
For operation, all the regulations in the Chapter "Basic Safety and Environmental
regulations" apply.

Operating
Operation is described in the documentation for the manroland printing machine.

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8 Maintenance and service

Safety regulations for servicing
Regarding service and maintenance, all the rules in the Chapter "Basic Safety and
Environmental regulations" apply.

For all service and maintenance work, the following additional regulations apply
• The machine must be shut down
• All safety features must be reinstalled or made functional again after completion
of the work (safety equipment: see the chapter "Description of the machine").

Safety specifications for working on electrical technology

For work on the electrical system, the following additional regulations apply:
• Work on the electrical equipment may only be carried out by qualified
electricians.
• Repair and maintenance work may only be carried out when the entire printing
machine is shut down.
• The electrical system of the entire printing machine must be switched off and
secured against unintentional switching on.
• The electrical equipment should be checked for faults regularly (e.g. loose
connections, charred cables). Any faults which are detected must be remedied
immediately
After electrical assembly or maintenance, the correct function of all safety features must
be ensured.

Switching off the machine and disconnecting power

In order to switch off the machine and disconnect the power, proceed as follows:
• Switch off the printing machine at the main switch, and secure the main switch
against switching on.

For information about switching off the printing machine,

see the manroland operating instructions.

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Maintenance schedule
Systems Interval Servicing work
Electrical equipment Regularly Check for faults (e.g. loose connections,
charred cables), if necessary remedy
faults immediately.
Hoses Weekly • Check hoses for deposits, clean if
necessary
• Check hoses and connections for
leaks and, if necessary, tighten hose
clips or replace hoses
Pump hose Every 2000 Replacing the pump hose
operating hours or Instructions: see the operating
earlier if necessary instructions from Watson Marlow
Suction lance and return Monthly Clean lances
lance
Pump head Monthly or if dirty Grease the circulation gearbox in the
pump head
Instructions: see the operating
instructions from Watson Marlow
Coating collection trough As necessary Clean coating collection trough
Pull plunger and take out coating
collection trough.

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Replace protective switch on the peristaltic pump cover (only

I.LV.0030)
The protective switch must only be replaced by a trained electrician or manroland
Service personnel.
Procedure:
• Switch off the machine (see "Switching off the machine and disconnecting
power")
• Disconnect the plug (–B453 or –B454) from the old protective switch
• Remove the protective switch fixing screws
• Fit the new protective switch in the same place with the fixing screws
• Secure the fixing screws with screw-lock lacquer
• Connect the plug (–B453 or –B454) to the new protective switch
• Switch on the machine
• Check the function of the protective switch
• Open the cover of the peristaltic pump
• The pump switches off

Replace burst tube sensor

The burst hose sensor may only be replaced by a trained electrician or manroland
service personnel.
Procedure:
• Switch off the machine (see "Switching off the machine and disconnecting
power")
• Remove the plug (-B238) from the old burst tube sensor
• Unscrew the burst tube sensor from the fixing bracket
• Screw on the new burst tube sensor in the same place
• Secure the fixing nuts with screw-lock lacquer
• Insert the plug (-B238) to the new burst tube sensor
• Switch on the machine
• Check the function of the burst tube sensor
• Hold an object under the burst tube sensor at a maximum distance of 100 mm
• The pumps switch off

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9 Troubleshooting
Error messages and warnings are displayed on the control panel of the printing
machine.

Faults of the coating supply machine

Fault Possible cause Possible remedy
The peristaltic pump Suction lance clogged Clean suction lance
does not prime and Suction line leaking Check seals, tighten tube connections
does not pump Pump hose defective Install new pump hose
Paint temperature too low Check flow characteristics of pumping
See the Watson medium
Marlow operating Pump head cover not closed Install the hose according to the
instructions operating instructions
Burst tube sensor active Empty the collection trough and
replace hose if necessary
Pump hose defective Install new pump hose
Pumping flow of the Suction hose too long Do not exceed maximum hose length
tube pumps not (5m)
achieved The electrical specifications Check specifications, check electrical
of the drive motor are not installation, match the motor to the
See the Watson compatible with the mains mains.
Marlow operating No power supply Check connection –M204 or –M205
instructions
Coating machine motor Electrical supply cable faulty Check supply cable
does not start Fuse faulty Check fuse and replace if necessary
Protection switch on Replace protective switch
See schematic circuit peristaltic pump cover faulty. (only I.LV.0030)
diagram Pump cover open Close pump cover
Burst tube sensor active Empty the collection trough and
replace hoses if necessary
Burst tube sensor faulty Replace burst tube sensor
Counter pressure too high Clean coating forward flow and
replace if necessary
Solenoid valves have no Check connection of control –Y188/89
voltage supply to the sheet fed offset machine

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10 Spare parts and wearing parts

Coating supply machine

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Order numbers
Item Description BMK
manroland IAV
1 Peristaltic pump - Simplex (R700) 80.94Z13-0803 070.5412.MR2 -204/-205
2 Peristaltic pump - Simplex, with 070.5412.MR2.FS
fastening rod securing (R900/XXL) -204
3 Peristaltic pump - Duplex, with 80.94Z13-0806 070.5412.MRX.FS
fastening rod securing (R900/XXL) -205
-B453
4 Electrical sensor (24 V/DC) 81.37U44-3824 153.262.SA01
-B454
5 Magnet for sensor 153.262.SA01 81.37U44-3812 304.281.12BS
6 Ultrasonic sensor 80.37U44-A109 QS18UNAQ8-76772 -B238
7 Plunger with head, detent and GN.617.1-6-AK
locknut M12x1.5
8 Socket for 30 mm square tube GN.348-30-27-M12
9 Adjustable foot with nut and rubber GN.344-60-M12-98-BG
covering
10 Block roller 2198.UIO.045.P60-67x24
11 Galvanized cable fixing clip 1015.11
12 Self-adhesive direction arrow, red 179933.AD
13 Edge protection angle 25.4 x 25.4 SR1042

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11 Index

Intended use ...................................... 12

A
Abbreviations ....................................6, 8 L
Ambient temperature ..........................12 Lances ............................................... 19
Layout .............................................. 5, 7
B Leakages ........................................... 14
Burst tube sensor................................10 Location requirements ....................... 12

C M
Changes .............................................13 Maintenance schedule ....................... 19
Clean sensors.....................................20 Manufacturer addresses ...................... 3
Coating supply machine......................22
Components .......................................13 O
connecting ..........................................15 Operating ........................................... 17
Connections................................6, 8, 19
Contact addresses............................... 3 P
Personnel........................................... 12
D Protection switch on peristaltic pump
Danger areas ......................................13 cover. ................................................ 9
Description..........................................12
Disconnecting power ..........................18 R
Documents........................................... 4 Regulations...................................12, 15
Regulations for the prevention of
E accidents......................................... 12
Electrical technology, safety Replace sensors ................................ 20
specifications ...................................18
Electromagnetic compatibility .............13 S
EMC....................................................13 Safety features............................... 9, 14
Safety regulations during operating ... 17
F Service............................................... 18
Faults, corrective action ......................21 Servicing ............................................ 18
Function description............................. 9 Spare parts ...................................13, 22
Spare signs........................................ 13
H
Hose assemblies, description .............10 T
Hose pumps, operating method..........10 Target groups ...................................... 4

I W
Icons .................................................... 4 Warning signs .................................... 13
Initial start-up ......................................15 Waste disposal .................................. 14
Intended usage .................................... 5 Wearing parts .................................... 22

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