Ist Uv Om

Operating manual
0.2307385
Translation of the original operating instructions
This operating manual must be kept permanently at hand at the location of the IST®-UV unit and
must be read carefully by the operating staff.
Please observe all safety instructions.
Imprint Neither parts nor the entire contents of this document may be
duplicated, made available to third parties, circulated or stored
in any form without the prior written approval of IST METZ
GmbH.
BLK®, BLK-U®, CCU®, ELC®, FLC®, IST®, MBS® and URS®

are registered brands and trademarks of IST METZ GmbH.
© Copyright by
IST METZ GmbH
Lauterstrasse 14-18
D-72622 Nürtingen
Tel: +49-(0)7022-6002-0
Fax: +49-(0)7022-6002-76
E-Mail: [email protected]
Subject to change.
Printed on chlorine-free paper.

Table of contents
Table of contents
EC DECLARATION OF CONFORMITY___________________________________ 5
1 TECHNICAL DATA OF THE IST® UNIT________________________________ 7
1.1 General details________________________________________________________7
1.2 Mechanical Equipment of the Unit_________________________________________8
1.3 Electrical Equipment____________________________________________________9
1.4 Working places_______________________________________________________10
1.5 Warranty____________________________________________________________ 11
2 SAFETY_______________________________________________________ 12
2.1 Operation of the Unit as Directed_________________________________________12
2.2 Enlargement of Application______________________________________________13
2.3 Safety Instructions____________________________________________________14
2.4 Symbolism__________________________________________________________19
2.5 Safety and Monitoring Equipment_________________________________________20
3 DESCRIPTION OF THE UV-TECHNIQUE_____________________________ 21
3.1 Design and Process of UV-Drying________________________________________21
3.2 Field of Utilisation of the UV-Unit_________________________________________22
3.3 Printing material______________________________________________________23
3.4 UV-Radiation_________________________________________________________24
3.5 IR radiation__________________________________________________________27
3.6 Ozone______________________________________________________________28
3.7 UV ink and varnishing systems___________________________________________29
4 ADDITIONAL EQUIPMENT________________________________________ 30
4.1 Nitrogen operation____________________________________________________30
5 INSTALLATION AND TRANSPORT_________________________________ 31
5.1 General_____________________________________________________________31
5.2 Lamp housings_______________________________________________________32
5.3 Switch Cabinet_______________________________________________________33
5.4 Suction_____________________________________________________________35
5.5 Completion of Installation_______________________________________________37
6 START-UP_____________________________________________________ 38
6.1 Signs_______________________________________________________________38
6.2 Operator keyboard____________________________________________________39
6.3 Operation of the Unit___________________________________________________47
6.4 Application of UV-lamps________________________________________________48
6.5 Remarks considering UV-lamps__________________________________________51
01/13 EN/0.2307385 3
Table of contents
7 FAILURES_____________________________________________________ 54
7.1 Automatic Circuit-Breaker for Control Voltage has been Activated________________54
7.2 Speed sign failure from press____________________________________________55
7.3 Failure frequency converter exhaust air____________________________________56
7.4 Failure ELC® not ready for operation + Index________________________________57
7.5 Failure ELC® ignition process____________________________________________58
7.6 Earth leakage ELC®___________________________________________________59
7.7 Operating voltage ELC®________________________________________________60
7.8 Overtemperature ELC®_________________________________________________61
7.9 ELC®/ Failure in UV lamp_______________________________________________62
7.10 ELC® run-up time too long______________________________________________63
7.11 Failure UV-Lamp______________________________________________________64
7.12 Excess temperature of reflectors_________________________________________65
7.13 Shutter not in position__________________________________________________66
7.14 Cassette not in position________________________________________________67
7.15 Motor Protecting Switch________________________________________________68
7.16 Emergency Stop______________________________________________________69
8 MAINTENANCE_________________________________________________ 70
8.1 Remarks____________________________________________________________70
8.2 Cleaning of Lamps and Reflectors________________________________________73
8.3 Replacement of UV-lamp and reflector (MBS®-6)_____________________________74
8.4 Fans_______________________________________________________________81
8.5 Filter_______________________________________________________________82
8.6 Maintenance Schedule_________________________________________________83
8.7 Recycling and Disposal________________________________________________86
8.8 Recycling and Disposal Measures________________________________________87
9 TECHNICAL DATA AND SPARE PARTS_____________________________ 89
9.1 UV-unit_____________________________________________________________89
9.2 Electrical____________________________________________________________90
9.3 Suction_____________________________________________________________92
10 ADDENDUM____________________________________________________ 93
01/13 EN/0.2307385 4
EC Declaration of Conformity
EC DECLARATION OF CONFORMITY
according to EC Machinery Directive (2006/42/EC), Annex II A
The manufacturer
IST METZ GmbH
Lauterstraße 14-18
D-72622 Nürtingen
hereby declares that the technical conception and the construction as well as the design of
the IST® unit described below and put into circulation by us complies with the relevant and
fundamental safety and health requirements provided by the EC Machinery Directive. Essential
for the safe operation of the UV unit is a correct connection of the electrical locking device and
correct installation of the mechanical safeguarding.
Type of unit: M-41-8x1-MBS®-6-OK-NIPE-ELC
Works number: 0.2307385
In case this unit is modified without prior approval on our part, this attestation becomes null
and void.
Relevant EC-Directives:
EC Machinery Directive (2006/42/EC)
EC EMC Directive (2004/108/EC)
Employed harmonised standards:

EN ISO 12100-1 / 12100-2 „Safety of machinery – General Principles for Design“
EN ISO 13849-1 / 13849-2 „Safety of machinery – Safety-related parts of control systems“
EN 60204-1 „Safety of machinery – Electrical equipment of machines“
EN 1010-1 / 1010-2 „Safety of machinery – Technical safety requirements for the design
and construction of printing and paper converting machines“
Employed standards and technical specifications:

EN 61000-6-4 „Electromagnetic Compatibility (EMC), Generic Emission Standard
Emitted interference for industrial environments
EN 61000-6-2 „Electromagnetic Compatibility (EMC), Generic Immunity Standard
Immunity for industrial environments“
Authorised person for compilation of technical documentation:

Achim Beutner, Lauterstraße 14-18, 72622 Nürtingen
Nürtingen, 2014/01/13
Dirk Jägers, Managing Director

01/13 EN/0.2307385 5
Definition of Symbols
Definition of Symbols
s Stop (Stop Danger). This symbol warns of serious danger of

severe injury to persons. It must be strictly observed.
a
Attention (Warning). This symbol indicates information the
non-observance of which can lead to extensive damage to
property. The safety warning must be strictly observed.
h Information. This symbol indicates key information on use.

Non-observance can lead to failure.
 Fault description.
 Procedure to remedy fault.
5/00 X/0.20000 Version identification

Month/Year Language/Order No.
5 Page number
01/13 EN/0.2307385 6
Technical Data of the IST® Unit 1
1 TECHNICAL DATA OF THE IST® UNIT
1.1 General details
Kind of system IST® UV-Polymerisation Unit
Type M-41-8x1-MBS®-6-OK-NIPE-ELC
Year of construction 2014
Client Nilpeter / India 1
Country India
Series MBS®-6
UV-radiation zone 180 nm - 450 nm
Relative air humidity 30 - 80% (non-moisting)
Ambient temperature 15°C - 35°C
Altitude max. 1.000 m above sea level
Radiation emission level Category 1 according to EN 12198-1
01/13 EN/0.2307385 7
1.2 Mechanical Equipment of the Unit
Lamp housing
- Reflector: 66 URS®
66 air-cooled
- Shielding system: 66 Shutter

66 air-cooled
- Water cooling: compressor chiller

water/water heat exchanger
to be provided by customer
- Undershielding: air-cooled
water-cooled
- Chill roll: water-cooled

66 to be provided by customer
- Housing: 66 air-cooled
- Supply air: 66 from workroom
- UV-measurement 66 UMS
(Preparation)
Suction
- Exhaust air: with filter

66 to atmosphere
into workroom
01/13 EN/0.2307385 8
1.3 Electrical Equipment
Operating voltage: 400 V ± 10%, 50/60 Hz
Control voltage: 24 V DC
Number of lamps: 8
Total current consumption: 83 A
Fuses, provided by customer: 100 A gG
Residual current device On account of their design, relatively high

(FI, RCD): earth leakage currents occur in electronic
ballasts for the supply of UV lamps.
This means that these devices may be
incompatible with upstream residual
current devices. For project planning,
EN 50178:1994 Par. 5.2.11 and 5.3.2
must be observed.
PE conductor cross section: Because of the high leakage currents,

the cross section of the PE conductor
provided by the customer must be at
least 10 mm², in accordance with EN
60204-1.
Supply line, provided by according to local prescriptions

customer:
Lamps: Type I-410-NA-1-60

66 with fast lamp changing
Power control: 66 with ELC® (Electronic Lamp Control)
Maximum lamp output: 120 W/cm
Execution: 66 with UCS-i

provided by customer
01/13 EN/0.2307385 9
1.4 Working places
General drawing The working places are essentially determined by the press in
which the unit is installed.
Operation The unit is operated via an operating console.
Maintenance Maintenance tasks are performed directly on the unit. Lamp

holders should be taken out of the machine in order to allow
better accessibility.
Noise Emission The main source of sound on the IST® unit is/are the exhaust
air fan(s) and the cooling fan.
The continuous sound pressure level at the operating console
of the unit is a maximum of 80 dB(A).
01/13 EN/0.2307385 10
1.5 Warranty
Warranty The manufacturer‘s warranty is not applicable to the following:
h
• Operation other than for the intended purpose
• Non-compliance with these operating instructions
• Operation by insufficiently qualified personnel
• Use of spare parts from other suppliers, i.e. spare parts not
manufactured by IST METZ GmbH
• Unauthorised modifications to the device or components

comprising the scope of supply from IST METZ GmbH,
including programme modifications (software) to
programmable control systems.
Warranty UV lamps The warranty period is a maximum of 24 months from the date
of delivery for a maximum of 4 on/off cycles per 8-hour day.
For up to 500 operation hours full replacement shall be paid,
from 501 to 2500 operation hours a percentage replacement,
provided the following conditions are complied with:
• Proper storage of the IST UV lamps
• Correct installation and commissioning of the IST UV unit
• Regular maintenance of the IST UV unit in accordance with

the operating manual
• Regular cleaning of the IST UV lamps in accordance with the

operating manual
• A reduction in drying power caused by external dirt

accumulation is not recognised as a reason for rejection
• A reduction in the UV radiant power to 75% of the original

value in the UV range in question during the warranty period
is not recognised as a reason for rejection
• Before installation of a new UV lamp, the FLC® contacts

must be examined and must be in good condition
01/13 EN/0.2307385 11
Safety 2
2 SAFETY
2.1 Operation of the Unit as Directed
Prerequisite
The operation of the IST® unit as directed implies that the
operating and maintenance manual as well as the safety
instructions contained therein are observed and that the unit
is operated only when in working order.
Any application other than originally intended is a misuse.

The manufacturer will not assume any responsibility for
damages resulting from misuse.
Prohibition
Any operation which may lead to a reduction of the exhaust
a
air or water quantity, the bridging of safety equipment, the
removal of protective covers or radiation shielding parts, the
modification of the electrical interlockings and equipment
must be stopped.
Operation of the unit is not permitted until the electrical

locking device has been correctly connected in accordance
with the wiring diagram and all mechanical safety devices
have been correctly installed and checked.
Users
Only experts and/or trained or instructed staff are allowed
h to operate the unit. The utilisation by any other persons is

explicitly prohibited. The operator has to see to it that only
authorized persons work on the unit.
01/13 EN/0.2307385 12
Safety 2
2.2 Enlargement of Application
Improper Use of Product
The IST® unit serves only for industrial curing purposes.
IST® units are only admitted for the specified application
field.
a
If the IST® unit is used for a purpose other than originally
intended, the manufacturer will not assume any
responsibility. The user acts at his own risk.
Improper use of the product means for ex. using the unit for
tanning purposes.
Modifications
h
Unauthorized modifications and reconstructions of the unit
are not allowed for reasons of safety. This applies also
to program changes (software) of programmable control
systems.
Provisions of Customer
IST® does not assume any liability for parts which have been
provided or will be provided by the customer.
Spare parts
Only original spare parts or products named by the
manufacturer should be used. The manufacturer does not
assume any responsibility for improper or substitute parts
which may have been fitted.
01/13 EN/0.2307385 13
Safety 2
2.3 Safety Instructions
General The IST® unit has been built according to the latest technical
h
development and is safe to operate.
Its utilization could nevertheless expose the operator or
third parties to danger or could lead to an impairment of the
machine.
On condition of proper handling the unit technology is
harmless. In any case the instructions of the operating manual
as well as the universally valid safety regulations and rules for
prevention of accidents should be observed.
Operation of the UV unit is only permitted in the installation
provided and in the designated mounting position.
In case there of faults at the safety devices the unit must
be stopped and the fault must be eliminated immediately. If
necessary contact IST METZ GmbH.
a
Control The operator is obliged to check at least once per shift whether
there are external damages or faults at the unit and to pass on
any changes which may affect security.
Moreover, the safe function of the safety equipment mentioned

under chapter Safety Equipment has to be checked by a
specialist at regular intervals, however, at least once a year.
At least twice a year, all screwed connections of the

IST®-UV unit as well as all fastening screws have to be
checked if tightly fitted.
01/13 EN/0.2307385 14
Safety 2
Electrical Equipment Only skilled electricians are allowed to carry out work at
s
the electrical equipment according to the electro technical
rules. Prior to such work, the unit must be disconnected
and a discharge time of 30 seconds has to be taken into
consideration.
If the unit is completely switched off during maintenance and

repair work, it must be secured against unintentional start-up.
Prior to each action, the safe isolation from supply of de-
energized parts has to be checked.
All safety-relevant functions are electrically interlocked in the

safety circuit.
In case of trouble this safety circuit prevents a release and
thus an operation of the unit.
Radiation area Before the dryers are used, the radiation area must be cleaned
s
of deposits like for instance substrate etc. If this precaution is
not observed, danger of ignition exists.
In the interior radiation zone (lamp, reflector, undershielding/

sub-structure, rear side of the unit) there is danger of burning
due to the high surface temperatures, especially when the
cooling down period is not observed.
A CO2-fire extinguisher has to be placed at the UV-unit in case

materials should come into the dryer.
Exhaust air The exhaust-air temperatures of the IST unit are usually higher
s
than 60°C. Unit parts from which there is a risk of burning will
be identified with warnings.
We recommend insulating the exhaust-air ducting in the

working area.
01/13 EN/0.2307385 15
Safety 2
UV-Lampe Both ends of the UV lamp are sensitive to pressure. Be careful
s
not to damage these ends when handling the lamps and
reflectors.
There is a risk of injury from a broken lamp (cuts from sharp
edges), as well as a risk of poisoning from the escaping
mercury and other substances.
Mercury gradually evaporates at room temperature. Damaged
lamps or parts contaminated with mercury must be removed
immediately and disposed of in sealed packaging.
Use of a mercury binding agent (e.g. Mercurosorb) is
recommended for the removal and disposal of mercury
particles.
Contaminated substrate (mercury, shards) must be destroyed
for safety reasons.
The parts must be disposed of by a waste removal company,
in accordance with regional, national and international
specifications.
Only replace parts using the recommended lamp tool. Wear
gloves (cut-resistance level 1, with grips and lint-free), as well
as protective goggles.
Solvents Solvents may not be used or stored near the dryer. Opened
s
solvents must not be stored close to machines. Although most
of the solvents have a fire point exceeding 55°C there will be
a danger of explosion if solvents reach the area of the IST®
system.
When running the system, the solvent evaporates. If the

lower explosion limit of the vapour/gas mixture produced is
exceeded, there will be a danger of explosion.
Before starting up the unit, remove a solvent-contaminated

web out of the dryer area.
01/13 EN/0.2307385 16
Safety 2
Chemicals By no means, chlorine compounds (for .ex. washing agents)
may be used or stored in the place where the unit is installed.
a
When operating presses, according to the latest technology
standards there may be no more than 25 mg/kg of chloride
in the water that comes into contact with the machine. This
also applies for the water fed into the air conditioning and
air humidification systems. Saline acids are produced by the
combined utilization of radiation and chlorous vapours which
may entail a destruction of the reflector surface and even an
excessive corrosion of the press.
The use of sulphurous or phosphorous compounds in the lamp

housing may cause damage to lamp and reflector.
Ink Mist If ink mist (or varnish mist) can’t be avoided, an ink mist
extraction must be installed.
a
The ink mist extraction is an optional supply by IST METZ GmbH.
By reducing the press speed the mist tendency can be lowered
or avoided.
h
Standstill of When the unit stops, the shutters are closed and lamp power
Machine is reduced, in order to prevent damage to the printing material.
Electronic power supply Danger from electromagnetic radiation

units Electromagnetic radiation can lead to the malfunctioning of
s
medical implants, in particular pacemakers and defibrillators.
Any persons at risk must keep a sufficient distance from open
switch cabinets.
01/13 EN/0.2307385 17
Safety 2
Incorrect web tension Risk of fire
To avoid the risk of fire, the operator must ensure that the web
a
tension is correct.
In the event of insufficient web tension, there is a risk that the

web will be drawn in by the UV unit, come into contact with hot
components or the UV lamp and thus catch fire.
In the event of excessive web tension, there is a risk that the

web will break, the end will be drawn in by the UV unit, come
into contact with hot components or the UV lamp and thus
catch fire.
A web break should be detected as quickly as possible in order

to reduce the risk of fire.
The residual risk associated with incorrect web tension/breaks
means the UV unit must be switched off immediately, ideally
as would happen with an emergency stop.
In the event that material makes its way into the dryer and
catches fire, there must be a CO² fire extinguisher in close
proximity to the unit.
Web infeed/outfeed; Risk of entanglement, Danger from UV radiation

protective equipment Safety distances must be observed.
s
For optimum radiation protection, existing infeed and outlet
protection must be set up in such a way that the distance
between the protective device and the substrate is as small
as possible (max. 4 mm). If this cannot be guaranteed for
technical reasons, the operating company must install further
protective equipment.
01/13 EN/0.2307385 18
Safety 2
2.4 Symbolism
Switch off lamps before detaching plug / unit connection!
Components could be damaged by non-observance!
Attention! External voltage even when main switch is

switched off!
In the case of non-observance there will be danger of life!
Attention! There is a high leakage current at the electrical

equipment!
At a feeder of < 10 mm², an additional protective conductor
with at least the same cross-section to the supply point of the
unit must be laid at the press.
Warning about UV radiation emission and definition of the

radiation category. Endangered areas are marked with
„Attention! Ultraviolet radiation!“ The operating manual
includes further information.
Caution! Hot surface!

In the case of non-observance there will be danger of burn.
Caution! Risk of crushing!

In the event of non-compliance, there is a risk of serious injury.
01/13 EN/0.2307385 19
Safety 2
2.5 Safety and Monitoring Equipment
The IST unit is equipped with safety and monitoring equipment
marked as follows. Triggering a safety or monitoring device
causes the unit to shut down.
Danger signs point out to dangers at the UV-unit.
Unit 66 1 Limit switch for monitoring the end open/close positions

of the shutters
Temperature limiter in the water return line of the
undershielding
66 Temperature sensor in the reflector
66 Safety switch for the status message „Unit unlocked“
Safety switch for the status message „Unit not in position“
66 Differential pressure controller for monitoring the function
of the exhaust air unit
Switch Cabinets 66 Motor protection relay (..Q..) / Overload cut-out (..F..)

for every user
66 Overload cut-out (..F0..) for every control circuit
66 Temperature monitoring of power supply units (ELC®)
66 Earth leakage monitoring (ELC®)
66 Emergency stop web break, interlocking via press
66 Impression ON, interlocking via press
Suction Low pressure control for stand-by and production

Provided by customer
01/13 EN/0.2307385 20
Description of the UV-Technique 3
3 DESCRIPTION OF THE UV-TECHNIQUE
3.1 Design and Process of UV-Drying
Principle Conventional drying means that the solvents contained in the
varnishes and inks must be removed by means of heat supply.
This is called physical drying.
UV-drying, in turn, concerns a chemical process. Under the

influence of intensive UV-rays the liquid binder components
are cross-linked to form a solid, dry ink film in a split second.
A subsequent treatment of the final product is immediately
possible.
Binders The binders of UV-curable systems (for ex. UV-inks and
h varnishes) consist of liquid or viscous pre-polymerised

synthetic materials. They are responsible for film formation and
provide adherence between film and substrate.
The molecules of the pre-polymerised synthetic materials have
not yet reached a stable chemical condition, i.e. they are still
reactive.
Photoinitiator Most photoinitiators are sensitive in a range above 300 nm.

A photoinitiator content of approximately 5% - 10% is typical.
As a consequence of the UV-radiation absorption the

photoinitiator molecule is disintegrated into various elements.
The disintegrated photoinitiator induces a chemical reaction
(polymerisation).
Polymerisation Upon polymerisation the already pre-polymerised molecules

of the binder are formed into macro molecules by means of
energy supply by UV-radiation. We talk about chain formation
or polymerisation.
Drying According to this, the expression „drying“ is not correct. A

better expression would be curing.
01/13 EN/0.2307385 21
3.2 Field of Utilisation of the UV-Unit
UV-Systems
The IST® UV-unit is designed solely for the curing of solvent-
free systems which are capable of being polymerised.
Polymerisation-capable systems are solid-state systems
curing under UV-radiation for ex. inks, varnishes, plastic
coatings and adhesives.
h The UV system is solvent-free if the according safety data

sheet declares the explosion limit as „not applicable“.
Coating Materials Coating materials are liquid, pasty or powdery products with a
protective, decorating or other specific quality developing when
applied to the surface.
h Coating materials on the basis of the following binders can

normally be cured:
Sensitized acrylic resins, unsaturated polyester, linked

polyurethanes as well as synthetic resins in sensitized form
which are curable by energy absorption on account of their
chemical structure. These systems are capable of being cured
solvent-free.
Solvents In a broad sense solvents are substances that can physically

dissolve other substances.
s Coating materials which can be cured only by evaporating or

releasing solvents are not allowed for reasons of safety.
01/13 EN/0.2307385 22
3.3 Printing material
Printing material has an influence on the UV-curing result with
regard to production speed and link-up of the ink to the printing
material (adherence).
Uncoated paper For absorbent surfaces (e.g. natural paper) realisable machine
speeds may be lower than production speeds for coated
h
papers.
The reasons are:
• the photo initiator can penetrate the paper and is not
involved in the reaction mechanism
• more ink is required for comparable colour densities
Plastics printing To obtain an optimum drying result in plastics printing, the ink /
printing material combination must be exactly matched. Mostly
a special ink series is required.
h Ink adherence is influenced by the surface tension of plastic.

Adherence may be tested by an adhesive tape. There is an
adherence problem if ink remains on the tape after being
stripped off.
Surface tension It is recommended by the suppliers of ink and varnish, that

surface tension is higher than 38 mN/m, in order to achieve
positive bonding between printing ink and the plastic substrate.
On the other hand, surface tension for PP should be higher
than 42 mN/m. Plastic materials, like for instance PA, PET and
PVC can normally be printed without any prior treatment.
An inline corona pre-treatment can be employed for purposes
of increasing surface tension.
Surface tension of synthetics can be checked by means of so-

called test inks.
01/13 EN/0.2307385 23
3.4 UV-Radiation
Electromagnetic Radiation
The visible light between 380 nm and 780 nm represents only

a small portion of the possible electromagnetic rays. The short-
wave light above 380 nm is seen to vary between blue and
violet. As far as wave lengths in the even shorter UV-range are
concerned, this radiation is no longer visible to the human eye.
Generation of UV-Radiation UV-rays are generated by means of mercury discharge

lamps. Such a lamp consists of a quartz tube filled with
inert gas and is equipped with metal electrodes sealed in
the lamp ends. When applying a high ignition voltage, an
electric arc is produced and the lamp is heated up. Mercury
is evaporated and the UV-lamp surface is heated up to
approx. 800 °C - 900 °C. UV-radiation is emitted. A small
portion of the emitted radiation lies in the visible range.
The above diagram shows the typical spectrum emitted by a

mercury lamp.
01/13 EN/0.2307385 24
Application of UV-radiation UV-radiation produces photochemical reactions of various
kinds. Depending on wave length and intensity, radiation can
be used for diverse applications.
UVA-radiation is mainly used for slow curing of thick varnish

and ink layers.
UVB-radiation is suitable for depth curing.
UVC-radiation provides a quick chemical reaction and a good

surface curing.
UV-radiation hazards Natural UV-radiation causes an alteration in the skin cells (sun
tan) up to the point of sunburn. The artificial UV-radiation,
s
however, is much stronger than the solar radiation on earth
which means that above all eyes, lips and skin are exposed to
danger.
UVA-rays may irritate the sensible mucous membrane of the

eyes and possibly the skin.
UVB-rays are detrimental to health, i.e. depending on intensity

and duration of exposure to rays, skin irritations and burn may
result.
The highly energetic UVC-radiation which may lead to severe

skin damage is most dangerous.
01/13 EN/0.2307385 25
Protection against The source of radiation is completely closed to protect the
UV-radiation environment against UV-radiation. Reflecting radiation is
screened off by means of protective filters, curtains or baffles.
s
With covers removed the machine is allowed to be started only
after all covers are mounted again.
Visual contact to the irradiating lamp has to be avoided.
Adjustment or repair work on the UV-unit should be carried out
only by skilled labour and with the corresponding personnel
protective equipment. In any way, it is recommended to carry
out this work with the unit switched off.
01/13 EN/0.2307385 26
3.5 IR radiation
Danger from IR radiation Optical radiation can cause damage to skin and eyes.
When generating UV light using mercury discharge lamps, IR
and visible radiation may be emitted.
s The visible radiation and near infrared radiation (up to 1400

nm) can cause, depending on wavelength and exposure time,
anything from photochemical and thermal damage to loss of
sight.
Long-wave infrared radiation (1400 nm to 1 mm) can cause
skin burns. Lens opacity can occur from long-term exposure to
infrared radiation.
Safety precautions The radiation source must be sealed off from the outside
to protect against IR radiation. Reflective radiation must be
s
shielded by protective filters, curtains or screens.
Only when any removed covers have been refitted can the
machine be started up again.
Avoid at all costs eye contact with the illuminated lamp.
Installation or repair work may only be carried out on the unit
by trained specialists. The relevant precautionary measures
(e.g. protective clothing) must also be taken.
The use of personal protective equipment is recommended
when working on a disconnected unit.
01/13 EN/0.2307385 27
3.6 Ozone
Ozone hazard Under the influence of highly energetic ultraviolet radiation,
ozone is formed out of the normal atmospheric oxygen (this
is the same procedure which also takes places in the outer
atmosphere of the earth where the very intensive UV-radiation
of the sun hits upon the air layer).
Ozone has a characteristic, very intensive smell which can be

usually detected already when the concentration is still within
the harmless range.
Threshold of smell: 0,01 ml/m³

Workplace limit value: 0,10 ml/m³
Ozone irritates eyes and the respiratory organs and is

detrimental to health when a certain concentration (which lies
above the workplace limit value) is exceeded.
Protection against ozone An air suction prevents UV-radiation, heat and ozone from
penetrating the workroom. The suction must be operated
before switching on the lamps.
The extracted ozone is disintegrated again into the harmless

oxygen quickly so there is no health hazard.
A prerequisite for the correct suction is that all machine covers

are mounted.
Measurement of ozone Ozone can be measured by means of a test tube, i.e. a

small hand pump feeds 100 cm³ air per stroke into the test
tube. Thus a certain quantity of the air which has to be
checked is sucked through the gas test-tube. On basis of the
discolouration of the reagent in the test tube, the concentration
of ozone in the air can be determined.
(example: Dräger-tube for ozone)
01/13 EN/0.2307385 28
3.7 UV ink and varnishing systems
Handling Careful handling is principally required for the handling
of UV-systems. The liquid, synthetic resins which are not
yet completely polymerised may cause skin irritations and
allergies due to their sensitizing and irritating potential.
The mucous membranes of eyes and lips are particularly
endangered. Following precautionary measures have to be
taken in order to guard against the danger emanating from the
UV-curable systems:
s
• Handling only in accordance with the security data sheets
and the local safety regulations.
• The direct contact of skin with UV-systems and cleansing
agent must be avoided. If necessary, protective gloves have
to be used or the work clothes have to be changed on a
regular basis.
• Skin care products have to be used before and after work.
• Protective glasses must be used if there is a risk of
splashing.
• Spilled components must be soaked up with appropriate
absorbing media like sawdust, granulated material, tone or
clay. Afterwards the surface must be washed with water and
soap.
First aid • In case of skin contact immediately wash with water and
soap. Soiled clothes must be changed immediately.
• When splashed in the eyes rinse immediately with water and
consult a doctor.
Mist Under certain conditions the splitting of UV-systems will cause

the formation of mist.
Production speed, binder, ink or varnish quantity, diameter of
ink and varnish rollers, temperature and relative atmospheric
moisture are of influence. The mist should be extracted by a
suction device installed above the ink units as it affects skin,
eyes and respiratory organs.
Waste Products Non-dried printing or coating products which are produced

for technical reasons must be marked and delivered to a
special waste disposal to avoid staff coming into contact with it
unintentionally.
01/13 EN/0.2307385 29
Additional equipment 4
4 ADDITIONAL EQUIPMENT
4.1 Nitrogen operation
The user benefits from nitrogen operation, as UV-drying under
normal conditions of atmospheric oxygen is subjected to the
effect of inhibition. Inhibition means that chain formation is
interrupted by atmospheric oxygen.
If the hardening zone is operated as a low oxygen zone with

the help of inert gas, then normally higher curing speeds and a
reduction of offensive odours can be achieved. This effect can
already be observed for a residual oxygen content of less than
5,000 ppm.
Further benefits are the avoidance of ozone formation in the

radiation area and a reduction of yellowing under nitrogen
conditions.
01/13 EN/0.2307385 30
Installation and Transport 5
5 INSTALLATION AND TRANSPORT
5.1 General
Staff The unit may only be installed by qualified electricians and
mechanics who have been trained in handling UV technology.
Installation and dismantling The installation implies that the machine is stopped and
disconnected from the supply. In principle, all local safety
regulations have to be observed.
a
The electrical connection and the inspection of the unit must
be done in accordance with the regulations in force at the
place of installation (in Europe i.e. EN 60204-1).
All lines and hoses must not block the way.
During installation, no other works must be carried out at the

machine. Make sure that the IST®-unit is disconnected from
the supply. If installation works have to be carried out above
height of head, safety ladders and working platforms will have
to be used.
Transport As regards the lifting of heavy components, total weight, lifting

devices and fastening points have to be observed.
a
Discharge After dismantling all metal parts may be recycled.
Due to their mercury content used UV-lamps are hazardous
waste and must be discharged by an authorized company.
Technical Data All important technical data are listed in chapter Technical Data
and Spare Parts.
01/13 EN/0.2307385 31
5.2 Lamp housings
Installation The lamp housing must be positioned according to the
specifications of the company IST METZ when it is installed.
The housing with cassette and substructure (undershielding or
a chill rolls) are firmly connected to the machine with a bracket.

The bracket must be designed such that the web is not
touched.
After installation, the housing must be connected to the

exhaust air installation and the power supply according to the
included plans of the company IST METZ.
Protection against radiation The lamp housing must be completely sealed in order to
protect against radiation. The radiation shielding parts used
must be fixed in such way that they cannot be removed without
the help of tools.
s All mobile parts allowing access to the radiation zone must be

interlocked with the unit control.
01/13 EN/0.2307385 32
5.3 Switch Cabinet
1 4
Switch cabinet type TS8...
 Switch cabinet
 Main switch
 Supply lines 3 5
 Electronic power supply
units ELC®
Connection load circuit
Transport and Installation For the transportation of the switch cabinets, they must be
lifted and moved using suitable means of transport (pallet truck
or fork-lift truck, transportation by crane is not possible). It
may only be transported in the upright position. Heavy impact
should be avoided.
During transport, the stacked electronic power supply devices
must be secured with restraints or steel straps to prevent them
from colliding with each other.
h When setting up the switch cabinets, it is important to take

account of the total weight of the cabinets (see Chapter 9.2)
and to ensure that they are stable. A space of at least the
door width plus 500 mm should be left in front of the cabinets
in order to guarantee optimum access. Foreign or replace
material may not be stored in the cabinets.
The inlet and outlet openings for the cooling air must not
be covered. It must be made sure that the air can flow
unhindered.
01/13 EN/0.2307385 33
Electrical Connection Before laying, check cables and protective hoses for transport
damage.
The protective conductor must be checked according to the
EN 60204 regulations.
The supply connection of the switch cabinets must correspond

to the instructions in chapter Electrical Equipment. The
connections must be protected by a contact safety device.
In all cases the standards:

EN 60204-1: „Safety of Machinery – Electrical equipment of
machines“
EN 50178: „Electronic equipment for use in power
installations“
EN 50160: „Voltage characteristics of electricity supplied by
public distribution networks“
IEC 60038: „IEC standard voltages“
must be noted.
When the lines are being installed, it is important to ensure that

there are no kinks. No lines may be installed within the direct
radiation zone of the unit.
All connections must be carried out according to the enclosed

connection diagrams.
All terminal connections and screw connections must be
tightened with the correct torque. Check existing connections.
When all connections have been established, the tests in

accordance with EN 60204-1 must be carried out before start-up.
01/13 EN/0.2307385 34
5.4 Suction
Exhaust air The exhaust air has to be led through an appropriate piping
to the outside according to the local environmental protection,
health and safety regulations. Ensure that the air outlet is
routed via the roof as far as possible and does not discharge
for example under inhabited parts of buildings, in the vicinity of
footpaths, roads and air conditioning units.
As an alternative the exhaust air may be returned back to the
workroom aver a fine or activated charcoal filter.
Installation The exhaust air device must be installed according to

IST®-instructions.
The lamp housing has to be connected to the customer
exhaust air ducting by means of the flexible exhaust air hoses
and must be fixed with clamps.
The hoses should be laid in the shortest possible way and with
a big radius. The flexible exhaust air hoses must be protected
against damage.
Excess-pressure connections of the exhaust air ductings (after
the fans) must be completely sealed.
a
Fans The exhaust air fans must not be operated before protecting
the access to rotary parts against contact by means of
connections or coverings both on the suction and exhaust
side.
Installation clearance (at least 100 mm above and to the side)
must be taken into account. Make sure that cooling air access
and exhaust air discharge are unhindered.
The ambient temperature must not exceed 40°C, otherwise
malfunctions in the temperature barrier are possible. The
function of the temperature barrier depends on the rotational
speed. For this reason, the rotational speed must not be
reduced when a temperature barrier is installed.
The drive controller contains components that can be
damaged by electrostatic charges! Before starting work in
the vicinity of the connections, personnel must eliminate all
electrostatic charges.
Before starting work on the drive controller, check to ensure
that all power terminals, the relay output and the pins of the
FIF interface are off circuit.
01/13 EN/0.2307385 35
Exhaust air ductings In general, the exhaust ducting must comply with the data by
IST®. The cross-section must not be reduced at any point and
the necessary bends should be large enough
(radius = 1,5 x ).
The exhaust air fans are laid out so that a duct length of
approx. 10m can be bridged by means of three quarter bends.
If the exhaust ducting is longer, the customer will have to
provide a supporting fan.
a
Hot surface!
The exhaust air temperatures of IST®-units are usually higher
than 60°C. We therefore recommend to insulate the exhaust
air ductings in the working area.
Risk of poisoning
There is a risk of poisoning (ozone, vapours) should there be
a leaky connection of the fan and exhaust-air ducting provided
by the customer. Any leakages must be sealed off using a
suitable adhesive tape.
The exhaust ducting must be ozone-resistant and
temperature-resistant up to at least 120°C. The ducting must
be designed so that the air can flow unhindered. If several
exhaust air ductings are gathered, the cross section must be
enlarged accordingly. Rectangular changes in direction and
entrances have to be avoided. The air outlet must be designed
so that the IST®-unit is not affected by external influence (for
ex. wind) causing impact pressure.No additional resistance
may be installed by the customer, e.g. silencers, filters or the
like, without the approval of IST.
If the forming of condensate is to be expected it is
recommendable to provide a condensate discharge at the
deepest point of the ducting.
We recommend to use ductings made from galvanized sheet
steel or ozone- and temperature-resistant synthetic material.
On account of the high pressure loss, the use of flexible
exhaust air ducting should be dispensed with.
01/13 EN/0.2307385 36
5.5 Completion of Installation
Cleaning Impurities on the unit have to be removed. Lamps and
reflectors must be cleaned with pure alcohol and a white, non-
fluffing cloth.
Connections The connections to be provided by the customer (supply line,

exhaust air, etc.) have been duly carried out.
Suction Direction of rotation of all fans has been checked.

All exhaust installations are functional and have been pre-set.
The underpressure and the exhaust air flap were inspected in
accordance with the requirements.
Measurement of Ozone content yielded a value of less than
the MAK value.
IPS board The basic setting for underpressure has been reset on the IPS
board.
The address setting on the unit, ELC® and cable is effected in
accordance with the circuit diagram.
Security devices All security devices (electrical interlockings) are checked and
in good working order.
s
All separating security devices (e.g. radiation protective parts)
are completely mounted and checked for maximum security.
All adjustment work on the control devices has been carried
out by skilled staff according to our data given.
Instruction The operating and maintenance staff has been instructed.
01/13 EN/0.2307385 37
Start-Up 6
6 START-UP
6.1 Signs
UV unit, type MBS®
Energy efficient equipment

Number of the UV unit
01/13 EN/0.2307385 38
Start-Up 6
6.2 Operator keyboard
Touch-Display
01/13 EN/0.2307385 39
Start-Up 6
Standard functions
Unit ON / OFF (Keep the key pressed approx. 0,5 s for

starting)
Acknowledgement: key white = ON
Unit ON
Unit OFF
Display the remaining cooling down interval after the UV unit is

turned off (300-0 s).
Display time
01/13 EN/0.2307385 40
Start-Up 6
Screen page unit overview
Call screen page unit overview
Display of the:
- operating state of the UV Lamp
- unit No.
- run up and cool down period in seconds
- current lamp power in percent
Call screen page UV adjustments
Call screen page service menu
Call screen page order administration
Request help for current page

use “up and down key” to browse in the complete help menu
01/13 EN/0.2307385 41
Start-Up 6
Screen page UV-adjustments
Screen page UV-adjustments
UV unit symbols
Acknowledgement: background white = UV lamp preselected
Adjustments for lamp no. X (with coloured display of the
operating state)
possible operating states:
Lamp not selected

Lamp selected
Run-up (background yellow)

ready for operation (background green)
Cool-down period (background blue)
Failure (background red)
Pop up appears by pushing a unit symbol

By pushing the input boxes (% and m/min) the keyboard is
shown for the numeric input of variables
Power between 25% and 100%h
Preselected UV lamps ON / OFF

Acknowledgement: key white = ON
Lamp not selected

Lamp selected
Pop up to the right
Pop up to the left
Take over settings to the area
Close Pop up
01/13 EN/0.2307385 42
Start-Up 6
Speed dependence of the UV lamp

(By pressing the key the keyboard is shown for the numeric
input of the speed)
Browse the screen pages
Keyboard for entering the numeric set values

(shown when touching the input box of variables)
01/13 EN/0.2307385 43
Start-Up 6
Screen page service menu
Call screen page service menu
Display of the national Hotline - phone number

The screen page Hotline can always be retrieved by
the IST®-logo.
Display: Hotline
Order number
Unit type
IST®-unit configuration
(Adjustment of the control parameter only possible with plant-
internal password entry)
Display the status of the unit
Language selector
By pressing the key the language can be changed. The active
language is shown in the symbol.
History of the failure messages
Reflector/shutter of the UV-lams OPEN/CLOSED manually

Acknowledgement: background white = OPEN (only possible
when unit OFF)
Setting date
Setting time
01/13 EN/0.2307385 44
Start-Up 6
Screen page order administration
Call screen page order administration

Maximal 60 individual orders can be administrated
New recipe
Save a recipe
Save a recipe under….
Delete a recipe
Transmit a recipe
Load a recipe
01/13 EN/0.2307385 45
Start-Up 6
Screen page failure messages
The following symbols are displayed in a red framed window

on the screen as soon as a failure arises:
Details about failure message (x for the number of current

failures)
Acknowledge fault signal, quit alarm signal
01/13 EN/0.2307385 46
Start-Up 6
6.3 Operation of the Unit
Safety Equipment In principle, no safety equipment must be dismantled or de-
activated.
s
Radiation shieldings and protective equipment must not be
removed during operation. Radiation shielding and protective
equipment have to be mounted again prior to re-starting
operation.
a
Suction Serving for the evacuation of heat and vapour, suction devices
mustn’t be switched off or dismantled during the operation of
the unit.
Danger of burning and fire In the interior radiation zone there is danger of burning due
to the high surface temperatures, especially when the cooling
a
down period is not observed.
A CO2-fire extinguisher has to be placed at the UV-unit in case
materials should come into the dryer.
Unit ON The heat exchanger, exhaust fans and ELC® cooling is

commissioned. At the same time, the safety chain is checked.
01/13 EN/0.2307385 47
Start-Up 6
6.4 Application of UV-lamps
UV-radiation Do not look / put your arms into the radiation zone. Skin
damages might occur within short time due to the intense
UV-radiation.
a
For optimum radiation protection, existing infeed and outlet
protection must be set up in such a way that the distance
between the protective device and the substrate is as small as
possible (max. 4 mm). For this purpose the fastenings A have
to be loosened for an adjustment of the web protection.
Never adjust the intake or outlet protection while the web is
running.
Example:
Since there may still be residual scattered radiation above the

limit value at critical infeed or outlet openings, we recommend
the use of personal protective equipment (e.g. safety goggles)
when working directly at the infeed or outlet area of the printing
substrate.
h Prior to the application of UV-lamps make sure that the unit is

in operation.
Consider chapter Operation of the unit.
Preselection The requested lamps are preselected, i.e. only preselected

of lamps lamps can be switched on. The lamps are numbered in
direction of pass of the machine.
By means of this preselection, lamps can be subsequently
switched on or off during operation.
UV-lamps ON All selected lamps are switched on.
During the warm-up time the status signal <UV lamps running
up> is issued and the run-up time for each lamp is displayed in
seconds.
After run-up the lamps revert to stand-by and the shutters are
closed.
01/13 EN/0.2307385 48
Start-Up 6
Lamp output ..with ELC® Assignment of the maximum output of all lamps to the machine
speed:
(Once this machine speed is reached, all lamps are operated
with maximum output.)
Input: Numeric via touch panel

Example: a = adjustment 100 m/min
b = adjustment 150 m/min
01/13 EN/0.2307385 49
Start-Up 6
Operation The shutters are opened, depending on machine speed and
the <Impression ON> command.
The <Impression OFF> command closes the shutters.

For machines with a run out, the swivel command is executed
after a time delay. The time delay ensures complete curing of
all substrates in the machine.
UV-lamps The lamps are normally switched off by means of the key
OFF <Lamps OFF>. When pressing this key, the lamps are
extinguished immediately.
h The unit must not be switched off directly by means of the

main switch as this would prevent the UV-lamps from being
properly cooled down which, in turn, may entail damages.
Re-start The lamps cannot be re-started immediately after the switching

off. First, one has to wait for the cooling down phase of the
lamps as the lamps cannot be ignited while hot.
Manual It is possible to swivel the shutters open with a switch in order

turning to perform maintenance and cleaning tasks.
It is a pre-condition for the unit to be switched off <Unit OFF>
a
for manual swivelling.
The cooling down period or run out time must have been
completed before manual swivelling in order to avoid the
danger of burns.
01/13 EN/0.2307385 50
Start-Up 6
6.5 Remarks considering UV-lamps
Lamps For new lamps it is recommended to burn them in for at least
1 hour.
The lamp should be cleaned after 8 service hours at the latest

(see chapter Maintenance) In doing so, the dirt accumulation
level of lamp and reflector has to be checked and respective
cleaning intervals have to be determined.
Exhaust Air A specific exhaust air temperature is required in order to

optimally operate the lamps. It depends on the combination of
lamp/reflector and is pre-set in the factory.
The required volume/temperature of exhaust air is controlled
by a vacuum controller in the exhaust air system. The volume
of exhaust air for units with automatic exhaust air control is set
on the controller.
Service life The service life of IST® lamps can amount to a few thousand
hours of operation if frequent switching on and off is avoided
and if the unit is cleaned regularly.
The lamp can be operated until there is no polymerisation

effect anymore.
Used UV-lamps must be delivered to a special waste disposal
a due to their mercury contents. These lamps could also be

returned in an airtight packaging to IST® METZ GmbH for
waste disposal subject to a fee.
Warranty see Chapter 1.5 „Warranty for UV lamps“
01/13 EN/0.2307385 51
Start-Up 6
6.6 Failures
Failures Should any problems occur, the warning can be acknowledged
by pressing the <Switch off warning signal> button.The unit,
however, cannot be put in operation unless the failure is
eliminated.
If this failure cannot be eliminated by simple means, please

apply to the shop electrician to find out the cause of this in
chapter Failure.
When calling the IST® hotline, exact information describing the

failure should be given.
In case of problems occurring during the operation, the unit

has to be switched off.
Reset After having eliminated the failure, press the key

failures <Acknowledge fault signal> to reset the failure. Only then the
unit can be put in operation again.
01/13 EN/0.2307385 52
Start-Up 6
6.7 Switching off
Unit OFF Afterwards the fans are switched off by pressing the
key <Unit OFF>. The fans continue running for max. 5 minutes
to cool down the unit.
Main switch OFF After the cooling-down phase, the unit may be switched off by
means of the main switch. This, however, is only necessary in
case of a prolonged stoppage.
Shut down When shutting down the whole system for servicing please
switch-off the main switch and secure against re-starting using
a padlock.
Emergency Stop The emergency stop button of the machine (not the one of
the IST®-unit) should be activated in case of emergency only.
<Emergency stop> means that the lamps are switched off
immediately while the fans continue running.
01/13 EN/0.2307385 53
Failures 7
7 FAILURES
7.1 Automatic Circuit-Breaker for Control Voltage has been Activated
The automatic circuit-breaker for the control circuit (DC) has

been activated.
Shutdown of the unit due to short circuit or overloading.
Check following points:
 • Qualified Electrical Technician in Charge: Check of control

circuits
• Skilled electrician: Renewed switching on of the automatic

circuit breaker
• Skilled electrician: In case this disturbance occurs

repeatedly, it has to be checked if the releasing current is
inferior to the total current of all connected consumers.
01/13 EN/0.2307385 54
Failures 7
7.2 Speed sign failure from press
Indication of the transfer of the speed signal for the printing

machine being faulty. It must be >0 V upon <Impression ON>.
The shutters close or they remain closed when this fault
occurs.
The printing machine stops and the UV system reverts to
stand-by operation.
 • Qualified Electrical Technician in Charge: Check signal

transmission to the IST® switching cabinet (10 V DC = max.
speed)
• Qualified Electrical Technician in Charge: Check all terminals
• Qualified Electrical Technician in Charge: Check installation

position and function of the initiator
• Qualified Electrical Technician in Charge: Check the

analogue 0 - 10 V output of the printing machine
01/13 EN/0.2307385 55
Failures 7
7.3 Failure frequency converter exhaust air
Switching off the unit due to a release by the internal

monitoring of the frequency converter.
Check the following points:
 • If it is possible to acknowledge the message, there is a

warning or an alarm, f. ex. for reasons of voltage fluctuations
or overtemperature.
• If it is not possible to acknowledge the message, there is

a failure and the unit must be switched off via main switch.
Among other things, earthing failures, short circuit or an
internal failure might be the reason. In such a case it is
inevitable to consult IST METZ.
01/13 EN/0.2307385 56
Failures 7
7.4 Failure ELC® not ready for operation + Index
The electronic power supply unit (ELC®) reports, that it is not

ready for operation.
This fault only occurs before ignition of the lamps.
 • Qualified Electrical Technician in Charge: Is 400/480 V

(2-phase) supply voltage present?
• Qualified Electrical Technician in Charge: Is 24 V (external)

supply voltage present?
• Qualified Electrical Technician in Charge: Is the electronic

power supply unit (ELC®) defective
If this is the case, consult with the company IST METZ.
Error codes ELC-DBC (Index)

0001 DU internal Error
0004 FAN fan is locked or net running
0010 WD internal Error
0020 BE no busconnection during Lamp ON
0040 OV internal Error
0080 LVH Lamp buring voltage is too high (wrong lamp?)
0100 OC internal Error
0200 LPH internal Error
0800 ZVS internal Error
1000 FM internal Error
01/13 EN/0.2307385 57
Failures 7
7.5 Failure ELC® ignition process
The electronic power supply unit (ELC®) failed to ignite the

lamp.
 • Has it been attempted to ignite the lamp in the hot condition?
• Is the lamp defective?
• Is a lamp in place and connected?
• Qualified Electrical Technician in Charge: The condition of

the connector.
01/13 EN/0.2307385 58
Failures 7
7.6 Earth leakage ELC®
The electronic power supply unit (ELC®) reports an earth

leakage fault (internally or on the unit).
 • Is the lamp defective?
• Qualified Electrical Technician in Charge: Are the contacts

and the isolation OK?
01/13 EN/0.2307385 59
Failures 7
7.7 Operating voltage ELC®
The electronic ballast (ELC®) reports power failure or

fluctuations
 • Qualified Electrical Technician in Charge: Qualified

electrician: connections and mains voltage (if possible)
01/13 EN/0.2307385 60
Failures 7
7.8 Overtemperature ELC®
The electronic ballast (ELC®) reports excess temperature

 • Ambient temperature too high?
• Clean ventilation duct in ELC®
01/13 EN/0.2307385 61
Failures 7
7.9 ELC®/ Failure in UV lamp
The electronic ballast (ELC®) reports a failure of the lamp

 • Possibly lamp excessively cooled or lamp defective?
• Reduce cooling or replace lamp
01/13 EN/0.2307385 62
Failures 7
7.10 ELC® run-up time too long
The electronic ballast (ELC®) needs too long to reach the

required power level
 • Possibly lamp excessively cooled
• Replace lamp if necessary
01/13 EN/0.2307385 63
Failures 7
7.11 Failure UV-Lamp
The lamp extinguishes during operation (after successful

ignition).
 • Qualified Electrical Technician in Charge: Is the fuse

defective?
• If the lamp is defective, the UV system can still be operated

by de-selecting this lamp (Lamp pre-selection OFF).
• Is the lamp temperature too low?
• If the exhaust air temperature is too low, consult with the

company IST METZ.
01/13 EN/0.2307385 64
Failures 7
7.12 Excess temperature of reflectors
The temperature sensor on the reflector has released.

Unit is shut down, since the reflectors and the exhaust air have
heated up beyond the limit value.
 • Are the reflectors dull? They do not reflect the radiation

energy but absorb it and heat up.
• Are the ventilation slots of the unit soiled?
• Has the exhaust air ducting been changed, e.g. have the
cross sectional areas been decreased, or have additional
plants been installed?
• Has the exhaust air ducting been damaged?
• Is the drive of the flaps for exhaust air control defective?
• Is vacuum control active?
• Is the underpressure on the IPS board correct?
• Has the fan been damaged or is it soiled?
• Is the direction of rotation of the exhaust fan correct?
• Is the back pressure of the exhaust air system after the IST®
fan > 150 Pa?
• Is the vacuum pressure of the exhaust air before the IST®

fan too low? (See Commissioning Report)
• If no fault can be found, the temperature sensor should be

checked.
01/13 EN/0.2307385 65
Failures 7
7.13 Shutter not in position
The proximity switch of the shutter has released. Unit is shut

down, since the shutter has not reached its end position.
 • Is the temperature in the unit too high?
• Is reflector clearance on hand?
• Qualified Electrical Technician in Charge: Is power supply

(24 V) available?

• Is the motor functional?
• IPS board
• If no fault is found, readjust or replace proximity switch.
01/13 EN/0.2307385 66
Failures 7
7.14 Cassette not in position
The unit cannot be started because the cassette has not been

inserted and fixed right against its stop.
 • Has the cassette been inserted right against the stop?
• Is the cassette missing?
• Is the handle for locking the unit fully folded down?
• Qualified Electrical Technician in Charge: Check connections

(f. ex. plugs, terminals)
01/13 EN/0.2307385 67
Failures 7
7.15 Motor Protecting Switch
Disconnection of the unit if the fan motor is overloaded. The

motor protecting switch may also respond to a switching on of
the same motor at short consecutive intervals.
 • In the case of an exhaust air fan, it has to be checked if

the exhaust ducting got blocked up and if the impeller runs
smoothly.
• In the case of the water pump, the function and the bearing
have to be checked.
• Qualified Electrical Technician in Charge: After the cooling

down time the fault signal can be eliminated by pressing the
button at the motor protective switch in the switch cabinet.
• Qualified Electrical Technician in Charge: In case this failure

occurs repeatedly check if the releasing current is inferior to
the service current.
01/13 EN/0.2307385 68
Failures 7
7.16 Emergency Stop
An emergency stop is generated by the machine or the

transportation unit into which this unit was installed.
This signal switches off the unit. Fans and heat exchangers
are excluded from this.
 • Eliminate the cause for emergency stop.
01/13 EN/0.2307385 69
Maintenance 8
8 MAINTENANCE
8.1 Remarks
Prior to commencing maintenance work, the following
h
conditions must be met:
• Lapse of cooling period
• Separation/Switching off of power supply
• Access to lamp (manual swivelling function)
• If possible, separate the lamp housing from its supply unit
and remove from machine.
Safety precautions
The electrical equipment of the unit must be inspected at
regular intervals. Visible deficiencies must be immediately
eliminated.
a
Only skilled electricians are allowed to carry out work at
the electrical equipment according to the electro technical
rules. Prior to such work, the unit must be disconnected
and a discharge time of 30 seconds has to be taken into
consideration.
If the unit is completely switched off during maintenance

and repair work, it must be secured against unintentional
start-up.
Prior to each action, the safe isolation from supply of de-
energized parts has to be checked.
Maintenance staff
Maintenance of the electrical equipment of the unit should
only be carried out by specialised electrical engineers
according to the electrotechnic rules. Other work may be
carried out by trained or instructed staff.
01/13 EN/0.2307385 70
Maintenance 8
General The units are taken out of the machine for maintenance.
h
If disassembly of safety features is required, then these must
be reassembled immediately after completion of the work and
the safety features must be checked.
Loose screwed connections must always be tightened.
Warning Hot surface!
s
There is an increased danger of burns at maintenance and
cleaning services at dryer cassettes.
It‘s utmost necessary to observe the cooling times and let the
dryer cassettes cool down to room temperature before making
maintenance and cleaning services at the dryer cassettes.
s
UV lamp Danger of lamp breaking when replacing it!
Both ends of the UV lamp are sensitive to pressure. Be careful
not to damage these ends when handling the lamps and
reflectors.
There is a risk of injury from a broken lamp (cuts from sharp
edges), as well as a risk of poisoning from the escaping
mercury and other substances.
Mercury gradually evaporates at room temperature. Damaged
lamps or parts contaminated with mercury must be removed
immediately and disposed of in sealed packaging.
Use of a mercury binding agent (e.g. Mercurosorb) is
recommended for the removal and disposal of mercury
particles.
Contaminated substrate (mercury, shards) must be destroyed
for safety reasons.
The parts must be disposed of by a waste removal company,
in ac-cordance with regional, national and international
specifications.
Only replace parts using the recommended lamp tool. Wear
gloves (cut-resistance level 1, with grips and lint-free), as well
as protective goggles.
01/13 EN/0.2307385 71
Maintenance 8
Fast Lamp Change (FLC®) IST UV lamps can be replaced quickly and easily with the Fast
Lamp Change system.
The FLC® contact is a part that is subjected to extreme stress
by ambient and operating conditions.
When replacing the UV lamps, the surface of the contact points
on the unit side must be checked for any visible signs of
oxidation or wear and replaced if necessary.
When installing an IST UV lamp, make sure the UV lamp
noticeably clicks into place and is thus securely positioned in
the FLC® contact.
a We recommend replacing the FLC® lamp holder on the unit

side after a period of 10,000 operation hours.
01/13 EN/0.2307385 72
Maintenance 8
8.2 Cleaning of Lamps and Reflectors
Dirt Depending on ambient conditions, a deposit of fine dust is
formed on internal parts, in particular on lamp and reflector.
Due to the high surface temperature of these parts, the dust
burns in and reduces the radiation efficiency in the course of
time.
Cleaning intervals The required cleaning intervals have to be determined by the

UV-unit operator in accordance with ambient conditions such
h
as dust content and cooling air composition.
We recommend weekly cleaning intervals. Cleaning is
generally required after longer shutdown periods.
Prerequisite The completion of the cool-down period is a precondition for
a cleaning.
After that, the cassette may be removed.
h
Remark UV-Lamps and reflectors are sensitive to contamination!
The quartz coat of the lamp respectively the reflector surface
may not be touched with naked hands as marks of sweat, fat
or contamination will burn-in and reduce the emission.
For this reason, the lamps and reflectors must be cleaned with
pure alcohol after successful replacement.
Wear for all services the protective gloves of the cleaning set.
Procedure If special care is taken, cleaning can be performed with the

lamp remaining installed.
Lamps and reflectors are cleaned with a brush or a soft cloth.
Finally all parts are wiped with a non-fluffing cloth, moistened
with alcohol.
s
Alcohol should be used sparingly for safety reasons. Lamps
moistened with alcohol should under no circumstances be
installed and switched on.
We recommend the IST® cleaning kit for cleaning.
01/13 EN/0.2307385 73
Maintenance 8
8.3 Replacement of UV-lamp and reflector (MBS®-6)
Removal of the UV-lamp  Release the unit by lifting the handle.
 Pull the inner housing in the direction of the arrow out of the
housing.
 Open reflector and apply the lamp tools next to socket

fixing.
 Pull out the UV-lamp carefully at one side - max. 10 mm -
with the lamp tool in arrow direction of the socket fixing.
Pull out the UV-lamp at the opposite side - max. 10 mm -
of the socket fixing and hold at the same time the lamp
socket which is already released.
 Lift out the UV-lamp carefully.
01/13 EN/0.2307385 74
Maintenance 8
Installation of the UV-lamp  Put the UV-lamp carefully at both ends with the sockets on
the contact springs and press by hand the sockets into the
fixing. When pressing the UV-lamp the sockets must lock in
place at both ends with an audible click.
 Check the proper seat of the UV-lamp.
 Mount the closing plate, making sure that it is properly in
place. Screw on the screws to both sides of the closing
plate.
 Push the unit into the housing and secure it in place by
folding down the handle.
01/13 EN/0.2307385 75
Maintenance 8
Removing the reflectors Before replacing reflectors, UV-lamps must be removed
according to the above instructions.
 Loosen screws on cover plate, lift cover plate upwards in

direction of arrow.
 Remove the thermal-relay cable on the terminal strip.
01/13 EN/0.2307385 76
Maintenance 8
Turn the unit upside down
 Loosen the screws on both sides of the cover plates.
 Remove the cover plates from the guide in the direction of
the arrow.
3
4
 Loosen the fastening screws of the inlay holder.

 Remove the inlay holder (4 parts) from the unit in the
direction of the arrow.
5
6
5
6
01/13 EN/0.2307385 77
Maintenance 8
 Remove inlays 1-3 from the unit in the direction of the
arrow.
7
6
01/13 EN/0.2307385 78
Maintenance 8
Removing the shutter Loosen the screws at the shutter.
8
7
8
7
Remove shutter from the unit in the direction of the arrow.
9
8
01/13 EN/0.2307385 79
Maintenance 8
Mounting the reflectors and The installation is done in reverse order to the above
the shutter instruction.
a
When installing the inlay bracket, it must be ensured that the
cable  for the temperature sensor is correctly positioned in the
slot  for the front plate  so that the cable does not get stuck
and  become damaged.
After finishing the services a function test has to be carried out:

By means of the function <manual turning> the final position
and re-flector position will be checked. (In case of failures
the message <re-flector not in position> is displayed. For the
position OPEN make sure that the reflector is directed towards
the web.)
01/13 EN/0.2307385 80
Maintenance 8
8.4 Fans
Prerequisite Before working on the ventilating system wait until the cooling
down interval is over and make sure that the unit has been
stopped.
a
The cooling down interval has to be determined in such way
that parts of the ventilating system can be touched without
danger of burning.
Motors The rib-cooled three-phase AC motors used for these fans are
normally maintenance-free.
It is recommended to grease the bearings after approximately

3 years. For this purpose, lithium saponified grease with a
melting point above 160°C has to be used.
Should the bearings be worn out, they have to be replaced.
For re-greasing, the motor must be dismounted, the rotor

removed and the bearings cleaned or drawn off. When
mounting the new bearings, care has to be taken that the
pressure acts only on the inner bearing ring. The re-assembly
must be done carefully. Do not forget the shaft springs for the
bearings.
Impellers Paddle wheels of fans may become clogged over time. This
results in a reduction of air volume, which again results
in temperature problems of the unit. In order to clean the
paddles, the suction piping is disconnected and the paddles
are cleaned with a scraper. After cleaning, the dirt must be
removed and the suction piping must be re-connected.
01/13 EN/0.2307385 81
Maintenance 8
8.5 Filter
Dust and activated charcoal The dust filter mats must be checked monthly for dirtiness and
filters replaced if necessary.
a
The active carbon filters (if present) serve the purpose of
capturing odours and to break down Ozone. If filter efficiency
decreases (odours start developing), they should be
exchanged.
Soiled dust and active carbon filters can be disposed off via
normal domestic waste.
ELC® In ELC®, there is a protective grid in front of the ventilation duct.

The protective grid must be cleaned when it becomes
contaminated.
Water cooling A dust filter is installed at the compressor chiller. For cleaning
purposes, the covers must be opened and the filters removed.
01/13 EN/0.2307385 82
Maintenance 8
8.6 Maintenance Schedule
Weekly
Device/Component Action Substance

66 Lamps and reflectors Check if dirty and clean with lint- Pure alcohol,
free cloth, if necessary Compressed air,
reflexion+
66 Radiation protection Check radiation protection and
replace if necessary
Monthly

66 Dust filter (and activated Cleaning or replacement of the (New filter mats)
carbon filter) filter mats in the ink mist extraction,
supply and exhaust air line
Water/water heat Control of system pressure (at Water
exchanger least 1,5 bar). If necessary add (+ Corrosion inhibitor)
water up to 2 bar.
Check if the safety valve is tight

Compressor chiller Cleaning or replacement of filter (New filter mats)
mats
Checking the fill level Water

(+ Corrosion inhibitor)
Water cooling supplied by Check water quality
the customer
01/13 EN/0.2307385 83
Maintenance 8
Semi-annual

66 Ventilation system Clean fan impellers Hand scraper, vacuum
cleaner and compressed
air
Check air hoses, replace if Air hose

damaged
Water/water heat Clean dirt trap in front of water Compressed air and
exchanger outlet (close shut-off valves) water
Compressor chiller Clean dirt trap in front of water Compressed air and
outlet (close shut-off valves) water
Water cooling supplied by Clean dirt trap in front of water Compressed air and
the customer outlet (close shut-off valves) water
66 Screwed connections Check if tightly seated
01/13 EN/0.2307385 84
Maintenance 8
Yearly

66 Water and exhaust air ducts Check if tight, replace if necessary
Water/water heat Replace water
exchanger
Replace corrosion protection i.e. TRAC 111
Check of expansion vessel by an

expert
Compressor chiller Replace water
Clean heat exchanger Vacuum cleaner and

compressed air
Water cooling supplied by Replace water
the customer
66 Electrical components and Check for damages and function
connections
Check connections (f. ex. plugs,
terminals)
66 Safety equipment Check operational reliability
01/13 EN/0.2307385 85
Maintenance 8
8.7 Recycling and Disposal
Recycling The machine, accessories and packaging should be recycled
in line with environmental protection considerations.
Recycling Risk of injury when disassembling metal and electrical
a
components.
We therefore recommend that protective gloves be worn

during all disassembly works.
Disposal Harmful chemicals can cause skin injuries when disposing of
a paints, varnishes and washing detergents.
We therefore recommend that protective gloves be worn

during all disposal measures.
01/13 EN/0.2307385 86
Maintenance 8
8.8 Recycling and Disposal Measures
Object Recycling and Disposal Measures

Metal parts • Following disassembly, all metal parts should be sorted by
type (e.g. steel, aluminium or brass) and recycled.
• Recycling may only be performed by a professional
disposal company in compliance with national and
international specifications.
Electronic components • Following disassembly, all electronic components should
be sorted by type (e.g. power supply units/transformers,
servomotors, cables, plugs or circuit boards) and recycled.
• Recycling may only be performed by a professional
disposal company in compliance with regional, national and
UV lamps • We recommend that lamps are stored and transported in
their original packaging after use.
• Damaged lamps or parts contaminated with mercury
must be packed in air-tight packaging and disposed of
immediately.
• We recommend that mercury particle leakages be collected
using a mercury binding agent (e.g. Mercurosorb) and then
disposed of.
• Disposal may only be performed by a professional disposal
company in compliance with regional, national and
Paint and varnish pastes • Paint and varnish pastes should be emptied into suitable,
appropriately marked containers (drum with locking ring on
mobile collecting reservoir) for disposal.
01/13 EN/0.2307385 87
Maintenance 8
Object Recycling and Disposal Measures
Washing detergents, liquid • Liquid paints, varnishes or washing detergents are water-
paints and varnishes pollutant and may not be poured into the waste water
system.
• Liquid paints, varnishes or washing detergent residue
should be emptied into suitable and appropriately marked
containers (bunghole drum on mobile collecting reservoir)
for disposal.
Empty paint drums and print • Empty paint drums (plastic and metal) that have been
samples scraped clean or non-dried print samples should be placed
in suitable containers (drum with locking ring) for disposal.
01/13 EN/0.2307385 88
Technical data and spare parts 9
9 TECHNICAL DATA AND SPARE PARTS
9.1 UV-unit
R-N° ID-N°
Type M-41-MBS -6 ®
225612
Length 684,5 mm
Height 130 mm
Width 114 mm
Weight 7,4 kg
Sensor NCB 1.5-8GM25-N0 -S2 232553
Lamp holder set FLC® -E 237890
Lamp instrument IST® /FLC® 157507
Lamps, types I-410 -NA-1-60 -E11 225773
I/O module IPS lamp module -AA1 176524
Terminal adapter Adapter board -AA2 212633
Viton tube 70° Shore A/black 195740
Front plate with microswitch 211482
Microswitch -S01 227846
Cable harness KON 1192 239073
Reflector set 4 coated profiles 228016
Reflector profile + temperature PT 1000 225593
sensor
Temperature sensor PT 1000 -R31 210812
Shutter profile + installation -R31 228093
material
Shutter drive 23HS 0408 -N2 208346
Cleaning
Cleaning set (alcohol cleaning for UV lamps 30357
cloths)
Cleaning set (reflexion+) for UV reflectors 174257
05/13 EN/0.2307385 89
9.2 Electrical
R-N° ID-N°
Basic switch cabinet TS8645.500 + ELC stack
®
Width 1200 mm
Depth 500 mm
Height (4-11 lamps) 1600 mm
(12 lamps) 1700 mm
Weight (4 lamps) 190 kg
(5 lamps) 205 kg
(6 lamps) 220 kg
(7 lamps) 235 kg
(8 lamps) 250 kg
(9 lamps) 265 kg
(10 lamps) 280 kg
(11 lamps) 295 kg
(12 lamps) 310 kg
Finish RAL 7035
Degree of protection IP 54
Electric parts basic switch cabinet

Top-hat rail power supply Trio-PS-3x400-500 V AC, -G31 175670
24 V DC, 40.0 A
Basic fuse terminal 303 363 72 -X19 202929
Emergency off function

System-specific main switch, see
circuit diagram
66 Main switch PN1 -100 Q0
Main switch PN1 -125 UL Q0
66 Main switch PN1 -160 Q0
Main switch PN1 -160 UL Q0
Operating and control elements

Operator terminal UCS -i A3 172667
05/13 EN/0.2307385 90
R-N° ID-N°
Type Module plate Nilpeter
Output control
Electronic power supply unit ELC® -X6-60 -1A41 - -#A41 203777
Control function
Safety relay PSR -SCF, 24V 149295
Emergency off function

Emergency off switching device PNOZ X 1 A100 100713
R-N° ID-N°
Type PLC modules ET 200 S
Analog electronic module DP/2AI 6ES7 134-4FB01-0AB0 -A3 201852

Analog electronic module DP/2AO 6ES7 135-4FB01-0AB0 -A3 201851
Digital electronic module DP/2RO 6ES7 132-4HB12-0AB0 -A3 214693
Digital electronic module DP/4DI 6ES7 131-4BD01-0AA0 -A3 158197
Digital electronic module DP/4DO 6ES7 132-4BD01-0AA0 -A3 158210
Digital electronic module DP/8DI 6ES7 131-4BF00-0AA0 -A3 201022
Digital electronic module DP/8DO 6ES7 132-4BF00-0AA0 -A3 201023
Interface module DP/IM 151-1 6ES7 151-1AA05-0AB0 -A3 158213
Power module DP/PM-E 6ES7 138-1CA01-0AA0 -A3 158211
Universal terminal module 6ES7 193-4CA30-0AA0 -A3 201849
DP/TM-E15C24-A1
Universal terminal module 6ES7 193-4CA50-0AA0 -A3 151301
DP/TM-E15C26-A1
Universal terminal module 6ES7 193-4CB30-0AA0 -A3 216279
DP/TM-E15C24-01
Terminal module DP/TM-P15C23-A0 6ES7 193-4CD30-0AA0 -A3 158205
Interface module DP/IM 151-1 6ES7 151-1AA05-0AB0 -A3 158213
05/13 EN/0.2307385 91
9.3 Suction
R-N° ID-N°
Type UV-Drying
Exhaust air / unit 295 m³/h

Exhaust air temperature 75 °C (maximum)
Exhaust air hose (not insulated) NW 102 mm 122372
Line cross section (pressure side) NW 315 mm
Length of ducting 10 m (maximum)
Pressure loss 150 Pa (maximum)
Stepless damper adjustment

Damper motor, complete LMC 24A-SR-C159-IST -M1 231443
Exhaust air
Fan, type DMVL 400-6-67/S/FQ/IE2 -A11/-A12 198801
400–500 V, 50/60 Hz
Motor power max. 5,5 kW
Degree of protection IP 55
05/13 EN/0.2307385 92
Addendum 10
10 ADDENDUM
Various other operating manuals and technical documentation are enclosed to this operating
manual.
01/13 EN/0.2307385 93

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Operating manual

BLK®, BLK-U®, CCU®, ELC®, FLC®, IST®, MBS® and URS®

Printed on chlorine-free paper.

Employed harmonised standards:

Employed standards and technical specifications:

Authorised person for compilation of technical documentation:

Dirk Jägers, Managing Director

s Stop (Stop Danger). This symbol warns of serious danger of

h Information. This symbol indicates key information on use.

 Procedure to remedy fault.

5/00 X/0.20000 Version identification

Kind of system IST® UV-Polymerisation Unit

Year of construction 2014

Client Nilpeter / India 1

UV-radiation zone 180 nm - 450 nm

Relative air humidity 30 - 80% (non-moisting)

Ambient temperature 15°C - 35°C

Altitude max. 1.000 m above sea level

Radiation emission level Category 1 according to EN 12198-1

- Shielding system: 66 Shutter

- Water cooling: compressor chiller

- Chill roll: water-cooled

- Supply air: 66 from workroom

- Exhaust air: with filter

Operating voltage: 400 V ± 10%, 50/60 Hz

Total current consumption: 83 A

Fuses, provided by customer: 100 A gG

Residual current device On account of their design, relatively high

PE conductor cross section: Because of the high leakage currents,

Supply line, provided by according to local prescriptions

Lamps: Type I-410-NA-1-60

Power control: 66 with ELC® (Electronic Lamp Control)

Maximum lamp output: 120 W/cm

Execution: 66 with UCS-i

Operation The unit is operated via an operating console.

Maintenance Maintenance tasks are performed directly on the unit. Lamp

• Non-compliance with these operating instructions

• Operation by insufficiently qualified personnel

• Unauthorised modifications to the device or components

• Proper storage of the IST UV lamps

• Correct installation and commissioning of the IST UV unit

• Regular maintenance of the IST UV unit in accordance with

• Regular cleaning of the IST UV lamps in accordance with the

• A reduction in drying power caused by external dirt

• A reduction in the UV radiant power to 75% of the original

• Before installation of a new UV lamp, the FLC® contacts

Any application other than originally intended is a misuse.

Operation of the unit is not permitted until the electrical

h to operate the unit. The utilisation by any other persons is

Moreover, the safe function of the safety equipment mentioned

At least twice a year, all screwed connections of the

If the unit is completely switched off during maintenance and

All safety-relevant functions are electrically interlocked in the

In the interior radiation zone (lamp, reflector, undershielding/

A CO2-fire extinguisher has to be placed at the UV-unit in case

We recommend insulating the exhaust-air ducting in the

When running the system, the solvent evaporates. If the

Before starting up the unit, remove a solvent-contaminated

The use of sulphurous or phosphorous compounds in the lamp