00 en

Speedmaster CX 102
Specifications
00.999.5895
Preface
Preface
00.956.0074-000UTKENU_01
1.1 Notes for the reader

Contents
This documentation provides you with information on
the versions, specifications and technical characteris‐
tics of the printing press and the associated peripher‐
al equipment.
Target group
This document is addressed to you if you
● think about purchasing a printing press;
● plan the installation and location of a printing
press.
Note
Always observe all applicable safety
rules whenever you use this informa‐
tion for planning and installation. The
safety requirements in the operating
manual must always be observed when
the printing press is in operation.
Abbreviations used
D.S. = drive side
O.S. = operator's side
PU = printing unit
CU = coating unit
EMC = electromagnetic compatibility
PE = earth potential
Relevance
The specifications in this document correspond to
the series version of the printing press at the time of
the publication of this document. We reserve the
right of making modifications that serve the technical
progress.
Please contact your Heidelberg agency if there are
any questions.
Protective note
Essential parts, equipment and assemblies as well
as the software and control and measuring devices
of our printing presses are internationally protected
by copyright, or by patent applications, patents, or util‐
ity patents. The reproduction, distribution and utiliza‐
tion of this document as well as the communication
of its contents to others without express authoriza‐
tion is prohibited. Offenders will be held liable for the
payment of damages. All rights reserved in the event
of the grant of a patent, utility model or design.
Copyright, address of the manufacturer

© Copyright by
Heidelberger Druckmaschinen AG
00.999.5895/
Preface
Kurfürstenanlage 52 - 60
69115 Heidelberg
Germany
00.999.5895/
Overall chapter overview
Table of Contents
A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1
1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5
2 Dimensions of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.7
3 Dimensions and weights of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
4 Floor space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16
5 Minimum working space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.19
6 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22
7 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.28
8 Electrical connection specifications, general information . . . . . . . . . . . . . . . . . . . . . . . A.1.31
9 Electrical connection specifications, printing press with 4 printing units . . . . . . . . . . . A.1.33
14 Electrical connection specifications of the DryStar IR dryers . . . . . . . . . . . . . . . . . . . . A.1.78
15 Specifications of the peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.79
16 Printing press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.93
17 Allocation of the peripheral equipment to the printing press . . . . . . . . . . . . . . . . . . . . A.1.94
18 Shipping data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99
Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1

1 Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
2 Floor plan legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23
3 Positions of the leveling blocks and gravity centers . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.27
4 Dimensions of the preloading device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.30
B Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.1

1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3
Preparation of the location of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1

1 Constructional requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
2 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.6
3 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.12
4 Supply systems and supply lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15
5 Printing Office Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . B.2.17
00.999.5895/ 1
Elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.1

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
2 Nonstop Preset Plus feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.5
3 Strip foundations for elevated printing presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6
4 Motor mounting base for elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.8
5 Oil drip pans for elevated presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.11
Electrical installation of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.1

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.3
2 Specifications of the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.4
3 Basic regulations for the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7
4 Basic recommendations and notes on the mains connection . . . . . . . . . . . . . . . . . . . B.4.14
5 Mains connection of the printing press to the three-phase mains . . . . . . . . . . . . . . . . B.4.16
6 Cross sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.23
Air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.1

1 Air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.3
2 Air-cooled AirStar air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.6
3 Water-cooled AirStar air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.8
4 Installation instructions for the AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.11
5 Installation of the air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.14
Pneumatic compressor ScrollStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.1

1 Pneumatic compressor ScrollStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3
2 Installation instructions for the ScrollStar .................................. B.6.5
3 Air supply via central air supply systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.8
Dampening solution supply CombiStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.1

1 CombiStar combination unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.3
2 Installation instructions for the CombiStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.5
3 Dampening solution supply via central dampening solution supply systems . . . . . . . . B.7.9
Washing fluid disposal WashStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.1

1 Installation instructions for the WashStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.3
Exhaust air cleaning cabinet CleanStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.1

1 Exhaust air cleaning cabinet CleanStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3
2 Installation instructions for the CleanStar exhaust air cleaning cabinet . . . . . . . . . . . . B.9.4
3 Exhaust air routing in presses with Preset Plus delivery . . . . . . . . . . . . . . . . . . . . . . . B.9.6
Varnish supply unit CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.1

1 Varnish supply unit CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.3
2 Installation instructions for the CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.6
2 00.999.5895/
IR dryer DryStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.1

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.3
2 IR Dryer DryStar Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.4
3 IR dryer DryStar Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.7
4 IR Dryer DryStar Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.11
5 Installation instructions for the DryStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.15
6 Exhaust air routing in presses with Preset Plus delivery . . . . . . . . . . . . . . . . . . . . . . . B.11.18
7 Mains connection of the IR dryers to the three-phase mains . . . . . . . . . . . . . . . . . . . . B.11.24
8 Ultraviolet drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30
Prinect peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.1

1 Mains connection of the Prinect peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.3
2 Overview of the standard power supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.4
Flexible peripherals installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.1

1 Flexible installation of peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.3
2 Double row installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
3 Raised and lowered installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.10
Permanent piping and exhaust air piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.1

1 Permanent piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.3
2 Exhaust air piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.6
Interface adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.1

1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3
2 Interface adapter, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4
3 SEM3 Interface input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5
4 SEM3 input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.8
5 SAM17 Interface output module 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.12
6 SAM17 output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.1
1 Physical measures and their units in the SI system and the ANSI system . . . . . . . . . B.16.3
2 Special conversions and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.4
3 Water hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.5
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ind.1
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4 00.999.5895/
Main chapter overview
A Specifications
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1
1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5

1.1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5
2 Dimensions of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.7

2.1 Dimensions of the printing press for standard installation . . . . . . . . . . . . . . . . . . . . . . A.1.7
2.2 Dimensions of the printing press for elevated installation . . . . . . . . . . . . . . . . . . . . . . A.1.8
3 Dimensions and weights of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10

3.1 Central control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
3.2 Prinect peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
3.3 AirStar (suction air and blast air supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
3.4 ScrollStar (compressed-air supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.11
3.5 HydroStar (dampening solution supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.11
3.6 CombiStar (dampening solution supply and inking unit temperature control) . . . . . . . A.1.11
3.7 FilterStar Compact (dampening solution filtration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.12
3.8 FilterStar (dampening solution filtration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.12
3.9 WashStar (washing fluid disposal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.12
3.10 Varnish supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.12
3.11 CleanStar (exhaust air cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.12
3.12 DryStar (IR drying) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.13
3.13 InkStar (automatic ink supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.14
3.14 Plate punch and plate bending device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.14
3.15 Special dimensions of the peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.14
3.16 Exhaust hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.15
4 Floor space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16

4.1 Floor space required for standard installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16
4.2 Floor space requirements for elevated installation . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.17
5 Minimum working space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.19

5.1 Minimum working space required in standard installation . . . . . . . . . . . . . . . . . . . . . . A.1.19
5.2 Minimum working space required in elevated installation . . . . . . . . . . . . . . . . . . . . . . A.1.20
6 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22

6.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22
6.2 Press weights and floor loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22
6.3 Weights of the machine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.23
6.4 Average static floor load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24
6.5 Maximum static surface pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24
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6.6 Material requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24

6.7 Foundation settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25
6.8 Flatness tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25
6.9 Dynamic foundation loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25
6.10 Floor compression under the foundation plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.26
6.11 Foundation plate rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.26
6.12 Installation of the printing press on an uncoupled foundation . . . . . . . . . . . . . . . . . . . A.1.26
7 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.28

7.1 Dimensions of the foundation for standard installations . . . . . . . . . . . . . . . . . . . . . . . A.1.28
7.2 Dimensions of the foundation for elevated installations . . . . . . . . . . . . . . . . . . . . . . . . A.1.29
8 Electrical connection specifications, general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.31

8.1 Mains connection of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.31
8.2 Using LVHBC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.32
8.3 Maximum short-circuit current Icu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.32
8.4 Mains connection of the DryStar infrared dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.32
9 Electrical connection specifications, printing press with 4 printing units . . . . . . . . . . . . . . . . A.1.33

9.1 Printing press without inking unit temperature control . . . . . . . . . . . . . . . . . . . . . . . . . A.1.33
9.2 Printing press with inking unit temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.36
9.3 Printing press with inking unit temperature control and pump and control station . . . . A.1.39




A. 2 00.999.5895/
14 Electrical connection specifications of the DryStar IR dryers . . . . . . . . . . . . . . . . . . . . . . . . . A.1.78

14.1 Electrical connection specifications of the DryStar IR dryers . . . . . . . . . . . . . . . . . . . . A.1.78
15 Specifications of the peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.79

15.3 AirStar (suction and blast air supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.80
15.11 Powder spray devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.87
15.14 CleanStar and DryStar process exhaust air volumes . . . . . . . . . . . . . . . . . . . . . . . . . A.1.89
16 Printing press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.93

16.1 Printing press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.93
17 Allocation of the peripheral equipment to the printing press . . . . . . . . . . . . . . . . . . . . . . . . . A.1.94

17.4 Pneumatic compressors (compressed-air supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.95
18 Shipping data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99

00.999.5895/ A. 3
18.2 Shipping data of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99

18.3 Shipping data of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99
18.4 Shipping data, miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.101
18.5 Building openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.101
Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1
1 Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3

1.1 CX 102-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
1.2 CX 102-4 + l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.4
1.3 CX 102-4 + L (X2) / CX 102-4 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.5
1.4 CX 102-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.6
1.5 CX 102-5 + l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.7
1.6 CX 102-5 + L (X2) / CX 102-5 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.8
1.7 CX 102-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.9
1.8 CX 102-6 + l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.10
1.9 CX 102-6 + L (X2) / CX 102-6 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.11
1.10 CX 102-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.12
1.11 CX 102-7 + L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.13
1.12 CX 102-7 + L (X2) / CX 102-7 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.14
1.13 CX 102-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.15
1.14 CX 102-8 + L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.16
1.15 CX 102-8 + L (X2) / CX 102-8 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.17
1.16 CX 102 - supplementary drawing for elevated installation . . . . . . . . . . . . . . . . . . . . . . A.2.18
1.17 CX 102 + L - supplementary drawing for elevated installation . . . . . . . . . . . . . . . . . . . A.2.19
1.18 CX 102 + L (X2) - supplementary drawing for elevated installation . . . . . . . . . . . . . . . A.2.20
2 Floor plan legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23

2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23
2.2 Notes on the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23
2.3 Floor plan legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.24
2.4 Variable dimensions in the supplementary drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.25
3 Positions of the leveling blocks and gravity centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.27

3.2 Preset Plus feeder, first printing unit and middle printing unit . . . . . . . . . . . . . . . . . . . A.2.27
3.3 Last printing unit and Preset Plus delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.28
3.4 Coating unit and Preset Plus delivery without extension module . . . . . . . . . . . . . . . . A.2.28
3.5 Coating unit and Preset Plus delivery with two extension modules . . . . . . . . . . . . . . . A.2.29
3.6 Coating unit and Preset Plus delivery with three extension modules . . . . . . . . . . . . . A.2.29
A. 4 00.999.5895/
4 Dimensions of the preloading device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.30

4.2 Preloading device on the Preset Plus feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.30
00.999.5895/ A. 5
A. 6 00.999.5895/
Specifications
Specifications
1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5

1.1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5
2 Dimensions of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.7

2.1 Dimensions of the printing press for standard installation . . . . . . . . . . . . . . . . . . . . . . A.1.7
2.2 Dimensions of the printing press for elevated installation . . . . . . . . . . . . . . . . . . . . . . A.1.8
3 Dimensions and weights of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10

3.1 Central control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
3.3 AirStar (suction air and blast air supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10
3.14 Plate punch and plate bending device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.14
3.15 Special dimensions of the peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.14
3.16 Exhaust hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.15
4 Floor space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16

4.1 Floor space required for standard installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16
4.2 Floor space requirements for elevated installation . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.17
5 Minimum working space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.19

5.1 Minimum working space required in standard installation . . . . . . . . . . . . . . . . . . . . . . A.1.19
5.2 Minimum working space required in elevated installation . . . . . . . . . . . . . . . . . . . . . . A.1.20
6 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22

6.2 Press weights and floor loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22
6.3 Weights of the machine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.23
6.4 Average static floor load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24
6.5 Maximum static surface pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24
6.6 Material requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24
00.999.5895/ A.1.1
Specifications
6.7 Foundation settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25

6.8 Flatness tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25
6.9 Dynamic foundation loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25
6.10 Floor compression under the foundation plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.26
6.11 Foundation plate rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.26
6.12 Installation of the printing press on an uncoupled foundation . . . . . . . . . . . . . . . . . . . A.1.26
7 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.28

7.1 Dimensions of the foundation for standard installations . . . . . . . . . . . . . . . . . . . . . . . A.1.28
7.2 Dimensions of the foundation for elevated installations . . . . . . . . . . . . . . . . . . . . . . . . A.1.29
8 Electrical connection specifications, general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.31

8.1 Mains connection of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.31
8.2 Using LVHBC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.32
8.3 Maximum short-circuit current Icu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.32
8.4 Mains connection of the DryStar infrared dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.32





14 Electrical connection specifications of the DryStar IR dryers . . . . . . . . . . . . . . . . . . . . . . . . . A.1.78

14.1 Electrical connection specifications of the DryStar IR dryers . . . . . . . . . . . . . . . . . . . . A.1.78
A.1.2 00.999.5895/
Specifications
15 Specifications of the peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.79

15.14 CleanStar and DryStar process exhaust air volumes . . . . . . . . . . . . . . . . . . . . . . . . . A.1.89
16 Printing press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.93

16.1 Printing press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.93
17 Allocation of the peripheral equipment to the printing press . . . . . . . . . . . . . . . . . . . . . . . . . A.1.94

17.4 Pneumatic compressors (compressed-air supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.95
18 Shipping data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99

18.2 Shipping data of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99
18.3 Shipping data of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99
00.999.5895/ A.1.3
Specifications
18.4 Shipping data, miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.101

18.5 Building openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.101
A.1.4 00.999.5895/
Specifications
1 Print-related specifications
SC.906.1101-000UTKENU_00
1.1 Print-related specifications
Print-related specifications Speedmaster CX 102

Printing materials Largest sheet size 720 × 1020 mm (28.35 × 40.16 in)
Smallest sheet size 340 × 480 mm (13.39 × 18.90 in)
Largest print format 710 × 1020 mm (27.95 × 40.16 in)
Largest coating format 710 × 1020 mm (27.95 × 40.16 in)
Gripper bite 10...12 mm (0.39...0.47 in), continuous‐
ly adjustable
Printing material thickness 0.03...1.0 mm (0.0012...0.039 in)
Printing perform‐ Maximum 16500 sheets/h (1)
ance
Minimum 3000 sheets/h
Crawl speed 5 rpm
Plate cylinder Printing plate size 790 × 1030 mm (31.10 × 40.55 in)
Printing plate thickness 0.2...0.3 mm (0.008...0.012 in)
Plate cylinder undercut 0.12 mm (0.005 in)
Distance between lead edge of plate and print start 43 mm (1.69 in) / 52 mm (2.05 in)
Coating blanket cyl‐ Format Coating plate 780 × 1030 mm (30.71 × 40.55 in)
inder
Coating blanket (metal- 800 × 1048 mm (31.50 × 41.26 in)
backed)
Thickness Coating plate varies depending on model (frequently
1.14 mm/ 1.16 mm (0.045 in/0.046 in))
Coating blanket 1.95 mm (0.077 in)
Coating blanket cylinder undercut 3.2 mm (0.126 in)
Distance between lead edge of plate and coating 43 mm (1.69 in)
start
Blanket cylinder Format Blanket (metal-backed) 840 × 1052 mm (33.07 × 41.42 in)
Packing sheets 735 × 1030 mm (28.94 × 40.55 in)
Blanket thickness 1.95 mm (0.077 in)
Blanket cylinder undercut 2.3 mm (0.091 in)
Inking unit Total number of rollers 20
Inking form rollers 4
Inking form rollers diameter 60 mm (2.36 in)
72 mm (2.83 in)
66 mm (2.60 in)
80 mm (3.15 in)
Ink zones 32
Dampening system Type Alcolor-Vario continuous dampening
system
00.999.5895/ A.1.5
Specifications
Print-related specifications Speedmaster CX 102

Total number of rollers 5
Dampening form roller 1
Dampening form roller diameter 78 mm (3.07 in)
Pile heights, gross Feeder 1320 mm (51.97 in)
(2 )
Delivery Pile removal from the front 1295 mm (50.98 in)
Pile removal from the side 1275 mm (50.20 in)
Pile heights, elevat‐ Elevation of the pile by elevating the printing press + 500 mm (19.69 in)
ed printing presses
Maximum pile Maximum pile Feeder 2000 kg (4410 lbs)
weight weight
Delivery 2000 kg (4410 lbs)
Maximum auxiliary Feeder
pile weight
Delivery
Noise emission Noise emission values according to EN 13023:
Sound pressure level at the feeder control console 80 dB(A)
Sound pressure level at the delivery 80 dB(A)
Additional measured value:
Sound pressure level at the suction head (center) 80 dB(A)
Sound pressure level at the printing unit 80 dB(A)
Heat emission According to power requirement
Tab. 1 Print-related specifications
(1): The maximum printing performance depends on
the conditions on site and on the materials used. De‐
viations may also be due to customer- or market-spe‐
cific special accessories. If this is the case, the devia‐
tions are documented in the press-specific publica‐
tions.
(2): Including pile support plate and pile table.
A.1.6 00.999.5895/
Specifications
2 Dimensions of the printing press

SC.906.1102-000UTKENU_00
2.1 Dimensions of the printing press for standard installation

The following specifications apply to all press ver‐
SC.906.1100-000GRAUND_00
sions:
1 Length: see table 2
2 2 Width: 3332 mm (131.18 in)

3 Height: 2145 mm (84.45 in)
Width of printing presses with interdeck dryer prepa‐
3 ration: 3632 mm (143.00 in)
1 Overall height of the printing press:
● with automatic ink dispensing system InkStar,
metering unit open: 2820 mm (111.02 in).
The minimum ceiling height required for conven‐
iently changing the InkStar cartridges is
Fig. 1 Dimensions of the printing press in stand‐ 3000 mm (118.10 in).
ard installation (CX 102-4 + L (X2)) ● with AutoPlate plate cylinder guard in upper lock‐
ing position and with printing plate installed:
2715 mm (106.89 in).
● with AutoPlate Plus plate changer in upper lock‐
2900 mm (114.17 in).
Press version Length of the printing press for standard installations [mm] ([in])
CX 102-4 10564 (415.90)
CX 102-4 + L 11784 (463.94)
CX 102-4 + L (X2) 13410 (527.93)
CX 102-4 + L (X3) 14222 (559.93)
CX 102-5 11784 (463.94)
CX 102-5 + L 13004 (511.97)
CX 102-5 + L (X2) 14630 (575.96)
CX 102-5 + L (X3) 15442 (607.96)
CX 102-6 13004 (511.97)
CX 102-6 + L 14224 (560.00)
CX 102-6 + L (X2) 15850 (624.00)
CX 102-6 + L (X3) 16662 (656.00)
CX 102-7 14224 (560.00)
CX 102-7 + L 15444 (608.03)
CX 102-7 + L (X2) 17070 (672.03)
CX 102-7 + L (X3) 17882 (704.02)
CX 102-8 15444 (608.03)
CX 102-8 + L 16664 (656.06)
CX 102-8 + L (X2) 18290 (720.06)
00.999.5895/ A.1.7
Specifications
Press version Length of the printing press for standard installations [mm] ([in])
CX 102-8 + L (X3) 19102 (752.06)
Tab. 2 Length of the printing press for standard installations
For further information see also the chapters Floor
space required and Minimum working space required.
2.2 Dimensions of the printing press for elevated installation

SC.906.1101-000GRAUND_00
sions:
4
2 Width in the feeder zone: 4010 mm (157.87 in)
1 3 Width of the platform for the Prinect Press Cen‐
ter (without tread on D.S.): 4514 mm (177.72 in)
4 Height: 2645 mm (104.13 in)
Overall height of the printing press:
3 2 ● with automatic ink dispensing system InkStar,
metering unit open: 3320 mm (130.71 in).
The minimum ceiling height required for conven‐
iently changing the InkStar cartridges is
Fig. 2 Dimensions of the printing press in elevat‐ 3500 mm (137.80 in).
ed installation (CX 102-4 + L (X2))
● with AutoPlate plate cylinder guard in upper lock‐
3215 mm (126.57 in).
● with AutoPlate Plus plate changer in upper lock‐
3400 mm (133.86 in).
Press version Length of the printing press for elevated installations [mm] ([in])
CX 102-4 15221 (599.24)
CX 102-4 + L 16441 (647.27)
CX 102-4 + L (X2) 18066 (711.26)
CX 102-4 + L (X3) 18879 (743.26)
CX 102-5 16441 (647.27)
CX 102-5 + L 17661 (695.30)
CX 102-5 + L (X2) 19286 (759.29)
CX 102-5 + L (X3) 20099 (791.29)
CX 102-6 17661 (695.30)
CX 102-6 + L 18881 (743.33)
CX 102-6 + L (X2) 20506 (807.33)
CX 102-6 + L (X3) 21319 (839.32)
CX 102-7 18881 (743.33)
CX 102-7 + L 20101 (791.36)
CX 102-7 + L (X2) 21726 (855.36)
A.1.8 00.999.5895/
Specifications
CX 102-7 + L (X3) 22539 (887.35)
CX 102-8 20101 (791.36)
CX 102-8 + L 21321 (839.39)
CX 102-8 + L (X2) 22946 (903.39)
CX 102-8 + L (X3) 23759 (935.39)
Tab. 3 Length of the printing press for elevated installation
For further information see also the chapters Floor
space required and Minimum working space required.
00.999.5895/ A.1.9
Specifications
3 Dimensions and weights of the peripheral units

SC.906.1103-000UTKENU_00
3.1 Central control cabinet
Version Width [mm] ([in]) Depth [mm] ([in]) Height [mm] ([in]) Weight [kg] ([lbs])
Central control cabinet ZSG, 1300 (51.18) 700 (27.56) 1930 (75.98) 780 (1720)
CX 102 with 4 printing units
Central control cabinet ZSG, 2100 (82.68) 700 (27.56) 1930 (75.98) 1150 (2535)
CX 102 with 5 or more print‐
ing units
Tab. 4 Dimensions and weights
3.2 Prinect peripheral equipment
Version Standard day‐ Width [mm] ([in]) Depth Height (1) [mm] Weight
light lamp [mm] ([in]) ([in]) [kg] ([lbs])
Without 1858 (73.15) 1278 (50.31) 880 (34.65) 530 (1170)
Prinect Press Center
With 2024 (79.68) 1414 (55.67) 2290 (90.16) 630 (1390)
Prinect Press Center Without 2078 (81.81) 1278 (50.31) 880 (34.65) 680 (1500)
with Prinect Axis Control With 2161 (85.08) 1414 (55.67) 2290 (90.16) 780 (1720)
with Prinect Inpress Con‐
With 2306 (90.79) 1414 (55.67) 2290 (90.16) 725 (1600)
trol
with drawer desk With 3101 (122.09) 1414 (55.67) 2290 (90.16) 930 (2050)
Prinect Image Control Without 2223 (87.52) 1278 (50.31) 1239 (48.78) 730 (1610)
(1): The adjustable base permits the height to be ad‐
justed to a maximum of + 70 mm.
3.3 AirStar (suction air and blast air supply)
Air-cooled
AirStar A1-R1-L 1200 (47.24) 700 (27.56) 1930 (75.98) 670 (1480)
AirStar A1-R2-L 1200 (47.24) 700 (27.56) 1930 (75.98) 750 (1655)
Water-cooled
AirStar A1-R1-W 1700 (66.93) 700 (27.56) 1930 (75.98) 815 (1800)
AirStar A1-R2-W 1700 (66.93) 700 (27.56) 1930 (75.98) 895 (1975)
A.1.10 00.999.5895/
Specifications
3.4 ScrollStar (compressed-air supply)
ScrollStar 590 (23.23) 650 (25.59) 1050 (41.34) 210 (460)
3.5 HydroStar (dampening solution supply)
Air-cooled
beta.d 40 L 1000 (39.37) 700 (27.56) 1930 (75.98) 385 (850)
beta.d 60 L 1000 (39.37) 700 (27.56) 1930 (75.98) 390 (860)
beta.d 100 L 1000 (39.37) 700 (27.56) 1930 (75.98) 420 (930)
Water-cooled
beta.d 40 G 1000 (39.37) 700 (27.56) 1930 (75.98) 370 (820)
beta.d 60 G 1000 (39.37) 700 (27.56) 1930 (75.98) 375 (830)
beta.d 100 G 1000 (39.37) 700 (27.56) 1930 (75.98) 405 (895)
Accessories
alcocontrol (1) 156 (6.14) 156 (6.14) 400 (17.75) -
(1): Integrated in the HydroStar.
3.6 CombiStar (dampening solution supply and inking unit temperature control)
Air-cooled
beta.c 130 L 1800 (70.87) 700 (27.56) 1930 (75.98) 670 (1480)
beta.c 170 L 1800 (70.87) 700 (27.56) 1930 (75.98) 720 (1590)
beta.c 220 L 2200 (86.61) 700 (27.56) 1930 (75.98) 810 (1790)
beta.c 280 L 2200 (86.61) 700 (27.56) 1930 (75.98) 920 (2030)
Water-cooled
beta.c 130 G 1800 (70.87) 700 (27.56) 1930 (75.98) 640 (1415)
beta.c 170 G 1800 (70.87) 700 (27.56) 1930 (75.98) 690 (1525)
beta.c 220 G 2000 (78.74) 700 (27.56) 1930 (75.98) 760 (1680)
beta.c 280 G 2000 (78.74) 700 (27.56) 1930 (75.98) 870 (1920)
Accessories
alcocontrol (1) 156 (6.14) 156 (6.14) 400 (17.75) -
(1): Integrated in the CombiStar.
00.999.5895/ A.1.11
Specifications
3.7 FilterStar Compact (dampening solution filtration)
FilterStar Compact 350 (13.78) 615 (24.21) 1070 (42.13) 86 (190)
3.8 FilterStar (dampening solution filtration)
FilterStar beta.f 600 (23.62) 700 (27.56) 1930 (75.98) 160 (353)
3.9 WashStar (washing fluid disposal)
WashStar I 630 (24.80) 400 (15.75) 630 (24.80) 56 (123)
WashStar II 630 (24.80) 400 (15.75) 630 (24.80) 56 (123)
WashStar in the cabinet 1000 (39.37) 700 (27.56) 1930 (75.98) 145 (320)
3.10 Varnish supply unit
LVG-550E (1) 750 (29.53) 480 (18.90) 395 (15.55) 117 (260)
LVG-550E UV (1) 750 (29.53) 480 (18.90) 395 (15.55) 117 (260)
CoatingStar Compact ( )1 700 (27.56) 505 (19.88) 400 (15.75) 105 (231)
CoatingStar 600 (23.62) 700 (27.56) 1365 (53.74) 245 (540)
(1): Installation: Underneath the footboard on D.S.
3.11 CleanStar (exhaust air cleaning)
CleanStar Compact
Exhaust air collecting box 600 (23.62) 700 (27.56) 392 (15.43) 25 (55)
CleanStar
Exhaust air cleaning cabinet 1000 (39.37) 700 (27.56) 1930 (75.98) 312 (690)
The exhaust air collecting box is equipped with an in‐
tegrated exhaust hood. The connection piece of the
exhaust hood has a diameter of DN 500 mm
(19.69 in).
A.1.12 00.999.5895/
Specifications
3.12 DryStar (IR drying)
3.12.1 Cooling and electric module, dryer cabinet
DryStar Ink
Cooling module (1) 730 (28.74) 320 (12.60) 1450 (57.09) 80 (176)
Electric module (2) 560 (22.05) 200 (7.87) 900 (35.43) 90 (198)
DryStar Coating
Dryer cabinet 1200 (47.24) 700 (27.56) 1930 (75.98) 450 (990)
DryStar Combination
Dryer cabinet (3) 1200 (47.24) 700 (27.56) 1930 (75.98) 450 (990)
(1): Integrated in the Preset Plus delivery.
(2): Installation: Underneath the footboard on D.S.
(3): Dryer cabinet for DryStar Combination with two
or three slide-in units.
3.12.2 Slide-in dryers
Slide-in dryer Length [mm] ([in]) Width [mm] ([in]) Height [mm] ([in]) Weight [kg] ([lbs])
DryStar Ink
Slide-in dryer 1 1526 (60.08) 548 (21.57) 190 (7.48) 45 (99)
(IR and suction)
DryStar Coating
Slide-in dryer 1 1526 (60.08) 548 (21.57) 190 (7.48) 56 (123)
(IR and hot air)
DryStar Combination (1)
Slide-in dryer 1 1526 (60.08) 548 (21.57) 190 (7.48) 56 (123)
(IR and hot air)
Slide-in dryer 2 1526 (60.08) 548 (21.57) 190 (7.48) 42 (93)
(hot air)
Slide-in dryer 3 1526 (60.08) 548 (21.57) 190 (7.48) 43 (95)
(Suction removal and ambi‐
ent air)
(1): Slide-in dryer 2 (hot air) is omitted when the print‐
ing press is equipped with the DryStar Combination
and two slide-in units.
3.12.3 Exhaust air collecting box

The dimensions and weights of the exhaust air col‐
lecting box are listed in section CleanStar (exhaust
air cleaning) (Table 14).
00.999.5895/ A.1.13
Specifications
3.13 InkStar (automatic ink supply)
InkStar 1335 (52.56) 439 (17.28) 666 (26.22) meter‐ 27 (60)per unit
ing unit open
3.14 Plate punch and plate bending device
Plate punch 1530 (60.24) 658 (25.91) 1427 (56.18) 140 (310)
Plate bending device 1530 (60.24) 655 (25.79) 1432 (56.38) 160 (350)
3.15 Special dimensions of the peripheral equipment
Version Depth with open doors (90° angle) Height with exhaust hood [mm] ([in])
[mm] ([in])
AirStar
All versions - 2430 (95.67)
ScrollStar
ScrollStar 1240 (48.82) -
HydroStar
All versions 1300 (51.18) 2430 (95.67)
CombiStar
All versions 1300 (51.18) 2430 (95.67)
FilterStar Compact
FilterStar Compact 965 (37.99) -
FilterStar
FilterStar beta.f 1300 (51.18) -
WashStar
WashStar in the cabinet 1200 (47.24) -
CleanStar
Exhaust air cleaning cabinet 1200 (47.24) 2430 (95.67)
DryStar
DryStar Coating 1300 (51.18) 2430 (95.67)
(dryer cabinet)
DryStar Combination 1300 (51.18) 2430 (95.67)
(dryer cabinet)
Tab. 19 Dimensions
A.1.14 00.999.5895/
Specifications
3.16 Exhaust hoods
Exhaust hood for version Width [mm] ([in]) Depth [mm] ([in]) Height [mm] ([in]) Socket diameter
[mm] ([in])
AirStar
All versions 1194 (47.01) 695 (27.36) 500 (19.69) DN 400 (15.75)
HydroStar
beta.d 40...100 968 (38.11) 700 (27.56) 500 (19.69) DN 560 (22.05)
CombiStar
beta.c 130, 170 768 (30.24) 700 (27.56) 500 (19.69) DN 560 (22.05)
beta.c 220, 280 1153 (45.39) 700 (27.56) 500 (19.69) DN 560 (22.05)
CleanStar
Exhaust air cleaning cabinet 995 (39.17) 700 (27.56) 500 (19.69) DN 315 (12.40)
DryStar
DryStar Coating 1200 (47.24) 700 (27.56) 500 (19.69) DN 400 (15.75)
(dryer cabinet)
DryStar Combination 1200 (47.24) 700 (27.56) 500 (19.69) DN 400 (15.75)
(dryer cabinet)
Tab. 20 Dimensions
00.999.5895/ A.1.15
Specifications
4 Floor space required

SC.906.1104-000UTKENU_00
4.1 Floor space required for standard installation

Floor space required by the printing press
SC.906.1102-000GRAUND_00
3 2 Width: see table 21

Floor space required by Prinect Press Center
4
4 Width: see table 22
Floor space required with interdeck dryer preparation

1 The floor space required by a printing press with in‐
terdeck dryer preparation is not included in Table 21.
2 The interdeck dryer preparation requires the foot‐
boards to be broadened. This increases the floor
Fig. 3 Floor space required for standard installa‐ space required by the printing press. The width of
tions the floor space required is increased to 5.08 m
(16.67 ft).
Note
The interdeck dryer preparation is not
possible when a printing press is equip‐
ped with the AutoPlate Plus.
Calculation of the floor space required by the printing

press:
Contour of the printing press with peripheral units (ba‐
sic configuration) in longitudinal and transversal direc‐
tion.
The length dimensions in Table 21 apply to one print‐
ing press without preloading device. The distance be‐
tween the beginning of the guide rails of a preloading
device and the front edge of the Preset Plus feeder
is 1640 mm (64.57 in).
Calculation Floor space required by Prinect Press

Center:
Contours of the Prinect Press Center in longitudinal
and lateral direction.
Prinect Press Center can be installed within a radius
of 5 m (16.4 ft) (optional 12.5 m (41 ft)) from the deliv‐
ery.
Press version Length [m] ([ft]) Width [m] ([ft]) Floor space [m2] ([sq ft])
CX 102-4 10.56 (34.66) 4.78 (15.69) 50.5 (543.8)
CX 102-4 + L 11.78 (38.66) 4.78 (15.69) 56.4 (606.6)
CX 102-4 + L (X2) 13.41 (43.99) 4.78 (15.69) 64.1 (690.2)
CX 102-4 + L (X3) 14.22 (46.66) 4.78 (15.69) 68.0 (732.1)
CX 102-5 11.78 (38.66) 4.78 (15.69) 56.4 (606.6)
CX 102-5 + L 13.00 (42.66) 4.78 (15.69) 62.2 (669.4)
A.1.16 00.999.5895/
Specifications
CX 102-5 + L (X2) 14.63 (48.00) 4.78 (15.69) 70.0 (753.0)
CX 102-5 + L (X3) 15.44 (50.66) 4.78 (15.69) 73.8 (794.9)
CX 102-6 13.00 (42.66) 4.78 (15.69) 62.2 (669.4)
CX 102-6 + L 14.22 (46.67) 4.78 (15.69) 68.0 (732.2)
CX 102-6 + L (X2) 15.85 (52.00) 4.78 (15.69) 75.8 (815.8)
CX 102-6 + L (X3) 16.66 (54.67) 4.78 (15.69) 79.7 (857.7)
CX 102-7 14.22 (46.67) 4.78 (15.69) 68.0 (732.2)
CX 102-7 + L 15.44 (50.67) 4.78 (15.69) 73.9 (794.9)
CX 102-7 + L (X2) 17.07 (56.00) 4.78 (15.69) 81.6 (878.6)
CX 102-7 + L (X3) 17.88 (58.67) 4.78 (15.69) 85.5 (920.5)
CX 102-8 15.44 (50.67) 4.78 (15.69) 73.9 (794.9)
CX 102-8 + L 16.66 (54.67) 4.78 (15.69) 79.7 (857.7)
CX 102-8 + L (X2) 18.29 (60.00) 4.78 (15.69) 87.5 (941.4)
CX 102-8 + L (X3) 19.10 (62.67) 4.78 (15.69) 91.3 (983.3)
Tab. 21 Floor space required by the printing press with peripheral units in standard installation
Version Length [m] ([ft]) Width [m] ([ft]) Floor space [m2] ([sq ft])
Prinect Press Center (1) 2.02 (6.63) 1.41 (4.63) 2.8 (30.7)
Tab. 22 Floor space required by Prinect Press Center
(1): Dimensions including standard daylight lamp.
Additional information can be found in chapter Floor
plans.
4.2 Floor space requirements for elevated installation

SC.906.1103-000GRAUND_00
Calculation of the floor space required by the printing

press:
2 Contour of the printing press with peripheral units (ba‐
sic configuration) in longitudinal and transversal direc‐
tion.
1
Fig. 4 Floor space required for elevated installa‐

tions
CX 102-4 15.22 (49.94) 5.89 (19.33) 89.7 (965.1)
CX 102-4 + L 16.44 (53.94) 5.89 (19.33) 96.9 (1042.5)
CX 102-4 + L (X2) 18.07 (59.27) 5.89 (19.33) 106.4 (1145.6)
00.999.5895/ A.1.17
Specifications
CX 102-4 + L (X3) 18.88 (61.94) 5.89 (19.33) 111.2 (1197.1)
CX 102-5 16.44 (53.94) 5.89 (19.33) 96.9 (1042.5)
CX 102-5 + L 17.66 (57.94) 5.89 (19.33) 104.0 (1119.9)
CX 102-5 + L (X2) 19.29 (63.27) 5.89 (19.33) 113.6 (1222.9)
CX 102-5 + L (X3) 20.10 (65.94) 5.89 (19.33) 118.4 (1274.5)
CX 102-6 17.66 (57.94) 5.89 (19.33) 104.0 (1119.9)
CX 102-6 + L 18.88 (61.94) 5.89 (19.33) 111.2 (1197.2)
CX 102-6 + L (X2) 20.51 (67.28) 5.89 (19.33) 120.8 (1300.3)
CX 102-6 + L (X3) 21.32 (69.94) 5.89 (19.33) 125.6 (1351.8)
CX 102-7 18.88 (61.94) 5.89 (19.33) 111.2 (1197.2)
CX 102-7 + L 20.10 (65.95) 5.89 (19.33) 118.4 (1274.6)
CX 102-7 + L (X2) 21.73 (71.28) 5.89 (19.33) 128.0 (1377.7)
CX 102-7 + L (X3) 22.54 (73.95) 5.89 (19.33) 132.8 (1429.2)
CX 102-8 20.10 (65.95) 5.89 (19.33) 118.4 (1274.6)
CX 102-8 + L 21.32 (69.95) 5.89 (19.33) 125.6 (1351.9)
CX 102-8 + L (X2) 22.95 (75.28) 5.89 (19.33) 135.2 (1455.0)
CX 102-8 + L (X3) 23.76 (77.95) 5.89 (19.33) 140.0 (1506.6)
Tab. 23 Floor space required by the printing press with peripheral units in elevated installation
Additional information can be found in chapter Floor
plans.
A.1.18 00.999.5895/
Specifications
5 Minimum working space required

SC.906.1105-000UTKENU_00
5.1 Minimum working space required in standard installation

Minimum working space required by the printing press
SC.906.1104-000GRAUND_00
3 2 Width: see table 24
Minimum working space required by the Prinect
Press Center
4
1 Minimum working space required with interdeck dry‐

er preparation
2 The minimum working space required by a printing
press with interdeck dryer preparation is not included
Fig. 5 Minimum working space required for stand‐ in Table 24. The interdeck dryer preparation requires
ard installations the footboards to be broadened. This increases the
minimum working space required by the printing
press. The width of the minimum working space re‐
quired is increased to 6.80 m (22.32 ft).
Note
The interdeck dryer preparation is not
possible when a printing press is equip‐
ped with the AutoPlate Plus.
Calculation of the minimum working space required

by the printing press:
Floor space required by the printing press plus addi‐
tional space for loading and removing piles and for
good accessibility to all press components and pe‐
ripheral units.
The dimensions in table 24 apply to loading and re‐
moving piles from the front side. Loading the piles lat‐
erally on the D.S. and removing them from D.S. or
O.S. permits the length of the floor space required to
be reduced as follows:
● Feeder: -1.0 m (3.28 ft);
● Delivery: -1.0 m (3.28 ft).
Calculation Minimum working space required by Pri‐

nect Press Center:
Floor space required by the Prinect Press Center
plus an additional surface in the operator area.
CX 102-4 14.30 (46.91) 6.50 (21.33) 93.0 (1000.7)
CX 102-4 + L 15.52 (50.92) 6.50 (21.33) 100.9 (1086.1)
CX 102-4 + L (X2) 17.14 (56.25) 6.50 (21.33) 111.5 (1199.9)
CX 102-4 + L (X3) 17.96 (58.91) 6.50 (21.33) 116.8 (1256.8)
00.999.5895/ A.1.19
Specifications
CX 102-5 15.52 (50.92) 6.50 (21.33) 100.9 (1086.1)
CX 102-5 + L 16.74 (54.92) 6.50 (21.33) 108.8 (1171.5)
CX 102-5 + L (X2) 18.36 (60.25) 6.50 (21.33) 119.4 (1285.3)
CX 102-5 + L (X3) 19.18 (62.92) 6.50 (21.33) 124.7 (1342.2)
CX 102-6 16.74 (54.92) 6.50 (21.33) 108.8 (1171.5)
CX 102-6 + L 17.96 (58.92) 6.50 (21.33) 116.8 (1256.9)
CX 102-6 + L (X2) 19.58 (64.25) 6.50 (21.33) 127.3 (1370.7)
CX 102-6 + L (X3) 20.40 (66.92) 6.50 (21.33) 132.6 (1427.5)
CX 102-7 17.96 (58.92) 6.50 (21.33) 116.8 (1256.9)
CX 102-7 + L 19.18 (62.92) 6.50 (21.33) 124.7 (1342.3)
CX 102-7 + L (X2) 20.80 (68.26) 6.50 (21.33) 135.3 (1456.0)
CX 102-7 + L (X3) 21.62 (70.92) 6.50 (21.33) 140.6 (1512.9)
CX 102-8 19.18 (62.92) 6.50 (21.33) 124.7 (1342.3)
CX 102-8 + L 20.40 (66.93) 6.50 (21.33) 132.6 (1427.7)
CX 102-8 + L (X2) 22.02 (72.26) 6.50 (21.33) 143.2 (1541.4)
CX 102-8 + L (X3) 22.84 (74.93) 6.50 (21.33) 148.5 (1598.3)
Tab. 24 Minimum working space required for printing press and peripheral units in standard installation
Version Length [m] ([ft]) Width [m] ([ft]) Floor space [m2] ([sq ft])
Prinect Press Center (1) 2.02 (6.63) 2.28 (7.48) 4.6 (49.6)
Tab. 25 Minimum working space required by the Prinect Press Center
(1): Dimensions including standard daylight lamp.
5.2 Minimum working space required in elevated installation

SC.906.1105-000GRAUND_00
Calculation of the minimum working space required

by the printing press:
2 Floor space required by the printing press plus addi‐
tional space for loading and removing piles and for
good accessibility to all press components and pe‐
1 ripheral units.
The dimensions in Table 26 refer to pile loading at
the side, and pile removal from D.S.
Fig. 6 Minimum working space required for elevat‐
ed installation
CX 102-4 15.22 (49.94) 7.09 (23.26) 107.9 (1161.7)
CX 102-4 + L 16.44 (53.94) 7.09 (23.26) 116.6 (1254.9)
CX 102-4 + L (X2) 18.07 (59.27) 7.09 (23.26) 128.1 (1378.9)
A.1.20 00.999.5895/
Specifications
CX 102-4 + L (X3) 18.88 (61.94) 7.09 (23.26) 133.9 (1441.0)
CX 102-5 16.44 (53.94) 7.09 (23.26) 116.6 (1254.9)
CX 102-5 + L 17.66 (57.94) 7.09 (23.26) 125.2 (1348.0)
CX 102-5 + L (X2) 19.29 (63.27) 7.09 (23.26) 136.8 (1472.0)
CX 102-5 + L (X3) 20.10 (65.94) 7.09 (23.26) 142.5 (1534.1)
CX 102-6 17.66 (57.94) 7.09 (23.26) 125.2 (1348.0)
CX 102-6 + L 18.88 (61.94) 7.09 (23.26) 133.9 (1441.1)
CX 102-6 + L (X2) 20.51 (67.28) 7.09 (23.26) 145.4 (1565.2)
CX 102-6 + L (X3) 21.32 (69.94) 7.09 (23.26) 151.2 (1627.2)
CX 102-7 18.88 (61.94) 7.09 (23.26) 133.9 (1441.1)
CX 102-7 + L 20.10 (65.95) 7.09 (23.26) 142.5 (1534.2)
CX 102-7 + L (X2) 21.73 (71.28) 7.09 (23.26) 154.1 (1658.3)
CX 102-7 + L (X3) 22.54 (73.95) 7.09 (23.26) 159.8 (1720.3)
CX 102-8 20.10 (65.95) 7.09 (23.26) 142.5 (1534.2)
CX 102-8 + L 21.32 (69.95) 7.09 (23.26) 151.2 (1627.3)
CX 102-8 + L (X2) 22.95 (75.28) 7.09 (23.26) 162.7 (1751.4)
CX 102-8 + L (X3) 23.76 (77.95) 7.09 (23.26) 168.5 (1813.4)
Tab. 26 Minimum working space required for printing press and peripheral units in elevated installation
00.999.5895/ A.1.21
Specifications
6 Machine foundation
SC.906.1106-000UTKENU_00
6.1 General information

The specifications in this chapter provide a frame‐
work planning engineer with the necessary input vari‐
ables required for safely designing the foundation
and thus ensuring the operability of the printing press.
When planning the foundation pay attention to the fol‐
lowing points:
● the floor characteristics,
● the machine loads,
● the dynamic forces,
● the maximum permissible subsidence,
● the bending strength of the foundation plate and
● the other environmental conditions (e.g. struc‐
ture-borne noise excitations and moving loads).
Please contact your Heidelberg agency or factory rep‐
resentative should you require any further informa‐
tion on how to lay the foundations.
Note
Heidelberg printing presses are preci‐
sion machines that must rest on a solid
foundation. The printing press consists
of interconnected modules that do not
have a common bed. The individual
components are thus loosely coupled.
We therefore recommend to install the
printing press on a separate uniform
press foundation. The press foundation
should be designed for the tensile
stress occurring under load. Avoid ex‐
pansion gaps and separation joints in
the press foundation. Always contact
your framework planning engineer and/
or your Heidelberg branch office or fac‐
tory representative if expansion joints
or separating lines cannot be avoided.
The customer must always commission
a framework planning engineer with ex‐
perience in machine foundations for de‐
signing and planning the press founda‐
tion
6.2 Press weights and floor loads

Press weight and floor load values of the printing
press with standard installation
Press version Press weight [kg] ([lbs]) Average static floor load
Without pile Including two piles [N/m2] ([lbf/sq ft])
CX 102-4 33010 (72755) 34700 (76500) 9671 (202.0)
A.1.22 00.999.5895/
Specifications
CX 102-4 + L 37780 (83291) 39470 (87016) 9861 (206.0)
CX 102-4 + L (X2) 39080 (86157) 40770 (89882) 8951 (187.0)
CX 102-4 + L (X3) 39730 (87590) 41420 (91315) 8574 (179.1)
CX 102-5 39440 (86950) 41130 (90676) 10276 (214.7)
CX 102-5 + L 44210 (97466) 45900 (101192) 10392 (217.1)
CX 102-5 + L (X2) 45510 (100332) 47200 (104058) 9499 (198.4)
CX 102-5 + L (X3) 46160 (101765) 47850 (105491) 9123 (190.6)
CX 102-6 45870 (101126) 47560 (104852) 10768 (224.9)
CX 102-6 + L 50640 (111642) 52330 (115368) 10832 (226.3)
CX 102-6 + L (X2) 51940 (114508) 53630 (118234) 9962 (208.1)
CX 102-6 + L (X3) 52590 (115941) 54280 (119667) 9591 (200.4)
CX 102-7 52300 (115302) 53990 (119027) 11175 (233.5)
CX 102-7 + L 57070 (125818) 58760 (129543) 11202 (234.0)
CX 102-7 + L (X2) 58370 (128684) 60060 (132409) 10359 (216.4)
CX 102-7 + L (X3) 59020 (130117) 60710 (133842) 9995 (208.8)
CX 102-8 58730 (129477) 60420 (133203) 11518 (240.6)
CX 102-8 + L 63500 (139993) 65190 (143719) 11518 (240.6)
CX 102-8 + L (X2) 64800 (142859) 66490 (146585) 10703 (223.6)
CX 102-8 + L (X3) 65450 (144292) 67140 (148018) 10348 (216.2)
Tab. 27 Press weight and floor load values of the printing press with standard installation
● The press weight specifies the overall weight of
the printing press without peripheral equipment.
● Weight of peripheral equipment: See the chap‐
ter "Dimensions and weight of peripheral equip‐
ment" in the main chapter entitled "Specifica‐
tions".
● Calculation of the paper pile weight at a paper
density of 1 kg/dm3 (0.036 lbs/cu in).
This corresponds to coarse paper of a gram‐
mage of 90 g/m2 (198 gr/sq ft).
6.3 Weights of the machine components
Machine component Weight [kg] ([lbs])

Preset Plus feeder 2000 (4410)
First printing unit (1) 6110 (13470)
Printing unit (from PU 2 onwards) (1) 6430 (14180)
Coating unit (2) 4770 (10520)
Preset Plus delivery without extension module 5210 (11490)
00.999.5895/ A.1.23
Specifications

Preset Plus delivery with two extension modules 6510 (14350)
Preset Plus delivery with three extension modules 7160 (15785)
Tab. 28 Weight of the press components
(1): Including inking rollers (200 kg (440 lbs)) and foot‐
boards (90 kg (200 lbs)).
(2): Including footboards (90 kg (200 lbs)).
6.4 Average static floor load

Average static floor load: see Table 27.
SC.906.1106-000GRAUND_00
Calculation of the average static floor load:
Ratio of press weight including two piles and floor
space required by the printing press (including foot‐
boards) without peripheral equipment.
1 Applicable area
Fig. 7 Standard area for determining the mean

static floor load
6.5 Maximum static surface pressure
Maximum static surface pressure

[N/cm2] ([lbf/sq in])
120 (174)
Tab. 29 Maximum static surface pressure
The maximum static surface pressure is the maxi‐
mum static surface pressure that occurs under the
feet of the printing units or the coating unit.
This value takes into account the fact that the print‐
ing units sit on four feet and are therefore geometri‐
cally unstable.
The surface of an adjustable base is:
● for the printing unit: 246 cm2 (38.13 sq in),
● for the coating unit: 246 cm2 (38.13 sq in).
6.6 Material requirements

We recommend an elastic machine foundation bed
with an adequate reinforcement and a quality of con‐
crete complying with at least C30/37 as per EN 206/1.
Characteristic values of high density concrete of con‐
crete property class C30/37:
A.1.24 00.999.5895/
Specifications
● Concrete group: XC1

● Density: approx. 1.9...2.8 kg/dm3
(0.067...0.101 lbs/cu in)
● E module: 30500 N/mm2 (4423660 lbs/sq in).
One cubic meter of set concrete of class C30/37 has
a mass of approx. 2500 kg (5510 lbs). This is assum‐
ing an average density of 2.5 kg/dm3 (0.090 lbs/
cu in).
6.7 Foundation settling

The absolute subsidence of the foundation after in‐
stalling and before assembling the printing units is of
no significance for the printing press.
Once the press has been installed and aligned, any
further non-uniform settling of the foundation must
not exceed 0.03 mm/m (0.36 mil/ft). This limit applies
to both longitudinal direction (bending) and trans‐
verse direction (torsion).
A uniform settling of the foundation which does not
cause the press to become deformed has no nega‐
tive side effects.
6.8 Flatness tolerance limit

The permitted limit value (Fig. 8/3) for flatness toler‐
LS.906.3804-000GRAUND_00
ances in a surface finished press foundation is a max‐

imum of 15 mm (0.59 in).
The flatness tolerances can be determined by taking
a diagonal measurement (Fig. 8/1) across the sur‐
1
face of the press foundation (Fig. 8/2). Two addition‐
al measurements (Fig. 8/1) should be performed in
the relevant control range of the leveling blocks.
For additional information and the allowed flatness tol‐
erances refer to the standard DIN 18202.
2
Fig. 8 Flatness tolerances in the press foundation
6.9 Dynamic foundation loads

Dynamic forces are applied to the ground during the
operation of the printing press.
The frequency at which the dynamic forces are trans‐
ferred to the foundation is closely connected to the
printing speed of the printing press.
00.999.5895/ A.1.25
Specifications
The speed-synchronous forces are the largest com‐

ponent. The cause is in the residual imbalance of the
single-speed cylinders. The amplitude of the applied
imbalance forces rises with the square of the printing
speed.
The excitation frequency corresponds to the printing
speed. It can be determined with the following formula:
f = printing speed (sheets/h) / 3600 = result in Hz.
A printing speed of 16,500 sheets/h results in an ex‐
citation frequency of 4.6 Hz.
In addition and to a lesser extent there are forces of
higher orders, the excitation frequencies of which are
also linked directly to the printing speed. Dynamic
forces up to the 5th order (4-fold rotary frequency)
are relevant to the foundation design.
citation frequency of the 5th order of 23 Hz.
The sum of the dynamic forces the printing press ap‐
plies to the foundation is not higher than 4 % of the
weight force of the printing press.
The dynamic forces are subdivided as follows:
● Single-speed forces (residual imbalance): 2 %
● Forces of the 2nd - 5th order (equally distribut‐
ed): 2 %.
6.10 Floor compression under the foundation plate

We recommend compressing the floor under the foun‐
dation plate with load-bearing and compression-capa‐
ble floor material to 97 % Proctor density.
Proctor density: Reference density for determining
the compressibility degree of a ground.
6.11 Foundation plate rigidity

When laying the foundations, please ensure that the
foundation plate is highly rigid. This will reduce the
static deflection and often the problem of foundation
vibrations, too.
6.12 Installation of the printing press on an uncoupled foundation

When installing the printing press on a decoupled
foundation, sufficient rigidity of the foundation must
be ensured.
With this type of installation, again ensure sufficient
foundation mass and suitable insulating layers. In
this way you will prevent impermissibly deep lower‐
ing of the foundation plate, e.g. in the case of pile feed.
Please, also consider direct uncoupling of press and
main drive by means of insulating boards.
A.1.26 00.999.5895/
Specifications
Note
The installation on an uncoupled foun‐
dation or on insulating boards requires
a thoroughly planned design. Please
consult your Heidelberg agency or fac‐
tory representative.
00.999.5895/ A.1.27
Specifications
7 Foundation dimensions
SC.906.1107-000UTKENU_00
7.1 Dimensions of the foundation for standard installations

SG.906.0002-000GRAUND_00
sions:
1 Recommended length: see Table 30
2
1 2 Recommended width: 2000 mm (78.74 in)
The surface requirement of the main drive is not in‐
cluded in the dimensions of the foundation.
Fig. 9 Dimensions of the foundation plate (sketch)

Recommended foundation length in standard installa‐
tion
Press version Recommended foundation length for standard installations [mm] ([in])
CX 102-4 10300 (405.51)
CX 102-4 + L 11520 (453.54)
CX 102-4 + L (X2) 13150 (517.72)
CX 102-4 + L (X3) 13960 (549.61)
CX 102-5 11520 (453.54)
CX 102-5 + L 12740 (501.57)
CX 102-5 + L (X2) 14370 (565.75)
CX 102-5 + L (X3) 15180 (597.64)
CX 102-6 12740 (501.57)
CX 102-6 + L 13960 (549.61)
CX 102-6 + L (X2) 15590 (613.78)
CX 102-6 + L (X3) 16400 (645.67)
CX 102-7 13960 (549.61)
CX 102-7 + L 15180 (597.64)
CX 102-7 + L (X2) 16810 (661.81)
CX 102-7 + L (X3) 17620 (693.70)
CX 102-8 15180 (597.64)
CX 102-8 + L 16400 (645.67)
CX 102-8 + L (X2) 18030 (709.84)
CX 102-8 + L (X3) 18840 (741.73)
Tab. 30 Recommended foundation length with standard installation
A.1.28 00.999.5895/
Specifications
7.2 Dimensions of the foundation for elevated installations

SG.906.0003-001GRAUND_00
sions:
3
2 2 Width: 1600 mm (63.00 in)
1 3 Width of the strip foundations: 350 mm (13.78 in)
4
4 Height: 500 mm (19.69 in)
To provide for an easy installation of cables and ho‐
ses, the strip foundations should have circular open‐
ings.
Diameter of the openings Distance of the openings

[mm] ([in]) from the floor [mm] ([in])
Fig. 10 Dimensions of the strip foundations for ele‐ 200 (7.87) 200 (7.87)
vated installations (diagram)
Tab. 31 Position and diameter of the openings
The main driving motor of an elevated printing press
is installed on a separate mounting base.
Dimensions of the motor mounting base [mm] ([in])

Length 1000 (39.37)
Width 800 (31.50)
Height 500 (19.69)
Tab. 32 Dimensions of the motor mounting base
Further information about the design of strip founda‐
tions and motor mounting base can be found in the
chapter Elevated printing press in the main chapter
Technical information.
Foundation length for elevated installation
Press version Length of the strip foundation segments [mm] ([in]) Total (theoretical)
[mm] ([in])
Delivery <- feeder
CX 102-4 3660 (144.09) | 2550 (100.39) 6210 (244.49)
CX 102-4 + L 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-4 + L (X2) 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-4 + L (X3) 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-5 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-5 + L 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-5 + L (X2) 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-5 + L (X3) 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-6 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-6 + L 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-6 + L (X2) 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-6 + L (X3) 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
00.999.5895/ A.1.29
Specifications
[mm] ([in])
Delivery <- feeder
CX 102-7 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-7 + L 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-7 + L (X2) 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-7 + L (X3) 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-8 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-8 + L 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
CX 102-8 + L (X2) 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
CX 102-8 + L (X3) 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
Tab. 33 Foundation length for elevated installations
A.1.30 00.999.5895/
Specifications
8 Electrical connection specifications, general information

SC.906.1200-000UTKENU_00
8.1 Mains connection of the printing press

The printing press is generally connected to the three-
phase mains via the central control cabinet (ZSG).
The operating voltage of the printing press is
A.C. 400 V.
A direct connection is possible with a mains frequen‐
cy of 50 Hz and mains voltage of AC 380, 400, and
415 V. Otherwise you will have to make adjustments
to meet the corresponding mains power. The adapta‐
tion is made via series transformers and matching
transformers.
The total power requirement of the printing press in‐
cludes the power demand of the following peripheral
units:
● Prinect Press Center/Prinect Press Center with
Prinect Axis Control;
● AirStar;
● ScrollStar;
● FilterStar Compact/FilterStar;
● WashStar;
● LVG-550E/CoatingStar Compact (for printing
presses with coating unit);
● CleanStar Compact/CleanStar;
● InkStar.
Variant/option:
● without inking unit temperature control: Hydro‐
Star;
● With inking unit temperature control: CombiStar;
● Pump and control station beta.ps (customizing
variant for printing presses with CombiStar Pro);
● CoatingStar (for printing presses with coating
unit);
● DryStar Ink (for printing presses without coating
unit).
The electrical connection specifications of the print‐
ing press are listed in the following chapters:
● Electrical connection specifications, printing
press with 4 printing units;
press with 8 printing units.
00.999.5895/ A.1.31
Specifications
Additional information about the topic Mains connec‐

tion of the printing press can be found in the main
chapter Technical information.
8.2 Using LVHBC fuses

When using the LVHBC fuse, you may reckon with a
minimum difference between the fuse value and the
nominal current of 10 %. Please observe the installa‐
tion conditions in the main chapter Technical informa‐
tion.
Typical calculation:
Nominal current of the printing press: In = 190 A
Rated value of the LVHBC fuse:
1.1 * In = 1.1 * 190 A = 209 A
LVHBC fuse to be used = 224 A
8.3 Maximum short-circuit current Icu

The term "rated ultimate short-circuit breaking capaci‐
ty" Icu defines the maximum short-circuit the select‐
ed circuit-breaker is able to interrupt.
Further information about the topic Rated ultimate
short-circuit breaking capacity can be found in the IEC/
EN 60947 Standard Specification.
8.4 Mains connection of the DryStar infrared dryer

With printing presses of the CX 102 product line, the
power supply of the IR dryer DryStar Ink comes from
the three-phase AC mains connection of the printing
press.
A separate three-phase AC mains connection feeds
the IR dryers DryStar Coating and DryStar Combina‐
tion. The electrical connection specifications are list‐
ed in the chapter Electrical connection specifications
of the DryStar IR dryers.
Further information about the topic Power supply of
the DryStar IR dryers can be found in the main chap‐
ter Technical information.
A.1.32 00.999.5895/
Specifications
9 Electrical connection specifications, printing press with 4 printing units

SC.906.1204-000UTKENU_00
9.1 Printing press without inking unit temperature control
9.1.1 CX 102-4
Printing press without inking unit temperature control

(with HydroStar)
Press version
Power re‐ Power factor Mains voltag‐ Current [A] Electrical fus‐ Icu 1 Icu 2
quired [kW] λ es [V] ing [A] [kA] [kA]
without DryStar Ink
200 258 400 30 30
220 234 315 30 30
230 224 315 30 30
240 215 315 30 30
350 147 200 25
76,0 0.85 380 135 200 25
400 129 160 25
415 124 160 25
440 117 160 25 25
480 107 160 25
600 86 125 18
CX 102-4
With DryStar Ink
200 324 400 30 30
220 295 400 30 30
230 282 400 30 30
240 270 400 30 30
350 185 250 25
99,0 0,88 380 170 224 25
400 162 200 25
415 156 200 25
440 147 200 25 25
480 135 200 25
600 108 160 18
Tab. 34 Electrical connection specifications of the printing press CX 102
(1): Maximum short-circuit current, applies to all coun‐
tries except in the US and Canada
(2): Maximum short-circuit current, only applicable in
the US and Canada
00.999.5895/ A.1.33
Specifications
9.1.2 CX 102-4 + L

(with HydroStar)
Press version
without CoatingStar
200 286 400 30 30
220 260 400 30 30
230 249 315 30 30
240 239 315 30 30
350 163 224 25
85,5 0.86 380 151 200 25
400 143 200 25
415 138 200 25
440 130 160 25 25
480 119 160 25
600 95 125 18
CX 102-4 + L
with CoatingStar
200 317 400 30 30
220 288 400 30 30
230 275 400 30 30
240 264 400 30 30
350 181 224 25
94,5 0.86 380 166 224 25
400 158 200 25
415 152 200 25
440 144 200 25 25
480 132 200 25
600 105 160 18
the US and Canada
A.1.34 00.999.5895/
Specifications
9.1.3 CX 102-4 + L (X2) / CX 102-4 + L (X3)

(with HydroStar)
Press version
without CoatingStar
200 303 400 30 30
220 276 400 30 30
230 264 400 30 30
240 253 315 30 30
350 173 224 25
89,5 0.85 380 159 200 25
400 151 200 25
415 146 200 25
440 138 200 25 25
480 126 160 25
CX 102-4 + L (X2) 600 101 125 18
CX 102-4 + L (X3) with CoatingStar
200 334 500 30 30
220 304 400 30 30
230 290 400 30 30
240 278 400 30 30
350 191 250 25
98,5 0.85 380 176 224 25
400 167 224 25
415 161 200 25
440 152 200 25 25
480 139 200 25
600 111 160 18
the US and Canada
00.999.5895/ A.1.35
Specifications
9.2 Printing press with inking unit temperature control
9.2.1 CX 102-4
Printing press with inking unit temperature control

(with CombiStar)
Press version
without DryStar Ink
200 286 400 30 30
220 260 400 30 30
230 249 315 30 30
240 239 315 30 30
350 163 224 25
83,5 0,84 380 151 200 25
400 143 200 25
415 138 200 25
440 130 160 25 25
480 119 160 25
600 95 125 18
CX 102-4
With DryStar Ink
200 349 500 30 30
220 317 400 30 30
230 303 400 30 30
240 291 400 30 30
350 199 250 25
106,5 0,88 380 183 250 25
400 174 224 25
415 168 224 25
440 158 200 25 25
480 145 200 25
600 116 160 18
the US and Canada
A.1.36 00.999.5895/
Specifications
9.2.2 CX 102-4 + L

(with CombiStar)
Press version
without CoatingStar
200 315 400 30 30
220 287 400 30 30
230 274 400 30 30
240 263 400 30 30
350 180 224 25
93,0 0.85 380 166 224 25
400 157 200 25
415 152 200 25
440 143 200 25 25
480 131 200 25
600 105 160 18
CX 102-4 + L
with CoatingStar
200 340 500 30 30
220 309 400 30 30
230 296 400 30 30
240 283 400 30 30
350 194 250 25
101,5 0.86 380 179 224 25
400 170 224 25
415 164 224 25
440 154 200 25 25
480 141 200 25
600 113 160 18
the US and Canada
00.999.5895/ A.1.37
Specifications
9.2.3 CX 102-4 + L (X2) / CX 102-4 + L (X3)

(with CombiStar)
Press version
without CoatingStar
200 333 500 30 30
220 303 400 30 30
230 289 400 30 30
240 277 400 30 30
350 190 250 25
97,0 0,84 380 175 224 25
400 166 224 25
415 160 200 25
440 151 200 25 25
480 138 200 25
CX 102-4 + L (X2) 600 111 160 18
200 358 500 30 30
220 325 500 30 30
230 311 400 30 30
240 298 400 30 30
350 204 315 25
105,5 0.85 380 188 250 25
400 179 224 25
415 172 224 25
440 162 200 25 25
480 149 200 25
600 119 160 18
the US and Canada
A.1.38 00.999.5895/
Specifications
9.3 Printing press with inking unit temperature control and pump and control station
9.3.1 CX 102-4
Printing press with inking unit temperature control (with CombiStar)

and pump and control station
Press version
without DryStar Ink
200 321 400 30 30
220 292 400 30 30
230 279 400 30 30
240 267 400 30 30
350 183 250 25
93,5 0,84 380 169 224 25
400 160 200 25
415 154 200 25
440 146 200 25 25
480 133 200 25
600 107 160 18
CX 102-4
With DryStar Ink
200 386 500 30 30
220 351 500 30 30
230 336 500 30 30
240 322 400 30 30
350 220 315 25
116,5 0,87 380 203 250 25
400 193 250 25
415 186 250 25
440 175 224 25 25
480 161 200 25
600 128 160 18
the US and Canada
00.999.5895/ A.1.39
Specifications
9.3.2 CX 102-4 + L

Press version
without CoatingStar
200 349 500 30 30
220 318 400 30 30
230 304 400 30 30
240 291 400 30 30
350 199 250 25
103,0 0.85 380 184 250 25
400 174 224 25
415 168 224 25
440 159 200 25 25
480 145 200 25
600 116 160 18
CX 102-4 + L
with CoatingStar
200 380 500 30 30
220 345 500 30 30
230 330 500 30 30
240 316 400 30 30
350 217 315 25
112,0 0.85 380 200 250 25
400 190 250 25
415 183 250 25
440 172 224 25 25
480 158 200 25
600 126 160 18
the US and Canada
A.1.40 00.999.5895/
Specifications
9.3.3 CX 102-4 + L (X2) / CX 102-4 + L (X3)

Press version
without CoatingStar
200 372 500 30 30
220 338 500 30 30
230 323 400 30 30
240 310 400 30 30
350 212 315 25
107,0 0,83 380 195 250 25
400 186 250 25
415 179 224 25
440 169 224 25 25
480 155 200 25
CX 102-4 + L (X2) 600 124 160 18
200 398 500 30 30
220 362 500 30 30
230 346 500 30 30
240 332 500 30 30
350 227 315 25
116,0 0,84 380 209 315 25
400 199 250 25
415 192 250 25
440 181 224 25 25
480 166 224 25
600 132 200 18
the US and Canada
00.999.5895/ A.1.41
Specifications

SC.906.1205-000UTKENU_00
10.1.1 CX 102-5

(with HydroStar)
Press version
without DryStar Ink
200 288 400 30 30
220 262 400 30 30
230 251 315 30 30
240 240 315 30 30
350 164 224 25
86,0 0.86 380 151 200 25
400 144 200 25
415 139 200 25
440 131 200 25 25
480 120 160 25
600 96 125 18
CX 102-5
With DryStar Ink
200 357 500 30 30
220 325 500 30 30
230 310 400 30 30
240 297 400 30 30
350 204 315 25
109,0 0,88 380 188 250 25
400 178 224 25
415 172 224 25
440 162 200 25 25
480 148 200 25
600 119 160 18
the US and Canada
A.1.42 00.999.5895/
Specifications
10.1.2 CX 102-5 + L

(with HydroStar)
Press version
without CoatingStar
200 318 400 30 30
220 289 400 30 30
230 277 400 30 30
240 265 400 30 30
350 182 224 25
95,0 0.86 380 167 224 25
400 159 200 25
415 153 200 25
440 144 200 25 25
480 132 200 25
600 106 160 18
CX 102-5 + L
with CoatingStar
200 347 500 30 30
220 315 400 30 30
230 302 400 30 30
240 289 400 30 30
350 198 250 25
103,5 0.86 380 182 224 25
400 173 224 25
415 167 224 25
440 157 200 25 25
480 144 200 25
600 115 160 18
the US and Canada
00.999.5895/ A.1.43
Specifications
10.1.3 CX 102-5 + L (X2) / CX 102-5 + L (X3)

(with HydroStar)
Press version
without CoatingStar
200 332 500 30 30
220 302 400 30 30
230 288 400 30 30
240 276 400 30 30
350 189 250 25
99,0 0.86 380 174 224 25
400 166 224 25
415 160 200 25
440 151 200 25 25
480 138 200 25
CX 102-5 + L (X2) 600 110 160 18
200 362 500 30 30
220 329 500 30 30
230 315 400 30 30
240 302 400 30 30
350 207 315 25
108,0 0.86 380 190 250 25
400 181 224 25
415 174 224 25
440 164 224 25 25
480 151 200 25
600 120 160 18
the US and Canada
A.1.44 00.999.5895/
Specifications
10.2.1 CX 102-5

(with CombiStar)
Press version
without DryStar Ink
200 322 400 30 30
220 293 400 30 30
230 280 400 30 30
240 268 400 30 30
350 184 250 25
95,0 0.85 380 169 224 25
400 161 200 25
415 155 200 25
440 146 200 25 25
480 134 200 25
600 107 160 18
CX 102-5
With DryStar Ink
200 388 500 30 30
220 353 500 30 30
230 338 500 30 30
240 323 400 30 30
350 222 315 25
118,5 0,88 380 204 315 25
400 194 250 25
415 187 250 25
440 176 224 25 25
480 161 200 25
600 129 160 18
the US and Canada
00.999.5895/ A.1.45
Specifications
10.2.2 CX 102-5 + L

(with CombiStar)
Press version
without CoatingStar
200 353 500 30 30
220 321 400 30 30
230 307 400 30 30
240 294 400 30 30
350 201 250 25
104,0 0.85 380 185 250 25
400 176 224 25
415 170 224 25
440 160 200 25 25
480 147 200 25
600 117 160 18
CX 102-5 + L
with CoatingStar
200 383 500 30 30
220 348 500 30 30
230 333 500 30 30
240 319 400 30 30
350 219 315 25
113,0 0.85 380 201 250 25
400 191 250 25
415 184 250 25
440 174 224 25 25
480 159 200 25
600 127 160 18
the US and Canada
A.1.46 00.999.5895/
Specifications
10.2.3 CX 102-5 + L (X2) / CX 102-5 + L (X3)

(with CombiStar)
Press version
without CoatingStar
200 368 500 30 30
220 334 500 30 30
230 320 400 30 30
240 307 400 30 30
350 210 315 25
108,5 0.85 380 193 250 25
400 184 250 25
415 177 224 25
440 167 224 25 25
480 153 200 25
CX 102-5 + L (X2) 600 122 160 18
200 397 500 30 30
220 361 500 30 30
230 345 500 30 30
240 331 500 30 30
350 227 315 25
117,0 0.85 380 209 315 25
400 198 250 25
415 191 250 25
440 180 224 25 25
480 165 224 25
600 132 200 18
the US and Canada
00.999.5895/ A.1.47
Specifications
10.3.1 CX 102-5

Press version
without DryStar Ink
200 362 500 30 30
220 329 500 30 30
230 315 400 30 30
240 302 400 30 30
350 207 315 25
105,5 0,84 380 190 250 25
400 181 224 25
415 174 224 25
440 164 224 25 25
480 151 200 25
600 120 160 18
CX 102-5
With DryStar Ink
200 426 630 30 30
220 387 500 30 30
230 370 500 30 30
240 355 500 30 30
350 243 315 25
128,5 0,87 380 224 315 25
400 213 315 25
415 205 315 25
440 193 250 25 25
480 177 224 25
600 142 200 18
the US and Canada
A.1.48 00.999.5895/
Specifications
10.3.2 CX 102-5 + L

Press version
without CoatingStar
200 393 500 30 30
220 357 500 30 30
230 342 500 30 30
240 327 500 30 30
350 224 315 25
114,5 0,84 380 207 315 25
400 196 250 25
415 189 250 25
440 178 224 25 25
480 163 224 25
600 131 200 18
CX 102-5 + L
with CoatingStar
200 422 630 30 30
220 384 500 30 30
230 367 500 30 30
240 352 500 30 30
350 241 315 25
123,0 0,84 380 222 315 25
400 211 315 25
415 203 250 25
440 192 250 25 25
480 176 224 25
600 140 200 18
the US and Canada
00.999.5895/ A.1.49
Specifications
10.3.3 CX 102-5 + L (X2) / CX 102-5 + L (X3)

Press version
without CoatingStar
200 407 630 30 30
220 370 500 30 30
230 354 500 30 30
240 339 500 30 30
350 232 315 25
118,5 0,84 380 214 315 25
400 203 250 25
415 196 250 25
440 185 250 25 25
480 169 224 25
CX 102-5 + L (X2) 600 135 200 18
200 438 630 30 30
220 398 500 30 30
230 381 500 30 30
240 365 500 30 30
350 250 315 25
127,5 0,84 380 230 315 25
400 219 315 25
415 211 315 25
440 199 250 25 25
480 182 224 25
600 146 200 18
the US and Canada
A.1.50 00.999.5895/
Specifications

SC.906.1206-000UTKENU_00
11.1.1 CX 102-6

(with HydroStar)
Press version
without DryStar Ink
200 318 400 30 30
220 289 400 30 30
230 277 400 30 30
240 265 400 30 30
350 182 224 25
95,0 0.86 380 167 224 25
400 159 200 25
415 153 200 25
440 144 200 25 25
480 132 200 25
600 106 160 18
CX 102-6
With DryStar Ink
200 387 500 30 30
220 351 500 30 30
230 336 500 30 30
240 322 400 30 30
350 221 315 25
118,0 0,88 380 203 250 25
400 193 250 25
415 186 250 25
440 175 224 25 25
480 161 200 25
600 129 160 18
the US and Canada
00.999.5895/ A.1.51
Specifications
11.1.2 CX 102-6 + L

(with HydroStar)
Press version
without CoatingStar
200 349 500 85 85
220 317 400 85 85
230 303 400 85 85
240 290 400 85 85
350 199 250 50
104,0 0.86 380 183 250 50
400 174 224 50
415 168 224 50
440 158 200 35 35
480 145 200 35
600 116 160 25
CX 102-6 + L
with CoatingStar
200 373 500 85 85
220 339 500 85 85
230 324 400 85 85
240 311 400 85 85
350 213 315 50
112,5 0,87 380 196 250 50
400 186 250 50
415 179 224 50
440 169 224 35 35
480 155 200 35
600 124 160 25
the US and Canada
A.1.52 00.999.5895/
Specifications
11.1.3 CX 102-6 + L (X2) / CX 102-6 + L (X3)

(with HydroStar)
Press version
without CoatingStar
200 362 500 85 85
220 329 500 85 85
230 315 400 85 85
240 302 400 85 85
350 207 315 50
108,0 0.86 380 190 250 50
400 181 224 50
415 174 224 50
440 164 224 35 35
480 151 200 35
CX 102-6 + L (X2) 600 120 160 25
200 392 500 85 85
220 357 500 85 85
230 341 500 85 85
240 327 500 85 85
350 224 315 50
117,0 0.86 380 206 315 50
400 196 250 50
415 189 250 50
440 178 224 35 35
480 163 224 35
600 130 160 25
the US and Canada
00.999.5895/ A.1.53
Specifications
11.2.1 CX 102-6

(with CombiStar)
Press version
without DryStar Ink
200 374 500 30 30
220 340 500 30 30
230 325 500 30 30
240 312 400 30 30
350 214 315 25
109,0 0,84 380 197 250 25
400 187 250 25
415 180 224 25
440 170 224 25 25
480 156 200 25
600 124 160 18
CX 102-6
With DryStar Ink
200 439 630 30 30
220 399 500 30 30
230 382 500 30 30
240 366 500 30 30
350 251 315 25
132,5 0,87 380 231 315 25
400 219 315 25
415 211 315 25
440 199 250 25 25
480 183 250 25
600 146 200 18
the US and Canada
A.1.54 00.999.5895/
Specifications
11.2.2 CX 102-6 + L

(with CombiStar)
Press version
without CoatingStar
200 400 500 85 85
220 364 500 85 85
230 348 500 85 85
240 333 500 85 85
350 228 315 50
118,0 0.85 380 210 315 50
400 200 250 50
415 193 250 50
440 182 224 35 35
480 166 224 35
600 133 200 25
CX 102-6 + L
with CoatingStar
200 431 630 85 85
220 392 500 85 85
230 375 500 85 85
240 359 500 85 85
350 246 315 50
127,0 0.85 380 227 315 50
400 215 315 50
415 207 315 50
440 196 250 35 35
480 179 224 35
600 143 200 25
the US and Canada
00.999.5895/ A.1.55
Specifications
11.2.3 CX 102-6 + L (X2) / CX 102-6 + L (X3)

(with CombiStar)
Press version
without CoatingStar
200 420 630 85 85
220 382 500 85 85
230 366 500 85 85
240 350 500 85 85
350 240 315 50
122,5 0,84 380 221 315 50
400 210 315 50
415 202 250 50
440 191 250 35 35
480 175 224 35
CX 102-6 + L (X2) 600 140 200 25
200 444 630 85 85
220 404 500 85 85
230 386 500 85 85
240 370 500 85 85
350 254 315 50
131,0 0.85 380 234 315 50
400 222 315 50
415 214 315 50
440 202 250 35 35
480 185 250 35
600 148 200 25
the US and Canada
A.1.56 00.999.5895/
Specifications
11.3.1 CX 102-6

Press version
without DryStar Ink
200 426 630 30 30
220 387 500 30 30
230 370 500 30 30
240 355 500 30 30
350 243 315 25
122,5 0,83 380 224 315 25
400 213 315 25
415 205 315 25
440 193 250 25 25
480 177 224 25
600 142 200 18
CX 102-6
With DryStar Ink
200 490 630 30 30
220 445 630 30 30
230 426 630 30 30
240 408 630 30 30
350 280 400 25
146,0 0.86 380 257 400 25
400 245 315 25
415 236 315 25
440 222 315 25 25
480 204 315 25
600 163 224 18
the US and Canada
00.999.5895/ A.1.57
Specifications
11.3.2 CX 102-6 + L

Press version
without CoatingStar
200 451 630 85 85
220 410 630 85 85
230 392 500 85 85
240 376 500 85 85
350 258 400 50
131,5 0,84 380 237 315 50
400 225 315 50
415 217 315 50
440 205 315 35 35
480 188 250 35
600 150 200 25
CX 102-6 + L
with CoatingStar
200 482 630 85 85
220 438 630 85 85
230 419 630 85 85
240 402 500 85 85
350 275 400 50
140,5 0,84 380 254 315 50
400 241 315 50
415 232 315 50
440 219 315 35 35
480 201 250 35
600 160 200 25
the US and Canada
A.1.58 00.999.5895/
Specifications
11.3.3 CX 102-6 + L (X2) / CX 102-6 + L (X3)

Press version
without CoatingStar
200 473 630 85 85
220 430 630 85 85
230 411 630 85 85
240 394 500 85 85
350 270 400 50
136,0 0,83 380 248 315 50
400 236 315 50
415 227 315 50
440 215 315 35 35
480 197 250 35
CX 102-6 + L (X2) 600 157 200 25
200 502 630 85 85
220 456 630 85 85
230 437 630 85 85
240 418 630 85 85
350 287 400 50
144,5 0,83 380 264 400 50
400 251 315 50
415 242 315 50
440 228 315 35 35
480 209 315 35
600 167 224 25
the US and Canada
00.999.5895/ A.1.59
Specifications

SC.906.1207-000UTKENU_00
12.1.1 CX 102-7

(with HydroStar)
Press version
without DryStar Ink
200 354 500 85 85
220 321 400 85 85
230 307 400 85 85
240 295 400 85 85
350 202 250 50
105,5 0.86 380 186 250 50
400 177 224 50
415 170 224 50
440 160 200 35 35
480 147 200 35
600 118 160 25
CX 102-7
With DryStar Ink
200 421 630 85 85
220 383 500 85 85
230 366 500 85 85
240 351 500 85 85
350 240 315 50
128,5 0,88 380 221 315 50
400 210 315 50
415 203 250 50
440 191 250 35 35
480 175 224 35
600 140 200 25
the US and Canada
A.1.60 00.999.5895/
Specifications
12.1.2 CX 102-7 + L

(with HydroStar)
Press version
without CoatingStar
200 382 500 85 85
220 347 500 85 85
230 332 500 85 85
240 318 400 85 85
350 218 315 50
114,0 0.86 380 201 250 50
400 191 250 50
415 184 250 50
440 173 224 35 35
480 159 200 35
600 127 160 25
CX 102-7 + L
with CoatingStar
200 411 630 85 85
220 373 500 85 85
230 357 500 85 85
240 342 500 85 85
350 234 315 50
122,5 0.86 380 216 315 50
400 205 315 50
415 198 250 50
440 186 250 35 35
480 171 224 35
600 137 200 25
the US and Canada
00.999.5895/ A.1.61
Specifications
12.1.3 CX 102-7 + L (X2) / CX 102-7 + L (X3)

(with HydroStar)
Press version
without CoatingStar
200 400 500 85 85
220 364 500 85 85
230 348 500 85 85
240 333 500 85 85
350 228 315 50
118,0 0.85 380 210 315 50
400 200 250 50
415 193 250 50
440 182 224 35 35
480 166 224 35
CX 102-7 + L (X2) 600 133 200 25
200 431 630 85 85
220 392 500 85 85
230 375 500 85 85
240 359 500 85 85
350 246 315 50
127,0 0.85 380 227 315 50
400 215 315 50
415 207 315 50
440 196 250 35 35
480 179 224 35
600 143 200 25
the US and Canada
A.1.62 00.999.5895/
Specifications
12.2.1 CX 102-7

(with CombiStar)
Press version
without DryStar Ink
200 412 630 85 85
220 375 500 85 85
230 358 500 85 85
240 343 500 85 85
350 235 315 50
121,5 0.85 380 217 315 50
400 206 315 50
415 198 250 50
440 187 250 35 35
480 171 224 35
600 137 200 25
CX 102-7
With DryStar Ink
200 479 630 85 85
220 435 630 85 85
230 416 630 85 85
240 399 500 85 85
350 273 400 50
144,5 0,87 380 252 315 50
400 239 315 50
415 231 315 50
440 217 315 35 35
480 199 250 35
600 159 200 25
the US and Canada
00.999.5895/ A.1.63
Specifications
12.2.2 CX 102-7 + L

(with CombiStar)
Press version
without CoatingStar
200 441 630 85 85
220 401 500 85 85
230 383 500 85 85
240 367 500 85 85
350 252 315 50
130,0 0.85 380 232 315 50
400 220 315 50
415 212 315 50
440 200 250 35 35
480 183 250 35
600 147 200 25
CX 102-7 + L
with CoatingStar
200 472 630 85 85
220 429 630 85 85
230 410 630 85 85
240 393 500 85 85
350 269 400 50
139,0 0.85 380 248 315 50
400 236 315 50
415 227 315 50
440 214 315 35 35
480 196 250 35
600 157 200 25
the US and Canada
A.1.64 00.999.5895/
Specifications
12.2.3 CX 102-7 + L (X2) / CX 102-7 + L (X3)

(with CombiStar)
Press version
without CoatingStar
200 462 630 85 85
220 420 630 85 85
230 401 500 85 85
240 385 500 85 85
350 264 400 50
134,5 0,84 380 243 315 50
400 231 315 50
415 222 315 50
440 210 315 35 35
480 192 250 35
CX 102-7 + L (X2) 600 154 200 25
200 491 630 85 85
220 446 630 85 85
230 427 630 85 85
240 409 630 85 85
350 280 400 50
143,0 0,84 380 258 400 50
400 245 315 50
415 236 315 50
440 223 315 35 35
480 204 315 35
600 163 224 25
the US and Canada
00.999.5895/ A.1.65
Specifications
12.3.1 CX 102-7

Press version
without DryStar Ink
200 463 630 85 85
220 421 630 85 85
230 403 500 85 85
240 386 500 85 85
350 265 400 50
135,0 0,84 380 244 315 50
400 231 315 50
415 223 315 50
440 210 315 35 35
480 193 250 35
600 154 200 25
CX 102-7
With DryStar Ink
200 532 800 85 85
220 483 630 85 85
230 462 630 85 85
240 443 630 85 85
350 304 400 50
158,5 0.86 380 280 400 50
400 266 400 50
415 256 400 50
440 241 315 35 35
480 221 315 35
600 177 224 25
the US and Canada
A.1.66 00.999.5895/
Specifications
12.3.2 CX 102-7 + L

Press version
without CoatingStar
200 493 630 85 85
220 448 630 85 85
230 428 630 85 85
240 410 630 85 85
350 281 400 50
143,5 0,84 380 259 400 50
400 246 315 50
415 237 315 50
440 224 315 35 35
480 205 315 35
600 164 224 25
CX 102-7 + L
with CoatingStar
200 524 800 85 85
220 476 630 85 85
230 455 630 85 85
240 436 630 85 85
350 299 400 50
152,5 0,84 380 275 400 50
400 262 400 50
415 252 315 50
440 238 315 35 35
480 218 315 35
600 174 224 25
the US and Canada
00.999.5895/ A.1.67
Specifications
12.3.3 CX 102-7 + L (X2) / CX 102-7 + L (X3)

Press version
without CoatingStar
200 514 800 85 85
220 467 630 85 85
230 447 630 85 85
240 428 630 85 85
350 294 400 50
148,0 0,83 380 270 400 50
400 257 400 50
415 248 315 50
440 233 315 35 35
480 214 315 35
CX 102-7 + L (X2) 600 171 224 25
200 544 800 85 85
220 494 630 85 85
230 473 630 85 85
240 453 630 85 85
350 311 400 50
156,5 0,83 380 286 400 50
400 272 400 50
415 262 400 50
440 247 315 35 35
480 226 315 35
600 181 224 25
the US and Canada
A.1.68 00.999.5895/
Specifications

SC.906.1208-000UTKENU_00
13.1.1 CX 102-8

(with HydroStar)
Press version
without DryStar Ink
200 384 500 85 85
220 349 500 85 85
230 334 500 85 85
240 320 400 85 85
350 219 315 50
114,5 0.86 380 202 250 50
400 192 250 50
415 185 250 50
440 174 224 35 35
480 160 200 35
600 128 160 25
CX 102-8
With DryStar Ink
200 451 630 85 85
220 410 630 85 85
230 392 500 85 85
240 375 500 85 85
350 257 400 50
137,5 0,88 380 237 315 50
400 225 315 50
415 217 315 50
440 205 315 35 35
480 187 250 35
600 150 200 25
the US and Canada
00.999.5895/ A.1.69
Specifications
13.1.2 CX 102-8 + L

(with HydroStar)
Press version
without CoatingStar
200 414 630 85 85
220 376 500 85 85
230 360 500 85 85
240 345 500 85 85
350 236 315 50
123,5 0.86 380 218 315 50
400 207 315 50
415 199 250 50
440 188 250 35 35
480 172 224 35
600 138 200 25
CX 102-8 + L
with CoatingStar
200 443 630 85 85
220 402 500 85 85
230 385 500 85 85
240 369 500 85 85
350 253 315 50
132,0 0.86 380 233 315 50
400 221 315 50
415 213 315 50
440 201 250 35 35
480 184 250 35
600 147 200 25
the US and Canada
A.1.70 00.999.5895/
Specifications
13.1.3 CX 102-8 + L (X2) / CX 102-8 + L (X3)

(with HydroStar)
Press version
without CoatingStar
200 433 630 85 85
220 393 500 85 85
230 376 500 85 85
240 360 500 85 85
350 247 315 50
127,5 0.85 380 227 315 50
400 216 315 50
415 208 315 50
440 196 250 35 35
480 180 224 35
CX 102-8 + L (X2) 600 144 200 25
200 458 630 85 85
220 416 630 85 85
230 398 500 85 85
240 381 500 85 85
350 261 400 50
136,5 0.86 380 241 315 50
400 229 315 50
415 220 315 50
440 208 315 35 35
480 190 250 35
600 152 200 25
the US and Canada
00.999.5895/ A.1.71
Specifications
13.2.1 CX 102-8

(with CombiStar)
Press version
without DryStar Ink
200 443 630 85 85
220 402 500 85 85
230 385 500 85 85
240 369 500 85 85
350 253 315 50
130,5 0.85 380 233 315 50
400 221 315 50
415 213 315 50
440 201 250 35 35
480 184 250 35
600 147 200 25
CX 102-8
With DryStar Ink
200 509 630 85 85
220 463 630 85 85
230 442 630 85 85
240 424 630 85 85
350 291 400 50
153,5 0,87 380 268 400 50
400 254 315 50
415 245 315 50
440 231 315 35 35
480 212 315 35
600 169 224 25
the US and Canada
A.1.72 00.999.5895/
Specifications
13.2.2 CX 102-8 + L

(with CombiStar)
Press version
without CoatingStar
200 473 630 85 85
220 430 630 85 85
230 411 630 85 85
240 394 500 85 85
350 270 400 50
139,5 0.85 380 249 315 50
400 236 315 50
415 228 315 50
440 215 315 35 35
480 197 250 35
600 157 200 25
CX 102-8 + L
with CoatingStar
200 504 630 85 85
220 458 630 85 85
230 438 630 85 85
240 420 630 85 85
350 288 400 50
148,5 0.85 380 265 400 50
400 252 315 50
415 243 315 50
440 229 315 35 35
480 210 315 35
600 168 224 25
the US and Canada
00.999.5895/ A.1.73
Specifications
13.2.3 CX 102-8 + L (X2) / CX 102-8 + L (X3)

(with CombiStar)
Press version
without CoatingStar
200 494 630 85 85
220 449 630 85 85
230 430 630 85 85
240 412 630 85 85
350 282 400 50
144,0 0,84 380 260 400 50
400 247 315 50
415 238 315 50
440 224 315 35 35
480 206 315 35
CX 102-8 + L (X2) 600 164 224 25
200 517 800 85 85
220 470 630 85 85
230 450 630 85 85
240 431 630 85 85
350 295 400 50
152,5 0.85 380 272 400 50
400 258 400 50
415 249 315 50
440 235 315 35 35
480 215 315 35
600 172 224 25
the US and Canada
A.1.74 00.999.5895/
Specifications
13.3.1 CX 102-8

Press version
without DryStar Ink
200 494 630 85 85
220 449 630 85 85
230 430 630 85 85
240 412 630 85 85
350 282 400 50
144,0 0,84 380 260 400 50
400 247 315 50
415 238 315 50
440 224 315 35 35
480 206 315 35
600 164 224 25
CX 102-8
With DryStar Ink
200 562 800 85 85
220 511 630 85 85
230 488 630 85 85
240 468 630 85 85
350 321 400 50
167,5 0.86 380 295 400 50
400 281 400 50
415 270 400 50
440 255 315 35 35
480 234 315 35
600 187 250 25
the US and Canada
00.999.5895/ A.1.75
Specifications
13.3.2 CX 102-8 + L

Press version
without CoatingStar
200 532 800 85 85
220 483 630 85 85
230 462 630 85 85
240 443 630 85 85
350 304 400 50
153,0 0,83 380 280 400 50
400 266 400 50
415 256 400 50
440 241 315 35 35
480 221 315 35
600 177 224 25
CX 102-8 + L
with CoatingStar
200 556 800 85 85
220 506 630 85 85
230 484 630 85 85
240 463 630 85 85
350 318 400 50
162,0 0,84 380 293 400 50
400 278 400 50
415 268 400 50
440 253 315 35 35
480 231 315 35
600 185 250 25
the US and Canada
A.1.76 00.999.5895/
Specifications
13.3.3 CX 102-8 + L (X2) / CX 102-8 + L (X3)

Press version
without CoatingStar
200 547 800 85 85
220 497 630 85 85
230 476 630 85 85
240 456 630 85 85
350 313 400 50
157,5 0,83 380 288 400 50
400 273 400 50
415 263 400 50
440 248 315 35 35
480 228 315 35
CX 102-8 + L (X2) 600 182 224 25
200 570 800 85 85
220 518 800 85 85
230 496 630 85 85
240 475 630 85 85
350 325 500 50
166,0 0,84 380 300 400 50
400 285 400 50
415 274 400 50
440 259 400 35 35
480 237 315 35
600 190 250 25
the US and Canada
00.999.5895/ A.1.77
Specifications
14 Electrical connection specifications of the DryStar IR dryers

SC.906.1108-000UTKENU_00
14.1 Electrical connection specifications of the DryStar IR dryers

Mains connection of the DryStar infrared dryers
The IR dryers DryStar Coating and DryStar Combina‐
tion are connected separately to the three-phase AC
mains.
The operating voltage of the DryStar IR dryers is
AC 400 V.
A direct connection is possible with a mains frequen‐
cy of 50 Hz and mains voltage of AC 380, 400, and
415 V. Otherwise you will have to make adjustments
to meet the corresponding mains power. The adapta‐
tion is made via series transformers and matching
transformers.
Dryer version Power required [kW] Power factor λ Mains voltages of Electrical fusing [A]
the three-phase
mains [V]
200, 220 200
230, 240 160
350 125
DryStar Coating 50,7 0,995
380, 400, 415, 440 100
480 80
600 63
200 315
220, 230, 240 250
DryStar Combination 350, 380, 400 160
71,6 0,995
with two slide-in units
415, 440, 480 125
600 100
200, 220, 230, 240 400

350, 380 250
DryStar Combination
105,5 0,995 400, 415, 440 200
with three slide-in units
480, 600 160
Tab. 79 Electrical connection specifications of the DryStar IR dryers
A.1.78 00.999.5895/
Specifications
15 Specifications of the peripheral equipment

SC.906.1109-000UTKENU_00

● The dimensions and weights of the peripheral
units and exhaust hoods are listed in the chap‐
ter Dimensions and weights of the peripheral
units.
● The power demand of the peripheral equipment
is included in the overall power demand of the
printing press (see chapters Electrical connec‐
tion specifications, printing press with 4 printing
units ... Electrical connection specifications,
printing press with 8 printing units).
Exceptions:
○ The Prinect peripheral unit "Prinect Image
Control" requires a separate AC mains con‐
nection.
○ The IR dryers DryStar Coating and Dry‐
Star Combination require a separate three-
phase AC mains connection (see chapter
Electrical connection specifications of the
DryStar IR dryers).
● Always restore the exhaust air volume (cooling
air, process air) via the supply air.
● The exhaust air from the process is polluted
with emission. Always guide the exhaust air out
of the pressroom.
● The entries regarding the power requirement,
waste heat, heating output, cooling output, vol‐
ume of exhaust air and noise emission are max‐
imum values.
● Fresh water connection of all dampening units:
Ø 12 mm (0.47 in) (hose socket).
Version Power required [kW] Mains voltages of the AC Electrical fusing [A]
mains [V]
50 Hz 60 Hz
Prinect Press Center 1.5 1.5 Power supply via the central control cabinet
Prinect Press Center with 1.5 1.5 Power supply via the central control cabinet
Prinect Axis Control
Prinect Inpress Control 1,4 1,4 Power supply via the central control cabinet
Prinect Image Control 2.7 2.7 115/230 16
Prinect Autoregister - - Power supply via Prinect Press Center
Tab. 80 Electrical connection values
00.999.5895/ A.1.79
Specifications
15.3 AirStar (suction and blast air supply)
15.3.1 Air-cooled version (LGK)
Version Power required (1) [kW] Waste heat power [kW]

50 Hz 60 Hz 50 Hz 60 Hz
AirStar A1-R1-L 17,8 19,9 12.5 15,0
AirStar A1-R2-L 26,0 28,1 15,0 17,5
Tab. 81 Power required and waste heat capacity
(1): The power demand of the AirStar is included in
the overall power demand of the printing press (see
chapter Electrical connection specifications, printing
press with 4 printing units ... Electrical connection
specifications, printing press with 8 printing units).
Version Outlet air volume (1) [m3/h] ([cu ft/min]) Noise emission [dB(A)]
50 Hz 60 Hz
AirStar A1-R1-L 2400 (1415) 3100 (1825) 75
AirStar A1-R2-L 2400 (1415) 3100 (1825) 77
Tab. 82 Volume of exhaust air and noise emission
(1): The exhaust air volume consists of cooling air
and process air in the standard state
(p0 = 1013 mbars (14.7 psi), T0 = 20°C (68°F)).
15.3.2 Water-cooled version

50 Hz 60 Hz 50 Hz 60 Hz
AirStar A1-R1-W 21,5 24,3 12.5 15,0
AirStar A1-R2-W 29,7 32,5 15,0 17,5
(1): The power demand of the AirStar is included in
chapter Electrical connection specifications, printing
Version Cooling water connection Maximum cooling water Noise emission [dB(A)]
(inside thread) pressure [bar] ([psi])
AirStar A1-R1-W 1" 10 (145) 73
AirStar A1-R2-W 1" 10 (145) 75
Tab. 84 Cooling water connection, cooling water pressure, and noise emission
Version Cooling water requirement [m3/h] ([cu ft/min]) at an inlet temperature of

10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
AirStar A1-R1-W 50 Hz 0.30 (0.18) 0.40 (0.24) 0.60 (0.35) 1.35 (0.79)
A.1.80 00.999.5895/
Specifications

10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
60 Hz 0.35 (0.21) 0.45 (0.26) 0.65 (0.38) 1.45 (0.85)
50 Hz 0.35 (0.21) 0.45 (0.26) 0.65 (0.38) 1.45 (0.85)
AirStar A1-R2-W
60 Hz 0.40 (0.24) 0.50 (0.29) 0.70 (0.41) 1.70 (1.00)
Tab. 85 Cooling water required
Version Pressure drop Δp in the refrigeration cycle [bar] ([psi]) at a volumetric flow of
1.0 m3/h (0.59 cu ft/min) 2.0 m3/h (1.18 cu ft/min) 3.0 m3/h (1.77 cu ft/min)
AirStar A1-R1-W 0.3 (4.35) 1.0 (14.50) 2.1 (30.46)
AirStar A1-R2-W 0.3 (4.35) 1.0 (14.50) 2.1 (30.46)
Tab. 86 Pressure drop Δp in the refrigeration cycle
15.4 ScrollStar (compressed-air supply)
Version Power required (1) [kW] Cooling air outlet volume [m3/h] ([cu ft/min])
ScrollStar 3,7 720 (425)
Tab. 87 Power required and cooling air outlet volume
(1): The power demand of the ScrollStar is included
in the overall power demand of the printing press
(see chapters Electrical connection specifications,
printing press with 4 printing units ... Electrical con‐
nection specifications, printing press with 8 printing
units).
Version Maximum operating pres‐ Volumetric flow [m3/h] Noise emission [dB(A)]
sure [bar] ([psi]) ([cu ft/min])
ScrollStar 10 (145) 15 (8.83) ≤ 56
Tab. 88 Maximum pressure, volume flow and noise emission
Version Power required (1) [kW] Waste heat power [kW] Cooling capaci‐
ty [kW]
50 Hz 60 Hz (2) 50 Hz 60 Hz
beta.d 40 L 3,3 4,4 7 9 4
beta.d 60 L 4,0 5,3 10 12 6
beta.d 100 L 5,8 7,3 15 17 10
Tab. 89 Power demand, waste heat power and cooling capacity
(1): The power demand of the HydroStar is included
(see chapter Electrical connection specifications,
00.999.5895/ A.1.81
Specifications

units).
(2): Peripheral units designed for a mains frequency
of 60 Hz may also be used with a mains frequency of
50 Hz.
Version Cooling air outlet volume [m3/h] ([cu ft/min]) Noise emission [dB(A)]
50 Hz 60 Hz
beta.d 40 L 4000 (2355) 4500 (2650) ≤ 73
beta.d 60 L 4000 (2355) 4500 (2650) ≤ 73
beta.d 100 L 4200 (2475) 4800 (2825) ≤ 73
Tab. 90 Cooling air outlet volume and noise emission
Version Power required (1) [kW] Waste heat power [kW] Cooling capaci‐
ty [kW]
50 Hz 60 Hz (2) 50 Hz 60 Hz
beta.d 40 G 2,8 3,7 7 9 4
beta.d 60 G 3,6 4,6 10 12 6
beta.d 100 G 5,3 6,6 15 17 10
Tab. 91 Power demand, waste heat power and cooling capacity
(1): The power demand of the HydroStar is included
units).
50 Hz.
beta.d 40 G 3
/4" 10 (145) ≤ 73
beta.d 60 G 3
/4" 10 (145) ≤ 73
beta.d 100 G 3
/4" 10 (145) ≤ 73
Tab. 92 Cooling water connection, cooling water pressure, and noise emission

10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
50 Hz 0.26 (0.15) 0.41 (0.24) 1.00 (0.59) 1.00 (0.59)
beta.d 40 G
60 Hz 0.33 (0.19) 0.53 (0.31) 1.29 (0.76) 1.29 (0.76)
50 Hz 0.37 (0.22) 0.59 (0.35) 1.43 (0.84) 1.43 (0.84)
beta.d 60 G
60 Hz 0.37 (0.22) 0.59 (0.35) 1.43 (0.84) 1.43 (0.84)
beta.d 100 G 50 Hz 0.56 (0.33) 0.88 (0.52) 2.14 (1.26) 2.14 (1.26)
A.1.82 00.999.5895/
Specifications

10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
60 Hz 0.56 (0.33) 0.88 (0.52) 2.14 (1.26) 2.14 (1.26)
Tab. 93 Cooling water required
Version Pressure drop Δp in the refrigeration cycle [bar] ([psi]) at an inlet temperature of
10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
50 Hz 1.0 (14.5) 1.0 (14.5) 2.0 (29.0) 2.0 (29.0)
beta.d 40 G
60 Hz 1.0 (14.5) 1.1 (16.0) 2.1 (30.5) 2.1 (30.5)
50 Hz 1.0 (14.5) 1.2 (17.4) 2.2 (31.9) 2.2 (31.9)
beta.d 60 G
60 Hz 1.0 (14.5) 1.2 (17.4) 2.2 (31.9) 2.2 (31.9)
50 Hz 1.0 (14.5) 1.5 (21.8) 2.5 (36.3) 2.5 (36.3)
beta.d 100 G
60 Hz 1.0 (14.5) 1.5 (21.8) 2.5 (36.3) 2.5 (36.3)
Tab. 94 Pressure drop Δp in the refrigeration cycle

50 Hz 60 Hz (2) 50 Hz 60 Hz
beta.c 130 L 13,0 16,8 20 23
beta.c 170 L 18,9 23,2 27 32
beta.c 220 L 21,3 28,2 35 41
beta.c 280 L 23,0 30,1 43 52
(1): The power demand of the CombiStar is included
units).
50 Hz.
Version Cooling capacity [kW] Heat output of temperature

control circuit [kW]
50 Hz 60 Hz
beta.c 130 L 13 15 3
beta.c 170 L 17 19 6
beta.c 220 L 22 25 9
beta.c 280 L 28 32 9
Tab. 96 Heat output and cooling capacity
00.999.5895/ A.1.83
Specifications
Version Cooling air outlet volume [m3/h] ([cu ft/min]) Noise emission [dB(A)]
50 Hz 60 Hz
beta.c 130 L 7000 (4120) 8000 (4710) ≤ 73
beta.c 170 L 7000 (4120) 8000 (4710) ≤ 73
beta.c 220 L 13000 (7660) 14500 (8540) ≤ 73
beta.c 280 L 13000 (7660) 14500 (8540) ≤ 73
Tab. 97 Cooling air outlet volume and noise emission

50 Hz 60 Hz (2) 50 Hz 60 Hz
beta.c 130 G 12,2 15,5 20 23
beta.c 170 G 18,1 22,0 27 32
beta.c 220 G 19,7 25,7 35 41
beta.c 280 G 21,5 27,6 43 52
(1): The power demand of the CombiStar is included
units).
50 Hz.
Version Cooling capacity [kW] Heat output of temperature

control circuit [kW]
50 Hz 60 Hz
beta.c 130 G 13 15 3
beta.c 170 G 17 19 6
beta.c 220 G 22 25 9
beta.c 280 G 28 32 9
Tab. 99 Waste heat power and cooling capacity
beta.c 130 G 1" 10 (145) ≤ 73
beta.c 170 G 1" 10 (145) ≤ 73
beta.c 220 G 1 1/4" 10 (145) ≤ 73
beta.c 280 G 1 1/4" 10 (145) ≤ 73
Tab. 100Cooling water connection, cooling water pressure, and noise emission
A.1.84 00.999.5895/
Specifications

10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
50 Hz 0.74 (0.44) 1.18 (0.69) 2.86 (1.68) 2.86 (1.68)
beta.c 130 G
60 Hz 0.85 (0.50) 1.35 (0.79) 3.29 (1.94) 3.29 (1.94)
50 Hz 1.00 (0.59) 1.59 (0.94) 3.86 (2.27) 3.86 (2.27)
beta.c 170 G
60 Hz 1.19 (0.70) 1.88 (1.11) 4.57 (2.67) 4.57 (2.67)
50 Hz 1.30 (0.77) 2.06 (1.21) 5.00 (2.94) 5.00 (2.94)
beta.c 220 G
60 Hz 1.52 (0.89) 2.41 (1.42) 5.86 (3.45) 5.86 (3.45)
50 Hz 1.59 (0.94) 2.53 (1.49) 6.14 (3.61) 6.14 (3.61)
beta.c 280 G
60 Hz 1.93 (1.14) 3.06 (1.80) 7.43 (4.37) 7.43 (4.37)
Tab. 101Cooling water required
Version Pressure drop Δp in the refrigeration cycle [bar] ([psi]) at an inlet temperature of
10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
50 Hz 1.0 (14.5) 1.0 (14.5) 2.0 (29.0) 2.0 (29.0)
beta.c 130 G
60 Hz 1.0 (14.5) 1.1 (16.0) 2.5 (36.3) 2.5 (36.3)
50 Hz 1.0 (14.5) 1.7 (24.7) 2.7 (39.2) 2.7 (39.2)
beta.c 170 G
60 Hz 1.0 (14.5) 1.8 (26.1) 3.3 (47.9) 3.3 (47.9)
50 Hz 1.0 (14.5) 1.3 (18.9) 2.3 (33.4) 2.3 (33.4)
beta.c 220 G
60 Hz 1.0 (14.5) 1.4 (20.3) 2.8 (40.6) 2.8 (40.6)
50 Hz 1.0 (14.5) 2.0 (29.0) 3.0 (43.5) 3.0 (43.5)
beta.c 280 G
60 Hz 1.0 (14.5) 2.1 (30.5) 3.5 (50.8) 3.5 (50.8)
Tab. 102Pressure drop Δp in the refrigeration cycle
Version Power required (1) [kW] Compressed air require‐ Noise emission [dB(A)]
ment [bar] ([psi])
WashStar I 0,5 6.0...6.5 (87...94) 70
WashStar II (2) 0,5 6.0...6.5 (87...94) 70
Tab. 103Power required, compressed air requirement, and noise emission
(1): The power demand of the WashStar is included
(see chapters Electrical connection specifications,
units).
(2): Additional equipment for printing presses with 7
or more printing units.
00.999.5895/ A.1.85
Specifications
Version Power required (1) [kW] Recirculation capacity [dm3/ Noise emission [dB(A)]
h] ([cu ft/h])
FilterStar Compact 0,6 900 (31.78) 50
Tab. 104Power demand, recirculation capacity and noise emission
(1): The power demand of the FilterStar Compact is
included in the overall power demand of the printing
press (see chapters Electrical connection specifica‐
tions, printing press with 4 printing units ... Electrical
connection specifications, printing press with 8 print‐
ing units).
Version Power required (1) [kW] Maximum filtration Noise emission

capacity [dm3/h] [dB(A)]
50 Hz 60 Hz
([cu ft/h])
FilterStar beta.f 0,49 0,56 800 (28.25) ≤ 73
Tab. 105Power demand, max. filtration capacity and noise emission
(1): The power demand of the FilterStar is included in
chapters Electrical connection specifications, printing
Version Power required (1) [kW] Heating capaci‐ Maximum dis‐ Noise emission
ty [kW] placed vol‐ [dB(A)]
50 Hz 60 Hz
ume (2) [dm3/h]
([cu ft/h])
LVG-550E 0,34 0,46 - 450 (15.89) 68
LVG-550E UV 0,34 0,46 - 450 (15.89) 68
CoatingStar Compact 1,2 1,2 - 600 (21.19) ≤ 73
CoatingStar 10,9 10,9 9,0 600 (21.19) ≤ 73
Tab. 106Power demand, heat output, max. delivery volume and noise emission
(1): The power demand of the varnish supply unit is
press (see chapter Electrical connection specifica‐
ing units).
(2): Related to water of 20 °C (68 °F).
A.1.86 00.999.5895/
Specifications
15.11 Powder spray devices
Technical characteristics WEKO

PowderStar AP 232 PowderStar AP 262 PowderStar AP 500
ON/OFF operation via the Prinect
× × ×
Press Center
Sheet length adap‐ manually

tation automatic × × ×
manually on the
×
device
Powder volume
metering electronically via
the Prinect × ×
Press Center
Automatic speed compensation of the
× × ×
powder volume (1)
visually on the de‐
vice (inspection × × ×
Powder level mon‐ glass)
itoring electronically via
the Prinect × × ×
Press Center
Powder refill in non-stop operation × × ×
visually on the de‐
× × ×
Monitoring the vice
compressed-air electronically via
supply the Prinect × × ×
Press Center
manually on the
×
device
Format width ad‐
justment electronically via
the Prinect × ×
Press Center
Tab. 107Powder spray devices
(1): Adjustment of the delivered powder volume to
the production speed of the printing press.
Version Power required (1) [kW] Noise emission [dB(A)]

Exhaust air cleaning cabi‐ 4 74
net
Tab. 108Power requirement and noise emission
(1): The power demand of the CleanStar is included
00.999.5895/ A.1.87
Specifications

units).
Process exhaust-air volume

On printing presses of the CX 102 product line, the
peripheral equipment CleanStar and DryStar have
common exhaust air interfaces. The process exhaust
air volume of the CleanStar is therefore specified in
the sections CleanStar and DryStar process exhaust
air volumes.
15.13.1 Common data (air-cooled version and water-cooled version)
Version Power required [kW] Waste heat pow‐ Noise emission

er [kW] [dB(A)]
DryStar Ink 24.0 (1) 6 ≤ 74
DryStar Coating 50.7 (2) 8 ≤ 74
DryStar Combination with two slide-in units 71.6 (2) 13 ≤ 74
DryStar Combination with three slide-in units 105.5 (2) 15 ≤ 74
Tab. 109Power demand, waste heat power and noise emission
(1): The power demand of the DryStar Ink IR dryer is
press (see chapters Electrical connection specifica‐
ing units).
(2): The IR dryers DryStar Coating and DryStar Com‐
bination require a separate three-phase AC mains
connection. You can find further details about the pow‐
er demand of the DryStar IR dryers in the chapter
Electrical connection specifications of the DryStar IR
dryers.
Process exhaust-air volume

common exhaust air interfaces. The process exhaust
air volumes of the DryStar IR dryers are therefore
specified in the section CleanStar and DryStar proc‐
ess exhaust air volumes.
Version Cooling air outlet volume [m3/h] ([cu ft/min])

DryStar Ink 600 (355)
DryStar Coating 1800 (1060)
DryStar Combination with two slide-in units 2800 (1650)
A.1.88 00.999.5895/
Specifications
Version Cooling air outlet volume [m3/h] ([cu ft/min])

DryStar Combination with three slide-in units 2800 (1650)
Tab. 110Volume of cooling exhaust air
Version Cooling water connection (inside Maximum cooling water pres‐

thread) sure [bar] ([psi])
DryStar Ink 1" 10 (145)
DryStar Coating 1" 10 (145)
DryStar Combination with two slide-in units 1" 10 (145)
DryStar Combination with three slide-in units 1" 10 (145)
Tab. 111Cooling water connection and cooling water pressure
Version Cooling water requirement [m3/h] ([cu ft/min]) at an inlet tempera‐

ture of
10 °C (50 °F) 20 °C (68 °F) 30 °C (86 °F) 40 °C (104 °F)
DryStar Ink 0.31 (0.18) 0.31 (0.18) 0.46 (0.27) 0.83 (0.49)
DryStar Coating 0.61 (0.36) 0.61 (0.36) 0.92 (0.54) 1.66 (0.98)
DryStar Combination with two slide-in units 0.66 (0.39) 0.66 (0.39) 1.00 (0.59) 1.80 (1.06)
DryStar Combination with three slide-in units 0.76 (0.45) 0.76 (0.45) 1.15 (0.68) 2.08 (1.22)
Tab. 112Cooling water required
15.14 CleanStar and DryStar process exhaust air volumes

common exhaust air interfaces. This section speci‐
fies the process exhaust air volumes of the individual
press configurations.
15.14.1 Printing press without coating unit

Printing press without DryStar Ink
Press version Version Process exhaust air volume [m3/h]

([cu ft/min])
Printing press with CleanStar Compact Exhaust air collecting box 1350 (795)
Printing press with CleanStar Exhaust air cleaning cabinet 1500 (885)
Tab. 113Process exhaust air volumes without DryStar Ink
Printing press with DryStar Ink
Press version Waste heat pow‐ Version Process exhaust air vol‐
er (1) [kW] ume [m3/h] ([cu ft/min])
Printing press without CleanStar Com‐
- - 400 (235)
pact or CleanStar
Printing press with CleanStar Compact 8 Exhaust air collecting box 1350 (795)
00.999.5895/ A.1.89
Specifications
Printing press with CleanStar Exhaust air cleaning cabi‐
9 1500 (885)
net
Tab. 114Process exhaust air volumes with DryStar Ink
(1): Maximum waste heat power that must be dissipat‐
ed via the exhaust air collecting box or the exhaust
air cleaning cabinet at maximum dryer output.
Note
The specified waste heat power values
are maximum values at highest power
rating. For individual jobs, there is sig‐
nificantly less waste heat power in prac‐
tice.
15.14.2 Printing press with coating unit and delivery without extension module
Printing press with DryStar Coating
Printing press without CleanStar Com‐
10 - -
pact or CleanStar
Printing press with CleanStar Exhaust air cleaning cabi‐
12 1800 (1060)
net
Tab. 115Process exhaust air volume with DryStar Coating
ed via the exhaust air collecting box or the exhaust
Note
tice.
15.14.3 Printing press with coating unit and extended delivery

Printing press with DryStar Combination with two
slide-in units
Exhaust air cleaning cabi‐
net 2400 (1415)
Printing press with CleanStar 40 (powder suction removal)
Exhaust air collecting box 2000 (1175)
A.1.90 00.999.5895/
Specifications
(dryer suction removal)
Tab. 116Process exhaust air volume with DryStar Combination with two slide-in units
ed via the exhaust air collecting box and the exhaust
Note
tice.
Printing press with DryStar Combination with three
slide-in units
Exhaust air cleaning cabi‐
net 2400 (1415)
Printing press with CleanStar 40 (powder suction removal)
Exhaust air collecting box
2000 (1885)
(dryer suction removal)
Tab. 117Process exhaust air volume with DryStar Combination with three slide-in units
ed via the exhaust air collecting box and the exhaust
Note
tice.
Version Power required (1) [kW] Traveling speed [cm/ Noise emission [dB(A)]
min] ([in/min])
InkStar 0,014 150 (59.1) ≤ 75
Tab. 118Power demand, moving speed and noise emission
(1): The power demand of the InkStar is included in
the overall power demand of the printing press
(please refer to the chapters Electrical connection
specifications, printing press with 4 printing units ...
Electrical connection specifications, printing press
with 8 printing units).
● Compressed air:
00.999.5895/ A.1.91
Specifications
Supply pressure 5.5...6.5 bars (80...95 psi)

Operating pressure max. 6.5 bars (95 psi)
● Maximum traverse path of the metering unit:
1031 mm (40.59 in)
● Use only the standardized 2-kg valve cartridges
for the automatic ink supply InkStar. Cross-slot‐
ted cartridges are not suitable.
A.1.92 00.999.5895/
Specifications
16 Printing press configuration

SC.906.1110-000UTKENU_00
16.1 Printing press configuration
Press version Number of Coating unit Feeder Delivery

printing units
Preset Plus Preset Plus Preset Plus Preset Plus
feeder delivery with‐ delivery with delivery with
out extension two extension three exten‐
module modules sion modules
CX 102-4 4 × ×
CX 102-4 + L 4 × × ×
CX 102-4 + L (X2) 4 × × ×
CX 102-4 + L (X3) 4 × × ×
CX 102-5 5 × ×
CX 102-5 + L 5 × × ×
CX 102-5 + L (X2) 5 × × ×
CX 102-5 + L (X3) 5 × × ×
CX 102-6 6 × ×
CX 102-6 + L 6 × × ×
CX 102-6 + L (X2) 6 × × ×
CX 102-6 + L (X3) 6 × × ×
CX 102-7 7 × ×
CX 102-7 + L 7 × × ×
CX 102-7 + L (X2) 7 × × ×
CX 102-7 + L (X3) 7 × × ×
CX 102-8 8 × ×
CX 102-8 + L 8 × × ×
CX 102-8 + L (X2) 8 × × ×
CX 102-8 + L (X3) 8 × × ×
Tab. 119Printing press configuration
00.999.5895/ A.1.93
Specifications
17 Allocation of the peripheral equipment to the printing press

SC.906.1111-000UTKENU_00

The following allocations apply to the Heidelberg
base standard. Depending on country and/or Sales &
Service Unit (SSU), the country standards may differ
from the Heidelberg base standard.
If in doubt, please ask your Heidelberg branch office
or factory agency to confirm the configuration of your
printing press.

All printing presses of the CX 102 product line can
be equipped with the following Prinect peripheral units:
Standard Option Remark

Prinect Press Center ● Prinect Press Center with Prinect Prinect Inpress Control is not possi‐
Axis Control ble in combination with Prinect Autor‐
or egister.
● Prinect Press Center with Prinect
Inpress Control
Prinect Image Control
Prinect Autoregister Prinect Autoregister is not possible
in combination with Prinect Inpress
Control.
Tab. 120Prinect peripheral equipment
17.3 AirStar (suction and blast air supply)

The standard configuration of all printing presses of
the CX 102 product line is equipped with an AirStar.
Press version AirStar

Air-cooled version (LGK) Water-cooled version
(standard) (option)
CX 102-4 A1-R1-L A1-R1-W
CX 102-4 + L A1-R1-L A1-R1-W
CX 102-4 + L (X2) A1-R1-L A1-R1-W
CX 102-4 + L (X3) A1-R1-L A1-R1-W
CX 102-5 A1-R1-L A1-R1-W
CX 102-5 + L A1-R1-L A1-R1-W
CX 102-5 + L (X2) A1-R1-L A1-R1-W
CX 102-5 + L (X3) A1-R1-L A1-R1-W
CX 102-6 A1-R1-L A1-R1-W
CX 102-6 + L A1-R1-L A1-R1-W
CX 102-6 + L (X2) A1-R1-L A1-R1-W
A.1.94 00.999.5895/
Specifications
Press version AirStar

Air-cooled version (LGK) Water-cooled version
(standard) (option)
CX 102-6 + L (X3) A1-R1-L A1-R1-W
CX 102-7 A1-R1-L A1-R1-W
CX 102-7 + L A1-R1-L A1-R1-W
CX 102-7 + L (X2) A1-R1-L A1-R1-W
CX 102-7 + L (X3) A1-R1-L A1-R1-W
CX 102-8 A1-R1-L A1-R1-W
CX 102-8 + L A1-R2-L A1-R2-W
CX 102-8 + L (X2) A1-R2-L A1-R2-W
CX 102-8 + L (X3) A1-R2-L A1-R2-W
Tab. 121AirStar
17.4 Pneumatic compressors (compressed-air supply)

the CX 102 product line is equipped with a ScrollStar.

the CX 102 product line is equipped with a HydroStar.
Number of printing units HydroStar

4 beta.d 40
5, 6 beta.d 60
7, 8 beta.d 100
Accessories
4...8 alcocontrol
(option)
Tab. 122HydroStar
All HydroStar units are available in the following ver‐
sions:
● Air-cooled (standard)
● Water-cooled (option)
the CX 102 product line is equipped with a HydroStar.
These printing presses can optionally be equipped
with a CombiStar, instead of a HydroStar.
Number of printing units CombiStar

4 beta.c 130
00.999.5895/ A.1.95
Specifications
Number of printing units CombiStar

5 beta.c 170
6 beta.c 220
7, 8 beta.c 280
Accessories
4...8 alcocontrol
(standard)
Tab. 123CombiStar
All CombiStar units are available in the following ver‐
sions:

All printing presses of the CX 102 product line can op‐
tionally be equipped with a FilterStar Compact

tionally be equipped with a FilterStar beta.f.

tionally be equipped with the WashStar unit for wash‐
ing fluid disposal.
Printing presses with 4...6 printing units have one
unit assigned. Printing presses with 7 or more print‐
ing units have two units.
Upon request, the WashStar is also available with a
cabinet.

All printing presses of the CX 102 product line that
contain a coating unit are equipped with one of the fol‐
lowing varnish supply units:
● LVG-550E (standard)
● LVG-550E UV (option)
● CoatingStar Compact (option)
● CoatingStar (option).
17.11 Powder spray devices

Depending on the actual press version, printing
presses of the CX 102 product line can optionally be
equipped with one of the following powder spray de‐
vices:
A.1.96 00.999.5895/
Specifications
Press version Powder spray devices

WEKO
Printing press without CleanStar or PowderStar AP 232 /
CleanStar Campt PowderStar AP 262 /
PowderStar AP 500
Printing press with CleanStar or PowderStar AP 500
CleanStar Compact
Tab. 124Powder spray devices

All printing presses of the CX 102 can optionally be
equipped with the CleanStar Compact or the CleanS‐
tar for powder suction removal or dryer suction remov‐
al.
17.12.1 Allocation of exhaust air collecting box/exhaust air cleaning cabinet

Printing press without coating unit
Press version Exhaust air collecting box/exhaust air cleaning cabinet

Printing press with CleanStar Compact Exhaust air collecting box
Printing press with CleanStar Exhaust air cleaning cabinet
Tab. 125Exhaust air collecting box for printing presses without coating unit
Printing press with coating unit and delivery without
extension module

Printing press with DryStar Coating Exhaust air collecting box
and CleanStar Compact
Printing press with DryStar Coating Exhaust air cleaning cabinet
and CleanStar
Tab. 126Exhaust air collecting box for printing presses with coating unit without extension module
Printing press with coating unit and extended delivery

Printing press with DryStar Combina‐ Exhaust air collecting box
tion and CleanStar Compact
Printing press with DryStar Combina‐ Exhaust air cleaning cabinet (powder suction removal)
tion and CleanStar Exhaust air collecting box (dryer suction removal)
Tab. 127Exhaust air collecting box for printing presses with coating unit and extended delivery

Depending on the press version, the printing presses
of the CX 102 product line can optionally be equip‐
ped with one of the following DryStar units:
00.999.5895/ A.1.97
Specifications
Press version DryStar

Without coating unit DryStar Ink
With coating unit and delivery without
DryStar Coating
extension module
With coating unit and with extended de‐ DryStar Combination with two slide-in units/
livery DryStar Combination with three slide-in units
Tab. 128DryStar
All DryStar units are available in the following versions:
17.13.1 Cooling and electric module, dryer cabinet
Version Cooling and electric module, dryer cabinet

DryStar Ink Cooling module
Electric module
DryStar Coating Dryer cabinet
DryStar Combination (1) Dryer cabinet
Tab. 129Cooling and electric module, dryer cabinet
(1): Applies to DryStar Combination with two or three
slide-in units.
17.13.2 Slide-in dryers
Version Slide-in dryers

DryStar Ink Slide-in dryer 1 (IR and suction device)
DryStar Coating Slide-in dryer 1 (IR and hot air)
DryStar Combination with Slide-in dryer 1 (IR and hot air)
two slide-in units Slide-in dryer 2 (suction removal and ambient air)
DryStar Combination with Slide-in dryer 1 (IR and hot air)
three slide-in units Slide-in dryer 2 (hot air)
Slide-in dryer 3 (suction removal and ambient air)
Tab. 130Slide-in dryers
17.13.3 Allocation of exhaust air collecting box/exhaust air cleaning cabinet

The allocation of exhaust air collecting box and ex‐
haust air cleaning cabinet can be found in the sec‐
tion CleanStar (exhaust air cleaning).

tionally be equipped with the automatic ink supply
unit InkStar or InkStar Direct.
A.1.98 00.999.5895/
Specifications
18 Shipping data
SC.906.1112-000UTKENU_00

● All crate dimensions and weights can vary slight‐
ly from those given in the table.
● Some dispatch units contain one press compo‐
nent and one additional standard spare parts
set. The net weight therefore does not always
correspond to the weight of the press compo‐
nent in question.
● For overseas shipments only case packaging is
used.
18.2 Shipping data of the printing press
Shipping unit Dimensions of the crate [mm] ([in]) Weights [kg] ([lbs])
Length Width Height Net With pallet With crate
Preset Plus feeder 3200 2290 2450 (96.46) 2850 (6283) 3200 (7055) 3550 (7825)
(125.98) (90.16)
First printing unit 2000 (78.74) 2290 2430 (95.67) 5620 5900 6160
(90.16) (12390) (13010) (13580)
Printing unit (from PU 2 on‐ 2000 (78.74) 2290 2430 (95.67) 5940 6220 6480
wards) (90.16) (13100) (13710) (14290)
Coating unit 2000 (78.74) 2290 2230 (87.80) 4680 4960 5200
(90.16) (10320) (10940) (11460)
Preset Plus delivery without 4100 2290 2360 (92.91) 5200 5670 6120
extension module (161.42) (90.16) (11465) (12500) (13490)
Preset Plus delivery with two 5850 2290 2400 (94.49) 6800 7600 8100
extension modules (230.31) (90.16) (14990) (16760) (17860)
Preset Plus delivery with 6650 2290 2400 (94.49) 7800 8750 9350
three extension modules (261.81) (90.16) (17195) (19290) (20615)
Tab. 131Dispatch information regarding the printing press
18.3 Shipping data of the peripheral units
Central control cabinet
Central control cabinet 2400 (94.49) 1500 (59.05) 2220 (87.40) 980 (2165) 1080 (2380) 1320 (2910)
Prinect peripheral equipment
Prinect Press Center 2000 (78.74) 1650 (64.96) 2210 (87.01) 650 (1435) 740 (1630) 1040 (2295)
Prinect Image Control 2350 (92.52) 1650 (64.94) 1750 (68.90) 670 (1475) 775 (1710) 990 (2185)
Drawer desk 2000 (78.74) 1650 (64.96) 1470 (57.87) 320 (705) 410 (905) 560 (1235)
Depositing desk 1490 (58.66) 1450 (57.09) 2220 (31.95) 95 (210) 165 (365) 335 (740)
Wallscreen 2020 (79.53) 800 (31.50) 1340 (52.76) 85 (185) 185 (410) 285 (630)
00.999.5895/ A.1.99
Specifications
AirStar (suction and blast air supply)
Air-cooled
AirStar A1-R1-L, 1400 (55.12) 1000 (39.37) 2190 (86.22) 850 (1875) 890 (1960) 1070 (2360)
AirStar A1-R2-L
Water-cooled
AirStar A1-R1-W, 1860 (73.23) 1000 (39.37) 2190 (86.22) 1100 (2425) 1170 (2580) 1330 (2930)
AirStar A1-R2-W
ScrollStar (compressed-air supply)
ScrollStar 1400 (55.12) 1000 (39.37) 2190 (86.22) 185 (410) 225 (495) 305 (670)
HydroStar (dampening solution supply)
beta.d 40...100 1400 (55.12) 1000 (39.37) 2190 (86.22) 410 (905) 450 (990) 630 (1390)
CombiStar (dampening solution supply and inking unit temperature control)
beta.c 130, 170 2040 (80.31) 1000 (39.37) 2190 (86.22) 560 (1235) 620 (1365) 800 (1765)
beta.c 220, 280 2400 (94.49) 1000 (39.37) 2190 (86.22) 780 (1720) 880 (1940) 1100 (2425)
WashStar (washing fluid disposal)
WashStar I in the cabinet 1400 (55.12) 1000 (39.37) 2190 (86.22) 145 (320) 185 (410) 365 (805)
WashStar II in the cabinet ( ) 1400 (55.12) 1000 (39.37) 2190 (86.22)
1 145 (320) 185 (410) 365 (805)
CleanStar (exhaust air cleaning)
Exhaust air cleaning cabinet 1490 (58.66) 1450 (57.09) 2220 (87.40) 300 (660) 370 (815) 540 (1190)
DryStar (IR drying process)
DryStar Coating 1750 (68.90) 1450 (57.09) 2210 (87.01) 420 (930) 500 (1100) 690 (1520)
DryStar Combination 1750 (68.90) 1450 (57.09) 2210 (87.01) 420 (930) 500 (1100) 690 (1520)
InkStar (automatic ink supply)
InkStar with 4 printing units 1750 (68.90) 1450 (57.09) 2210 (87.01) 120 (265) 200 (440) 390 (860)
InkStar with 5 and 6 printing 2000 (78.74) 1650 (64.96) 1470 (57.87) 180 (395) 270 (595) 420 (925)
units
InkStar with 7 and 8 printing 2000 (78.74) 1650 (64.96) 2210 (87.01) 270 (595) 360 (795) 660 (1455)
units
Plate punch and plate bending device
Plate punch 1860 (73.23) 1000 (39.37) 1660 (65.35) 140 (310) 210 (465) 330 (730)
Plate bending device 1860 (73.23) 1000 (39.37) 1660 (65.35) 140 (310) 210 (465) 330 (730)
Tab. 132Shipping information of the peripheral equipment
(1): Additional equipment for printing presses with 7
or more printing units.
A.1.100 00.999.5895/
Specifications
18.4 Shipping data, miscellaneous
Component 2000 (78.74) 1650 (64.96) 1470 (57.87) 760 (1675) 850 (1875) 1000 (2205)
Component 2500 (98.43) 1650 (64.96) 1730 (68.11) 820 (1810) 930 (2050) 1100 (2425)
Packages of accessories (1)
Crate module 1 2280 (89.76) 1280 (50.39) 480 (18.90) - - -
Crate module 2 2280 (89.76) 1280 (50.39) 580 (22.83) - - -
Crate module 3 2280 (89.76) 1280 (50.39) 680 (26.77) - - -
Crate module 4 2280 (89.76) 1280 (50.39) 780 (30.71) - - -
Tab. 133Dispatch information - Miscellaneous
(1): The packages of accessories consist of one or
more crate modules which are piled up and screwed
together.
18.5 Building openings
18.5.1 General guidance values

The building openings required for bringing the print‐
ing press into the building should usually be of the fol‐
lowing dimensions:
● Width = 3000 mm (118 in);
● Height = 2800 mm (110 in).
The same is required when the printing press is
moved out of the printshop building.
18.5.2 Minimum installation opening in building
Installation unit Dimensions [mm] ([in])

Width Height
With crate 2300 (90.55) 2600 (102.36)
With pallet 2300 (90.55) 2500 (98.43)
Tab. 134Minimum building opening
Please take the dimensions of the transportation
gear into account.
00.999.5895/ A.1.101
Specifications
A.1.102 00.999.5895/
Floor plans
Floor plans
1 Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3

1.1 CX 102-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3
1.2 CX 102-4 + l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.4
1.3 CX 102-4 + L (X2) / CX 102-4 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.5
1.4 CX 102-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.6
1.5 CX 102-5 + l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.7
1.6 CX 102-5 + L (X2) / CX 102-5 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.8
1.7 CX 102-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.9
1.8 CX 102-6 + l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.10
1.9 CX 102-6 + L (X2) / CX 102-6 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.11
1.10 CX 102-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.12
1.11 CX 102-7 + L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.13
1.12 CX 102-7 + L (X2) / CX 102-7 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.14
1.13 CX 102-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.15
1.14 CX 102-8 + L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.16
1.15 CX 102-8 + L (X2) / CX 102-8 + L (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.17
1.16 CX 102 - supplementary drawing for elevated installation . . . . . . . . . . . . . . . . . . . . . . A.2.18
1.17 CX 102 + L - supplementary drawing for elevated installation . . . . . . . . . . . . . . . . . . . A.2.19
2 Floor plan legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23

2.1 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23
2.2 Notes on the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23
2.3 Floor plan legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.24
2.4 Variable dimensions in the supplementary drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.25
3 Positions of the leveling blocks and gravity centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.27

3.2 Preset Plus feeder, first printing unit and middle printing unit . . . . . . . . . . . . . . . . . . . A.2.27
3.3 Last printing unit and Preset Plus delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.28
3.4 Coating unit and Preset Plus delivery without extension module . . . . . . . . . . . . . . . . A.2.28
3.5 Coating unit and Preset Plus delivery with two extension modules . . . . . . . . . . . . . . . A.2.29
3.6 Coating unit and Preset Plus delivery with three extension modules . . . . . . . . . . . . . A.2.29
4 Dimensions of the preloading device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.30

4.2 Preloading device on the Preset Plus feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.30
00.999.5895/ A.2.1
Floor plans
A.2.2 00.999.5895/
1 CX 102
1220
1.1 CX 102-4 577
2 1
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 4720 2528
10564
Maximalausstattung
wassergekühlt
1700 1300 min.700 Maximum equipment
water-cooled
1000 590 1800 Equipement maximal
min.700
min.700
refroidi par léau
Equipamiento maximo
refrigerado por aqua
700
CombiStar AirStar
700
Scroll-
9 Star beta.c 130 G A1-R1-W
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
1200 1300 Equipement de base
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
refrigerado por aire
Scroll- HydroStar AirStar min.700
700
700
8 Star beta.d 40 L A1-R1-L
ZSG
750
max. 5000 / 12500
1380
679 1442
1264
1092
6332
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
3
1000 mm
(39.37 in)
10300 4
A.2.3
1.2 CX 102-4 + L
1220
1220 577
2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 5940 2528
11784
Maximalausstattung
wassergekühlt
590 1800 Maximum equipment
1200 1700 1300 min.700
water-cooled
1000 600 Equipement maximal
min.700
min.700
min.700
11 refroidi par léau
Equipamiento maximo
Coating-
700
DryStar CombiStar AirStar
700
Scroll-
9 Coating Star Star beta.c 130 G A1-R1-W
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
1200 1200 1300 Equipement de base
refroidi à láir
600 590 1000
min.700
min.700
min.700
Equipamiento basico
11
DryStar Scroll- HydroStar AirStar min.700
700
700
8 Coating Star beta.d 40 L A1-R1-L
ZSG
750
max. 5000 / 12500
1380
679 1442
1264
10
1092
7552
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 min. 1600 6
930
1000 mm
(39.37 in)
11520 4
A.2.4
1.3 CX 102-4 + L (X2) / CX 102-4 + L (X3)
1220
X3: 2438,3 1220 577

X2: 1625,5 2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
X3: 5490
1414 X2: 4677 5940 2528
CX102-4+L(X3): 14222
CX102-4+L(X2): 13410
Maximalausstattung
wassergekühlt
1200 1700 1300 min.700 Maximum equipment
water-cooled
1000 600 600 590 1800 Equipement maximal
min.700
min.700
min.700
refroidi par léau
11 Equipamiento maximo
Coating-
700
700
Scroll-
9 8 Combination Star Star beta.c 130 G A1-R1-W
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
min.700
Equipamiento basico
11
700
DryStar Scroll- HydroStar AirStar min.700
700
8 Combination Star beta.d 40 L A1-R1-L
ZSG
750
max. 5000 / 12500
1380
679 1442
1264
10
1092
7552
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 min. 1600 6
930
1000 mm CX102-4+L(X3): 13960

(39.37 in) CX102-4+L(X2): 13150 4
A.2.5
1.4 CX 102-5
1220
577
2 1
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 5940 2528
11784
Maximalausstattung
wassergekühlt
water-cooled
min.700
refroidi par léau
Equipamiento maximo
700
CombiStar AirStar
700
Scroll-
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
Equipamiento basico
Scroll- HydroStar AirStar
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
1092
7552
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 min. 1600 6
930
1000 mm
(39.37 in)
11520 4
A.2.6
1.5 CX 102-5 + L
1220
1220 577
2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 7160 2528
13004
Maximalausstattung
wassergekühlt
1200 1700 2100 Maximum equipment
water-cooled
1000 600 590 1800 Equipement maximal
min.700
min.700
refroidi par léau
Coating-
700
700
Scroll-
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
DryStar Scroll- HydroStar AirStar
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
8772
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
12740 4
A.2.7
1.6 CX 102-5 + L (X2) / CX 102-5 + L (X3)
1220
X3: 2438,3 1220 577

X2: 1625,5 2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
X3: 5490
1414 X2: 4677 7160 2528
CX102-5+L(X3): 15442
CX102-5+L(X2): 14630
Maximalausstattung
wassergekühlt
water-cooled
min.700
min.700
refroidi par léau
Coating-
700
700
Scroll-
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
8772
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm CX102-5+L(X3): 15180

(39.37 in) CX102-5+L(X2): 14370 4
A.2.8
1.7 CX 102-6
1220
577
2 1
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 7160 2528
13004
Maximalausstattung
wassergekühlt
water-cooled
min.700
refroidi par léau
Equipamiento maximo
700
CombiStar AirStar
700
Scroll-
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
Equipamiento basico

700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
1092
8772
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
12740 4
A.2.9
1.8 CX 102-6 + L
1220
1220 577
2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 8380 2528
14224
Maximalausstattung
wassergekühlt
water-cooled
1000 600 590 2000 Equipement maximal
min.700
min.700
refroidi par léau
Coating-
700
700
Scroll-
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
9992
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
13960 4
A.2.10
1.9 CX 102-6 + L (X2) / CX 102-6 + L (X3)
1220
X3: 2438,3 1220 577

X2: 1625,5 2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
X3: 5490
1414 X2: 4677 8380 2528
CX102-6+L(X3): 16662
CX102-6+L(X2): 15850
Maximalausstattung
wassergekühlt
water-cooled
min.700
min.700
refroidi par léau
Coating-
700
700
Scroll-
ZSG
750
WashStar
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
9992
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm CX102-6+L(X3): 16400

(39.37 in) CX102-6+L(X2): 15590 4
A.2.11
1.10 CX 102-7
1220
577
2 1
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 8380 2528
14224
Maximalausstattung
wassergekühlt
water-cooled
min.700
refroidi par léau
Equipamiento maximo
WashStar I + II refrigerado por aqua
CombiStar AirStar
700
700
Scroll-
ZSG
750
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
Equipamiento basico

700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
1092
9992
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
13960 4
A.2.12
1.11 CX 102-7 + L
1220
1220 577
2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 9600 2528
15444
Maximalausstattung
wassergekühlt
water-cooled
1000 600 880 880 590 2000 Equipement maximal
min.700
min.700
refroidi par léau
DryStar Coating- CombiStar AirStar
700
700
Scroll-
ZSG
750
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
11212
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
15180 4
A.2.13
1.12 CX 102-7 + L (X2) / CX 102-7 + L (X3)
1220
X3: 2438,3 1220 577

X2: 1625,5 2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
X3: 5490
1414 X2: 4677 9600 2528
CX102-7+L(X3): 17882
CX102-7+L(X2): 17070
Maximalausstattung
wassergekühlt
water-cooled
1000 600 600 880 880 590 2000 Equipement maximal
min.700
min.700
refroidi par léau
700
700
Scroll-
ZSG
750
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
11212
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm CX102-7+L(X3): 17620

(39.37 in) CX102-7+L(X2): 16810 4
A.2.14
1.13 CX 102-8
1220
577
2 1
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 9600 2528
15444
Maximalausstattung
wassergekühlt
water-cooled
min.700
refroidi par léau
Equipamiento maximo
CombiStar AirStar
700
700
Scroll-
ZSG
750
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
Equipamiento basico

700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
1092
8772
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
15180 4
A.2.15
1.14 CX 102-8 + L
1220
1220 577
2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
1414 X0: 3052 10820 2528
16664
Maximalausstattung
wassergekühlt
water-cooled
1000 600 880 880 590 2000 Equipement maximal
min.700
min.700
refroidi par léau
700
700
Scroll-
ZSG
750
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
11212
Prinect Press
1747
2024
1858
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm
(39.37 in)
16400 4
A.2.16
1.15 CX 102-8 + L (X2) / CX 102-8 + L (X3)
1220
X3: 2438,3 1220 577

X2: 1625,5 2 1
577
2900
2820
2290
2145
1905
1129
500
1278 1220 3588
X3: 5490
1414 X2: 4677 10820 2528
CX102-8+L(X3): 19102
CX102-8+L(X2): 18290
Maximalausstattung
wassergekühlt
water-cooled
1000 600 600 880 880 590 2000 Equipement maximal
min.700
min.700
refroidi par léau
700
700
Scroll-
ZSG
750
Grundausstattung
luftgekühlt
Basic equipment
air-cooled
refroidi à láir
600 590 1000
min.700
min.700
Equipamiento basico
11
700
700
ZSG
750
max. 5000 / 12500
1380
1181 940
1264
10
1092
11212
Prinect Press
1747
4782
5082
Center
2000
2253
1150
3632
3332
725
4
1585
min. 1600
300
7 5 6
min. 1600
930
1000 mm CX102-8+L(X3): 18840

(39.37 in) CX102-8+L(X2): 18030 4
A.2.17
1.16 CX 102 - hochgesetzt/ elevated/ rehaussee/ elevada
2 1
3400
3320
2645
2405
1000
500
485
485
ø200
14
200
120
2528 120
610 610 500 775 775 500
12 2408
13
700
3837 ZSG
687
750
15 1181 635
800
1000
150
Prinect Press
1821
1747
Center
350
5460
16
1600
1755
900
745
9
4010
3753
4514
2007
Prinect Image
2693
Control
687
2595
2862
4974
1000 mm
(39.37 in)
A.2.18
1.17 CX 102 + L - hochgesetzt/ elevated/ rehaussee/ elevada
2 1
3400
3320
2645
2405
1000
500
485
485
ø200
14
200
120
2528 120
610 610 500 775 775 500
12 2408
13
700
3837 ZSG
687
750
15 1181 635
800
1000
150
Prinect Press
1821
1747
Center
350
5460
16
1600
1755
900
745 9
4010
3753
4514
2007
Prinect Image
2693
Control
687
2595
2862
4974
1000 mm
(39.37 in)
A.2.19
1.18 CX 102 + L (X2) - hochgesetzt/ elevated/ rehaussee/ elevada
2 1
3400
3320
2645
2405
1000
500
485
485
ø200
14
200
120
2528 120
610 610 500 775 775 500
12 2408
13
700
3837 ZSG
687
750
15 1181 635
800
1000
150
Prinect Press
1821
1747
Center
350
5460
16
1600
1755
900
745 9
4010
3753
4514
2007
Prinect Image
2693
Control
687
2595
2862
4974
1000 mm
(39.37 in)
A.2.20
1.19 CX 102 + L (X3) - hochgesetzt/ elevated/ rehaussee/ elevada
2 1
3400
3320
2645
2405
1000
500
485
485
ø200
14
200
120
2528 120
610 610 500 775 775 500
12 2408
13
700
3837 ZSG
687
750
15 1181 635
800
1000
150
Prinect Press
1821
1747
Center
350
5460
16
1600
1755
900
745 9
4010
3753
4514
2007
Prinect Image
2693
Control
687
2595
2862
4974
1000 mm
(39.37 in)
A.2.21
A.2.22
Floor plans
2 Floor plan legend

SC.906.1121-000UTKENU_00
2.1 General notes

● All dimensions in mm
● Scale: 1:70
True-to-scale representation is not ensured with
own printouts.
● The following configuration variants are shown
in the floor plans:
○ Basic configuration;
○ Maximum configuration (but without Filter‐
Star Compact or FilterStar).
Printing presses in the basic configuration are al‐
ways shown with peripheral units in the air-
cooled variant. The maximum configuration in
the floor plans shows the peripherals as water-
cooled variants.
● The floor plans for elevated installation are sup‐
plementary drawings. Dimensions not shown
here can be found in the floor plans for the stand‐
ard installation.
● The floor plans for the elevated installation are
only valid for printing presses without Auto‐
pile Plus. Floor plans for printing presses with
Autopile Plus can be found in the documenta‐
tion Specifications Autopile Plus.
● You can find precise specifications of the posi‐
tions of the leveling blocks and the centers of
gravity in the chapter Position of the leveling
blocks and centers of gravity.
● The main chapter Technical information pro‐
vides information about the installation of the
printing press and its peripheral equipment.
2.2 Notes on the peripheral units
2.2.1 General information

All peripheral units can be opened at the press side
and at the wall side. The floor plans preferably show
the peripheral units with doors that are open at the
press side.
2.2.2 CombiStar
Air-cooled/water-cooled
The floor plans show the water-cooled CombiStar in
the maximum configuration.
For technical reasons, some CombiStar units with air
cooling are wider than units with water cooling (see
Table 2).
00.999.5895/ A.2.23
Floor plans
Version Width [mm] ([in])

Air-cooled ver‐ Water-cooled
sion (LGK) version
beta.c 220 2200 (86.61) 2000 (78.74)
beta.c 280 2200 (86.61) 2000 (78.74)
Tab. 2 Width CombiStar
2.2.3 WashStar
Upon request, the WashStar is also available with a
cabinet.
Cabinet dimensions: 1000 × 700 × 1930 mm
(39.37 × 27.56 × 75.98 in).
2.3 Floor plan legend

Numbering
1 Total height on a printing press with Auto‐
Plate Plus plate changer in top locking position
and with a printing plate inserted
2 Total height of a printing press with automatic
ink dispensing system InkStar and open meter‐
ing unit
3 Broadened footboard level for a printing press
with interdeck dryer preparation
4 Recommended foundation dimensions in stand‐
ard installation
5 This minimum distance is required for removing
the DryStar slide-in dryers
6 This minimum distance is required for removing
the impression cylinder washup device.
7 A Prinect Press Center with Prinect Axis Con‐
trol requires this safety distance to avoid crush
injuries from the measuring bar.
8 Exhaust air collecting box
9 Exhaust air cleaning cabinet
10 Varnish supply unit LVG-550E
11 Varnish drums on Europallet
Supplementary drawings for elevated installation:
12 Foundation length in elevated installation and
length of the strip foundation segments: see Ta‐
ble 3
13 Length of the printing press in elevated installa‐
tion (including gallery): see Table 4
14 Extension of the Preset Plus feeder on a print‐
ing press with equipment for automatic non-
stop pile change.
A.2.24 00.999.5895/
Floor plans
15 Main motor on motor mounting base:

The exact location of the main driving motor is
shown in the floor plans for standard installation.
16 Oil drip pans
Symbols
Pile loading and removal
Optional pile loading
Supply line for electrical energy
2.4 Variable dimensions in the supplementary drawing
2.4.1 Foundation length for elevated installations
[mm] ([in])
Delivery <- feeder
CX 102-4 3660 (144.09) | 2550 (100.39) 6210 (244.49)
CX 102-4 + L 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-4 + L (X2) 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-4 + L (X3) 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-5 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-5 + L 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-5 + L (X2) 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-5 + L (X3) 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-6 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-6 + L 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-6 + L (X2) 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-6 + L (X3) 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-7 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-7 + L 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-7 + L (X2) 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-7 + L (X3) 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-8 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-8 + L 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
CX 102-8 + L (X2) 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
CX 102-8 + L (X3) 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
2.4.2 Length of the printing press for elevated installation
CX 102-4 15221 (599.24)
00.999.5895/ A.2.25
Floor plans
CX 102-4 + L 16441 (647.27)
CX 102-4 + L (X2) 18066 (711.26)
CX 102-4 + L (X3) 18879 (743.26)
CX 102-5 16441 (647.27)
CX 102-5 + L 17661 (695.30)
CX 102-5 + L (X2) 19286 (759.29)
CX 102-5 + L (X3) 20099 (791.29)
CX 102-6 17661 (695.30)
CX 102-6 + L 18881 (743.33)
CX 102-6 + L (X2) 20506 (807.33)
CX 102-6 + L (X3) 21319 (839.32)
CX 102-7 18881 (743.33)
CX 102-7 + L 20101 (791.36)
CX 102-7 + L (X2) 21726 (855.36)
CX 102-7 + L (X3) 22539 (887.35)
CX 102-8 20101 (791.36)
CX 102-8 + L 21321 (839.39)
CX 102-8 + L (X2) 22946 (903.39)
CX 102-8 + L (X3) 23759 (935.39)
Tab. 4 Length of the printing press for elevated installation
A.2.26 00.999.5895/
Floor plans
3 Positions of the leveling blocks and gravity centers

SC.906.1122-000UTKENU_00

● All dimensions in mm.
● Scale: 1:50.
own printouts.
● The following drawings show the positions of
the leveling blocks and centers of gravity seen
from above.
Symbols
Centers of gravity
3.2 Preset Plus feeder, first printing unit and middle printing unit
SC.906.1122-000GRAUND_00
1220 2225 1363
785 785 1283
5 128 5 128
1530
605
268 350
1932
605
35
75
1000 mm
(39.37 in) 1:50
205 x 120 282 x 65 107 x 201
Fig. 20 Leveling blocks and gravity centers
00.999.5895/ A.2.27
Floor plans
3.3 Last printing unit and Preset Plus delivery
SC.906.1123-000GRAUND_00
1220
1246 667 878 785
75 128
685
605
268
605
685
75
1000 mm
(39.37 in) 1:50
100 x 80 205 x 120
Fig. 21 Leveling blocks and gravity center
3.4 Coating unit and Preset Plus delivery without extension module
SC.906.1124-000GRAUND_00
1220
1246 667 878 785
75 128
685
605
228
605
685
95
1000 mm
(39.37 in) 1:50
100 x 80 205 x 120
A.2.28 00.999.5895/
Floor plans
3.5 Coating unit and Preset Plus delivery with two extension modules
SC.906.1125-000GRAUND_00
1220
1246 1265 1028 878 785
75 128
685
605
228
605
685
95
1000 mm
(39.37 in) 1:50
100 x 80 205 x 120
3.6 Coating unit and Preset Plus delivery with three extension modules
SC.906.1126-000GRAUND_00
1220
1246 1265 813 1028 878 785
75 128
685
605
228
605
685
95
1000 mm
(39.37 in) 1:50
100 x 80 205 x 120
00.999.5895/ A.2.29
Floor plans
4 Dimensions of the preloading device

SC.906.1123-000UTKENU_00

● All dimensions in mm.
● Scale: 1:50.
own printouts.
● All printing presses of the CX 102 product line
can optionally be equipped with a preloading de‐
vice. This means that paper piles can be prea‐
ligned accurately outside the printing press.
● The following illustration shows the preloading
device from the top view.
4.2 Preloading device on the Preset Plus feeder

The distance between the beginning of the guide
rails of a preloading device and the front edge of the
Preset Plus feeder is 1640 mm (64.57 in).
SC.906.1128-000GRAUND_00
720
640
40
1640
1000 mm
(39.37 in) 1:50
Fig. 25 Preloading device
A.2.30 00.999.5895/
B Technical information
Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.1
1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3

1.1 Explanation of the general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3
Preparation of the location of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1
1 Constructional requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3

1.1 Space requirements and room heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.2 Floors, ceilings, and floor coverings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.3 Supply and disposal lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.4 Walls, partitions and building openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.5 Air conditioning and ventilation of the pressroom . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.4
2 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.6

2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.6
2.2 Press weights and floor loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.6
2.3 Weights of the machine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.7
2.4 Average static floor load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.8
2.5 Maximum static surface pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.8
2.6 Material requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.8
2.7 Foundation settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.9
2.8 Flatness tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.9
2.9 Dynamic foundation loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.9
2.10 Floor compression under the foundation plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.10
2.11 Foundation plate rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.10
2.12 Installation of the printing press on an uncoupled foundation . . . . . . . . . . . . . . . . . . . B.2.10
3 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.12

3.1 Dimensions of the foundation for standard installations . . . . . . . . . . . . . . . . . . . . . . . B.2.12
3.2 Dimensions of the foundation for elevated installations . . . . . . . . . . . . . . . . . . . . . . . . B.2.13
4 Supply systems and supply lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15

4.1 Electric power supply - mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15
4.2 Water supply and water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15
4.3 Compressed-air supply and compressed-air treatment . . . . . . . . . . . . . . . . . . . . . . . . B.2.16
4.4 Suction air and blast air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.16
5 Printing Office Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . . . . . . B.2.17

5.1 Printing Office Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . . B.2.17
00.999.5895/ B. 1
Elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.1
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3

1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
1.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
1.4 Required accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.4
2 Nonstop Preset Plus feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.5

2.2 Pile heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.5
3 Strip foundations for elevated printing presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6

3.1 Possible versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6
3.2 Material requirements and weight calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6
3.3 Production and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.7
4 Motor mounting base for elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.8

4.2 Material requirements and weight calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.8
4.3 Design of the motor mounting base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.9
4.4 Installation of the prefabricated motor mounting base . . . . . . . . . . . . . . . . . . . . . . . . . B.3.10
5 Oil drip pans for elevated presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.11

5.1 Oil drip pans for elevated presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.11
Electrical installation of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.1
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.3

2 Specifications of the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.4

2.2 Nameplate for the electrical equipment of the printing press . . . . . . . . . . . . . . . . . . . . B.4.4
2.3 Indicator plate for the connection of the printing press to the electric mains . . . . . . . . B.4.5
2.4 Location of nameplate and indicator plate on/in the central control cabinet . . . . . . . . B.4.5
3 Basic regulations for the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7

3.1 Types of power supply systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7
3.2 Layout of the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7
3.3 Fuses and protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7
3.4 EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.8
3.5 Power supply tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.10
3.6 Mains impedance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.10
B. 2 00.999.5895/
3.7 Power cable requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.11

3.8 Notes on laying the cables for the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.11
3.9 Mains cable entry into the central control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.12
3.10 Checking the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.12
4 Basic recommendations and notes on the mains connection . . . . . . . . . . . . . . . . . . . . . . . . B.4.14

4.2 Selecting the material for power cables and PE conductors . . . . . . . . . . . . . . . . . . . . B.4.14
4.4 Switching on, starting up and running up the press . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.14
4.5 Load characteristics, harmonics and flickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.14
5 Mains connection of the printing press to the three-phase mains . . . . . . . . . . . . . . . . . . . . . B.4.16

5.2 Notes on the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.17
5.3 Overview of the standard mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.18
6 Cross sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.23

6.1 Cross sections of the line terminals on the main switch . . . . . . . . . . . . . . . . . . . . . . . B.4.23
6.2 Cross sections of the conductor terminals at the series transformer . . . . . . . . . . . . . . B.4.23
Air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.1
1 Air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.3

1.2 Process air supply of the AirStar for the printing process . . . . . . . . . . . . . . . . . . . . . . B.5.4
2 Air-cooled AirStar air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.6

2.2 Overall air throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.6
2.3 Air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.7
2.4 Process air supply for the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.7
3 Water-cooled AirStar air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.8

3.4 Extracting the process air from the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.9
3.5 Connection of external refrigeration cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.9
4 Installation instructions for the AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.11

4.1 Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.11
4.2 Minimum distances at the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.11
4.3 Standard installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.12
00.999.5895/ B. 3
4.4 Flexible installation of peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.13
5 Installation of the air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.14

5.1 Installation site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.14
5.2 Pressure drop when using exhaust hoods on the air-cooled AirStar . . . . . . . . . . . . . . B.5.14
5.3 Different diameter of air pipes >10 m (>33 ft) to the printing press . . . . . . . . . . . . . . . B.5.16
Pneumatic compressor ScrollStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.1
1 Pneumatic compressor ScrollStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3

1.2 ScrollStar overall air throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3
1.3 Requirements placed upon the place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3
2 Installation instructions for the ScrollStar ....................................... B.6.5

2.2 ScrollStar: Minimum distances at the place of installation . . . . . . . . . . . . . . . . . . . . . . B.6.5
3 Air supply via central air supply systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.8

3.2 Compressed air supply (high pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.8
Dampening solution supply CombiStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.1
1 CombiStar combination unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.3

1.2 Connection of the external refrigeration cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.3
2 Installation instructions for the CombiStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.5

3 Dampening solution supply via central dampening solution supply systems . . . . . . . . . . . . . B.7.9
3.2 Dampening solution supply via central dampening solution supply systems . . . . . . . . B.7.9
Washing fluid disposal WashStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.1
1 Installation instructions for the WashStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.3

1.3 Flexible peripherals installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.5
B. 4 00.999.5895/
Exhaust air cleaning cabinet CleanStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.1
1 Exhaust air cleaning cabinet CleanStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3

1.2 Method of functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3
1.3 Explosion prevention measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3
2 Installation instructions for the CleanStar exhaust air cleaning cabinet . . . . . . . . . . . . . . . . . B.9.4
3 Exhaust air routing in presses with Preset Plus delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.6

3.2 Exhaust air routing for DryStar Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.7
3.3 Exhaust air routing for DryStar Coating with CleanStar Compact . . . . . . . . . . . . . . . . B.9.8
3.4 Exhaust air routing for DryStar Coating with CleanStar . . . . . . . . . . . . . . . . . . . . . . . . B.9.9
3.5 Exhaust air routing for DryStar Combination with 2 slide-in units and CleanStar
Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.9
3.6 Exhaust air routing for DryStar Combination with 2 slide-in units and CleanStar . . . . B.9.10
Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.10
Varnish supply unit CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.1
1 Varnish supply unit CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.3

1.2 Task and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.4
1.3 Structure and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.4
1.4 Requirements for the place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.5
2 Installation instructions for the CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.6

2.2 Minimum distances at the place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.6
IR dryer DryStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.1
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.3

2 IR Dryer DryStar Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.4

2.1 Description of DryStar Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.4
00.999.5895/ B. 5
2.2 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.5

2.3 Air supply and air removal in the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.5
2.4 Cooling circulation of the sheet track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.6
3 IR dryer DryStar Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.7

3.1 Description of DryStar Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.7
3.3 Dryer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.8
3.4 Air supply and air removal during the printing process . . . . . . . . . . . . . . . . . . . . . . . . B.11.9
3.5 Cooling circulation of sheet track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.9
4 IR Dryer DryStar Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.11

4.1 Description of DryStar Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.11
4.3 Dryer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.13
4.6 Connecting external refrigeration cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.14
5 Installation instructions for the DryStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.15


Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.21
Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.22
7 Mains connection of the IR dryers to the three-phase mains . . . . . . . . . . . . . . . . . . . . . . . . . B.11.24

7.2 Overview of the standard mains connections, printing press with Preset Plus delivery
................................................................... B.11.24
7.3 Standard mains connection, variants A1 and A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.25
7.4 Cross sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.28
B. 6 00.999.5895/
8 Ultraviolet drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30

8.1 General note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30
8.2 Technical preinstallation by Heidelberger Druckmaschinen AG . . . . . . . . . . . . . . . . . B.11.30
8.3 Interdeck drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30
8.4 Requirements placed upon the UV drying system . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.31
8.5 Clarification of technical issues by the manufacturer of the UV dryers . . . . . . . . . . . . B.11.31
Prinect peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.1
1 Mains connection of the Prinect peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.3

1.2 Power supply for the Prinect peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.3
2 Overview of the standard power supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.4

2.1 Overview of standard power supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.4
Flexible peripherals installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.1
1 Flexible installation of peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.3

1.2 Extension kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.3
1.3 Distance of the peripheral units +5 m (16.4 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.4
1.4 Distance of the peripherals + 10 m (32.8 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.4
1.5 Distance of the peripheral units + 20 m (65.6 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.4
2 Double row installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
2.2 Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
2.3 Extension package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
2.4 Base system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.7
2.5 Center gangway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.8
2.6 Assembling cabinet base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.8
2.7 Minimum distances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.9
3 Raised and lowered installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.10

3.2 Raised installation on a scaffolding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.10
3.3 Raised installation on an upper floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.14
3.4 Lowered installation on a floor below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.14
00.999.5895/ B. 7
Permanent piping and exhaust air piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.1
1 Permanent piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.3

1.2 Permanent piping construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.3
2 Exhaust air piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.6

2.1 Flow-related and design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.6
2.2 Channel types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.7
2.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.8
2.4 Pressure conditions in exhaust hoods and exhaust air pipes . . . . . . . . . . . . . . . . . . . . B.14.9
2.5 Protection against environmental influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.10
2.6 Explosion prevention measures and zone structures . . . . . . . . . . . . . . . . . . . . . . . . . B.14.11
2.7 Fire protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.12
Interface adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.1
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3

1.1 Correct use of the interface adapter signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3
1.2 EMC regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3
2 Interface adapter, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4

2.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4
2.2 Place of installation of the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4
3 SEM3 Interface input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5

3.1 Design and task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5
3.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.7
4 SEM3 input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.8

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.8
4.2 External emergency stop (E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.8
4.3 Interdeck dryer in operation (E2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.9
4.4 UV dryer not ready to run (input E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.9
4.5 Malfunction: exhaust air (E4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.9
4.6 Dryer malfunction (E5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.10
4.7 Dryer blocking after washing (input E6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.10
4.8 Final UV dryer without shutter in operation (E7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.10
5 SAM17 Interface output module 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.12

5.1 SAM17, design and task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.12
5.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.13
B. 8 00.999.5895/
5.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.13
6 SAM17 output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16

6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16
6.2 Run (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16
6.3 Enable standby of final dryer (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.17
6.4 Enable production of final dryer (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.17
6.5 Sheets in printing unit 1 (A4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.18
6.6 Emergency stop (A5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.18
6.7 Sheet counter ON (A6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.19
6.8 Feeder ON (A7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.19
6.9 Enable powder spray device (A8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.19
6.10 Washup active (A9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.20
6.11 Emergency stop (A10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.20
6.12 Enable interdeck dryer (A11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.20
6.13 Enable final dryer (A12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.21
6.14 Enable standby of interdeck dryer (A13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.21
6.15 Air supply ON (A14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.22
6.16 CleanStar ON (A15) (SM 102, CD102 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.22
6.17 Main switch ON (A16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.22
6.18 Press cycle (A17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.23
Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.1
1 Physical measures and their units in the SI system and the ANSI system . . . . . . . . . . . . . . B.16.3
1.1 Physical measures and their units in the SI system and the ANSI system . . . . . . . . . . B.16.3
2 Special conversions and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.4

2.1 Special conversions and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.4
3 Water hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.5

3.1 Water hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.5
00.999.5895/ B. 9
B. 10 00.999.5895/
Important notes
Important notes
1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3

1.1 Explanation of the general notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.3
00.999.5895/ B.1.1
Important notes
B.1.2 00.999.5895/
Important notes
1 Important notes
XS.906.3001-000UTKENU_01
1.1 Explanation of the general notes

The Technical Information contains two information
categories which will be explained below. To give
you a better understanding of the information provid‐
ed, symbols (pictographs) with a fixed meaning are al‐
located to each category.
First-level instructions are used only in the operating
manual.
Second-level instruction
Meaning:
This safety information warns you of potentially haz‐
ardous situations.
Nonobservance can damage the presses and addi‐
tional equipment.
Relevant pictograph with signal word:
Caution - Brief description of the hazard
.
Example:
Caution - Damage and malfunction of
electrical devices due to electromagnet‐
ic interference!
Third-party equipment used on the print‐
ing press must not cause any malfunc‐
tions in the electronic system of the print‐
ing press or of the third-party equipment.
External equipment may only be put in‐
to circulation and used if it fulfills the
EMC requirements according to IEC/
EN 61000-6-2 and IEC/EN 61000-6-4,
if this compliance has been certified by
a properly authorized position at the
manufacturer's, and if the equipment is
marked with the CE mark.
Prior to installing external equipment
you must have checked the necessity
of EMC measures. EMC measures
must always be agreed with Heidelberg
Service.
Third-level instructions
Meaning:
This message gives you additional information and
provides tips for operating printing presses and addi‐
tional equipment.
Relevant pictograph with signal word:
00.999.5895/ B.1.3
Important notes
Note
.
Example:
Note
A series transformer is supplied togeth‐
er with the printing press.
B.1.4 00.999.5895/
Preparation of the location of the printing press
1 Constructional requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3

1.1 Space requirements and room heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.2 Floors, ceilings, and floor coverings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.3 Supply and disposal lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.4 Walls, partitions and building openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.3
1.5 Air conditioning and ventilation of the pressroom . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.4
2 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.6

2.2 Press weights and floor loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.6
2.3 Weights of the machine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.7
2.4 Average static floor load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.8
2.5 Maximum static surface pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.8
2.6 Material requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.8
2.7 Foundation settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.9
2.8 Flatness tolerance limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.9
2.9 Dynamic foundation loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.9
2.10 Floor compression under the foundation plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.10
2.11 Foundation plate rigidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.10
2.12 Installation of the printing press on an uncoupled foundation . . . . . . . . . . . . . . . . . . . B.2.10
3 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.12

3.1 Dimensions of the foundation for standard installations . . . . . . . . . . . . . . . . . . . . . . . B.2.12
3.2 Dimensions of the foundation for elevated installations . . . . . . . . . . . . . . . . . . . . . . . . B.2.13
4 Supply systems and supply lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15

4.1 Electric power supply - mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15
4.2 Water supply and water treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.15
4.3 Compressed-air supply and compressed-air treatment . . . . . . . . . . . . . . . . . . . . . . . . B.2.16
4.4 Suction air and blast air supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.16
5 Printing Office Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . . . . . . B.2.17

5.1 Printing Office Planning Department of Heidelberger Druckmaschinen AG . . . . . . . . . B.2.17
00.999.5895/ B.2.1
B.2.2 00.999.5895/
1 Constructional requirements
LS.906.3201-000UTKENU_04
1.1 Space requirements and room heights

The specifications of the floor space required by the
printing press, and the floor plans can be found in
the main chapter Specifications.
In the floor plans you can also find the additional dis‐
tances (space) required for performing maintenance
and repair work.
Good accessibility to the individual components of
the printing press and a good material flow should al‐
ways be provided for.
● Height clearance in the pressroom (excluding
suspended ceilings and false floors): approxi‐
mately 4000 mm (157 in) up to
5500 mm (217 in).
● General rule: the larger the room (air volume),
the more stable the ambient climate.
1.2 Floors, ceilings, and floor coverings

In general: opting for as high a load carrying capacity
for the floors and floor slabs as possible will provide
for a greater degree of flexibility for future extensions
or modernization work to the printing office.
Numerous factors are decisive in the selection of the
floor material to be used. Above all, these are a high
oil and abrasion resistance, as well as suitable anti‐
static properties.
Experts should be consulted in time in order to get
an idea of costs, service life, repair options, degree
of maintenance required and exchangeability.
1.3 Supply and disposal lines

We advise against installing supply or disposal lines
(electric power, water, air, etc.) in the floor since this
would reduce the flexibility at the press location.
Instead we recommend using cable and hose
bridges to cover the supply lines in order to minimize
the risk of stumbling.
1.4 Walls, partitions and building openings

The design of walls should be adapted to the local cli‐
matic conditions and the pressroom-specific require‐
ments.
Depending on the press version, medium to large
amounts of hot air escape into the pressroom during
press operation. This is why walls and/or doors
should have adequate vent holes to provide for well-
balanced air pressure conditions.
00.999.5895/ B.2.3
The building openings required for bringing the print‐

ing press into the building should usually be of the fol‐
lowing dimensions:
● Width = 3000 mm (118 in);
● Height = 2800 mm (110 in).
If there are already openings in walls, the branch or
representation in charge will decide whether these
are large enough for the selected printing press. This
also applies to the removal of the press from the print‐
ing office.
The dimensions and weights of the packing case of
printing press and peripheral equipment can be
found in the main chapter Specifications.
Note
The height of the transport devices
used for bringing the subassemblies of
the press and the peripheral equipment
into the pressroom or for removing
them from the pressroom must also be
taken into account.
We recommend consulting the architect in charge,
the contractor, and the Heidelberg Service to clarify
these details.
1.5 Air conditioning and ventilation of the pressroom

The air-conditioning equipment must be adapted to
the local climatic conditions and the pressroom-spe‐
cific requirements.
Good air circulation is necessary to obtain a healthy
indoor climate and to reduce energy costs. This can
be achieved by installing a ventilation and air remov‐
al system with heat exchanger and fresh air contents.
A well-balanced and constant climate in the press‐
room helps to minimize production shutdowns.
Commission the architect or heating engineer in
charge with planning these details.
Requirements placed upon the place of installation

● General dust limit level for room air: <6 mg/m3
(with particle diameters <10 μm).
● Ideal ambient air temperature (depending on
the activity): 20°C...24°C (68°F...75°F);
Minimum ambient air temperature: 15°C (59°F);
Maximum ambient air temperature: 35°C (95°F);
Maximum ambient air temperature for printing
presses with Anicolor inking unit: 30°C (86 °F).
● Ideal ambient air humidity (depending on print‐
ing material): 50 %...58 %.
● Steady temperature conditions must be ensured.
● The air quantity removed from the installation
site must be returned in a suitable form.
B.2.4 00.999.5895/
● Velocity of the ambient air in the pressroom

(e.g. from air conditioning system): <0.2 m/
s (<0.65 fps).
● Velocity of the ambient air in special equipment
rooms: <1.0 m/s (<3.28 fps).
00.999.5895/ B.2.5
2 Machine foundation
SC.906.1106-000UTKENU_00

The specifications in this chapter provide a frame‐
work planning engineer with the necessary input vari‐
ables required for safely designing the foundation
and thus ensuring the operability of the printing press.
When planning the foundation pay attention to the fol‐
lowing points:
● the floor characteristics,
● the machine loads,
● the dynamic forces,
● the maximum permissible subsidence,
● the bending strength of the foundation plate and
● the other environmental conditions (e.g. struc‐
ture-borne noise excitations and moving loads).
Please contact your Heidelberg agency or factory rep‐
resentative should you require any further informa‐
tion on how to lay the foundations.
Note
Heidelberg printing presses are preci‐
sion machines that must rest on a solid
foundation. The printing press consists
of interconnected modules that do not
have a common bed. The individual
components are thus loosely coupled.
We therefore recommend to install the
printing press on a separate uniform
press foundation. The press foundation
should be designed for the tensile
stress occurring under load. Avoid ex‐
pansion gaps and separation joints in
the press foundation. Always contact
your framework planning engineer and/
or your Heidelberg branch office or fac‐
tory representative if expansion joints
or separating lines cannot be avoided.
The customer must always commission
a framework planning engineer with ex‐
perience in machine foundations for de‐
signing and planning the press founda‐
tion
2.2 Press weights and floor loads

Press weight and floor load values of the printing
press with standard installation
CX 102-4 33010 (72755) 34700 (76500) 9671 (202.0)
B.2.6 00.999.5895/
CX 102-4 + L 37780 (83291) 39470 (87016) 9861 (206.0)
CX 102-4 + L (X2) 39080 (86157) 40770 (89882) 8951 (187.0)
CX 102-4 + L (X3) 39730 (87590) 41420 (91315) 8574 (179.1)
CX 102-5 39440 (86950) 41130 (90676) 10276 (214.7)
CX 102-5 + L 44210 (97466) 45900 (101192) 10392 (217.1)
CX 102-5 + L (X2) 45510 (100332) 47200 (104058) 9499 (198.4)
CX 102-5 + L (X3) 46160 (101765) 47850 (105491) 9123 (190.6)
CX 102-6 45870 (101126) 47560 (104852) 10768 (224.9)
CX 102-6 + L 50640 (111642) 52330 (115368) 10832 (226.3)
CX 102-6 + L (X2) 51940 (114508) 53630 (118234) 9962 (208.1)
CX 102-6 + L (X3) 52590 (115941) 54280 (119667) 9591 (200.4)
CX 102-7 52300 (115302) 53990 (119027) 11175 (233.5)
CX 102-7 + L 57070 (125818) 58760 (129543) 11202 (234.0)
CX 102-7 + L (X2) 58370 (128684) 60060 (132409) 10359 (216.4)
CX 102-7 + L (X3) 59020 (130117) 60710 (133842) 9995 (208.8)
CX 102-8 58730 (129477) 60420 (133203) 11518 (240.6)
CX 102-8 + L 63500 (139993) 65190 (143719) 11518 (240.6)
CX 102-8 + L (X2) 64800 (142859) 66490 (146585) 10703 (223.6)
CX 102-8 + L (X3) 65450 (144292) 67140 (148018) 10348 (216.2)
Tab. 1 Press weight and floor load values of the printing press with standard installation
● The press weight specifies the overall weight of
the printing press without peripheral equipment.
● Weight of peripheral equipment: See the chap‐
ter "Dimensions and weight of peripheral equip‐
ment" in the main chapter entitled "Specifica‐
tions".
● Calculation of the paper pile weight at a paper
density of 1 kg/dm3 (0.036 lbs/cu in).
This corresponds to coarse paper of a gram‐
mage of 90 g/m2 (198 gr/sq ft).
2.3 Weights of the machine components

Preset Plus feeder 2000 (4410)
First printing unit (1) 6110 (13470)
Printing unit (from PU 2 onwards) (1) 6430 (14180)
Coating unit (2) 4770 (10520)
Preset Plus delivery without extension module 5210 (11490)
00.999.5895/ B.2.7

Preset Plus delivery with two extension modules 6510 (14350)
Preset Plus delivery with three extension modules 7160 (15785)
Tab. 2 Weight of the press components
(1): Including inking rollers (200 kg (440 lbs)) and foot‐
boards (90 kg (200 lbs)).
(2): Including footboards (90 kg (200 lbs)).
2.4 Average static floor load

Average static floor load: see Table 1.
SC.906.1106-000GRAUND_00
Calculation of the average static floor load:
Ratio of press weight including two piles and floor
space required by the printing press (including foot‐
boards) without peripheral equipment.
1 Applicable area
Fig. 1 Standard area for determining the mean

static floor load
2.5 Maximum static surface pressure
Maximum static surface pressure

[N/cm2] ([lbf/sq in])
120 (174)
Tab. 3 Maximum static surface pressure
The maximum static surface pressure is the maxi‐
mum static surface pressure that occurs under the
feet of the printing units or the coating unit.
This value takes into account the fact that the print‐
ing units sit on four feet and are therefore geometri‐
cally unstable.
The surface of an adjustable base is:
● for the printing unit: 246 cm2 (38.13 sq in),
● for the coating unit: 246 cm2 (38.13 sq in).
2.6 Material requirements

We recommend an elastic machine foundation bed
with an adequate reinforcement and a quality of con‐
crete complying with at least C30/37 as per EN 206/1.
B.2.8 00.999.5895/

(0.067...0.101 lbs/cu in)
cu in).
2.7 Foundation settling

The absolute subsidence of the foundation after in‐
stalling and before assembling the printing units is of
no significance for the printing press.
Once the press has been installed and aligned, any
further non-uniform settling of the foundation must
not exceed 0.03 mm/m (0.36 mil/ft). This limit applies
to both longitudinal direction (bending) and trans‐
verse direction (torsion).
A uniform settling of the foundation which does not
cause the press to become deformed has no nega‐
tive side effects.
2.8 Flatness tolerance limit

The permitted limit value (Fig. 2/3) for flatness toler‐
LS.906.3804-000GRAUND_00
ances in a surface finished press foundation is a max‐

imum of 15 mm (0.59 in).
The flatness tolerances can be determined by taking
a diagonal measurement (Fig. 2/1) across the sur‐
1
face of the press foundation (Fig. 2/2). Two addition‐
al measurements (Fig. 2/1) should be performed in
the relevant control range of the leveling blocks.
For additional information and the allowed flatness tol‐
erances refer to the standard DIN 18202.
2
Fig. 2 Flatness tolerances in the press foundation
2.9 Dynamic foundation loads

Dynamic forces are applied to the ground during the
operation of the printing press.
The frequency at which the dynamic forces are trans‐
ferred to the foundation is closely connected to the
printing speed of the printing press.
00.999.5895/ B.2.9
The speed-synchronous forces are the largest com‐

ponent. The cause is in the residual imbalance of the
single-speed cylinders. The amplitude of the applied
imbalance forces rises with the square of the printing
speed.
The excitation frequency corresponds to the printing
speed. It can be determined with the following formula:
f = printing speed (sheets/h) / 3600 = result in Hz.
citation frequency of 4.6 Hz.
In addition and to a lesser extent there are forces of
higher orders, the excitation frequencies of which are
also linked directly to the printing speed. Dynamic
forces up to the 5th order (4-fold rotary frequency)
are relevant to the foundation design.
citation frequency of the 5th order of 23 Hz.
The sum of the dynamic forces the printing press ap‐
plies to the foundation is not higher than 4 % of the
weight force of the printing press.
The dynamic forces are subdivided as follows:
● Single-speed forces (residual imbalance): 2 %
● Forces of the 2nd - 5th order (equally distribut‐
ed): 2 %.
2.10 Floor compression under the foundation plate

We recommend compressing the floor under the foun‐
dation plate with load-bearing and compression-capa‐
ble floor material to 97 % Proctor density.
Proctor density: Reference density for determining
the compressibility degree of a ground.
2.11 Foundation plate rigidity

When laying the foundations, please ensure that the
foundation plate is highly rigid. This will reduce the
static deflection and often the problem of foundation
vibrations, too.
2.12 Installation of the printing press on an uncoupled foundation

When installing the printing press on a decoupled
foundation, sufficient rigidity of the foundation must
be ensured.
With this type of installation, again ensure sufficient
foundation mass and suitable insulating layers. In
this way you will prevent impermissibly deep lower‐
ing of the foundation plate, e.g. in the case of pile feed.
Please, also consider direct uncoupling of press and
main drive by means of insulating boards.
B.2.10 00.999.5895/
Note
The installation on an uncoupled foun‐
dation or on insulating boards requires
a thoroughly planned design. Please
consult your Heidelberg agency or fac‐
tory representative.
00.999.5895/ B.2.11
3 Foundation dimensions
SC.906.1107-000UTKENU_00
3.1 Dimensions of the foundation for standard installations

SG.906.0002-000GRAUND_00
sions:
1 Recommended length: see Table 4
2
1 2 Recommended width: 2000 mm (78.74 in)
The surface requirement of the main drive is not in‐
cluded in the dimensions of the foundation.
Fig. 3 Dimensions of the foundation plate (sketch)

Recommended foundation length in standard installa‐
tion
Press version Recommended foundation length for standard installations [mm] ([in])
CX 102-4 10300 (405.51)
CX 102-4 + L 11520 (453.54)
CX 102-4 + L (X2) 13150 (517.72)
CX 102-4 + L (X3) 13960 (549.61)
CX 102-5 11520 (453.54)
CX 102-5 + L 12740 (501.57)
CX 102-5 + L (X2) 14370 (565.75)
CX 102-5 + L (X3) 15180 (597.64)
CX 102-6 12740 (501.57)
CX 102-6 + L 13960 (549.61)
CX 102-6 + L (X2) 15590 (613.78)
CX 102-6 + L (X3) 16400 (645.67)
CX 102-7 13960 (549.61)
CX 102-7 + L 15180 (597.64)
CX 102-7 + L (X2) 16810 (661.81)
CX 102-7 + L (X3) 17620 (693.70)
CX 102-8 15180 (597.64)
CX 102-8 + L 16400 (645.67)
CX 102-8 + L (X2) 18030 (709.84)
CX 102-8 + L (X3) 18840 (741.73)
Tab. 4 Recommended foundation length with standard installation
B.2.12 00.999.5895/
3.2 Dimensions of the foundation for elevated installations

SG.906.0003-001GRAUND_00
sions:
3
2 2 Width: 1600 mm (63.00 in)
1 3 Width of the strip foundations: 350 mm (13.78 in)
4
4 Height: 500 mm (19.69 in)
To provide for an easy installation of cables and ho‐
ses, the strip foundations should have circular open‐
ings.
Diameter of the openings Distance of the openings

[mm] ([in]) from the floor [mm] ([in])
Fig. 4 Dimensions of the strip foundations for ele‐ 200 (7.87) 200 (7.87)
vated installations (diagram)
Dimensions of the motor mounting base [mm] ([in])

Length 1000 (39.37)
Width 800 (31.50)
Height 500 (19.69)
Tab. 6 Dimensions of the motor mounting base
Further information about the design of strip founda‐
tions and motor mounting base can be found in the
chapter Elevated printing press in the main chapter
Technical information.
Foundation length for elevated installation
[mm] ([in])
Delivery <- feeder
CX 102-4 3660 (144.09) | 2550 (100.39) 6210 (244.49)
CX 102-4 + L 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-4 + L (X2) 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-4 + L (X3) 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-5 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 7430 (292.52)
CX 102-5 + L 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-5 + L (X2) 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-5 + L (X3) 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-6 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 8650 (340.55)
CX 102-6 + L 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-6 + L (X2) 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-6 + L (X3) 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
00.999.5895/ B.2.13
[mm] ([in])
Delivery <- feeder
CX 102-7 3660 (144.09) | 3660 (144.09) | 2550 (100.39) 9870 (388.58)
CX 102-7 + L 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-7 + L (X2) 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-7 + L (X3) 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-8 3660 (144.09) | 2440 (96.06) | 2440 (96.06) | 2550 (100.39) 11090 (436.61)
CX 102-8 + L 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
CX 102-8 + L (X2) 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
CX 102-8 + L (X3) 3660 (144.09) | 3660 (144.09) | 2440 (96.06) | 2550 (100.39) 12310 (484.64)
B.2.14 00.999.5895/
4 Supply systems and supply lines

LS.906.3202-000UTKENU_05
4.1 Electric power supply - mains connection

Caution - Danger of damage to and mal‐
functions of electric devices through in‐
sufficient dimensioning of power supply
systems!
The management of the print shop
must clarify details of the layout of the
mains connection with the local energy
supply company.
This is also necessary when replacing
an old press with a new one since the
actual power requirements may differ.
Overhead installation of the connecting lines in pow‐
er supply ducts and/or on cable trays is a proven in‐
stallation practice.
The chapter Electric installation of the printing press
lists all requirements on the electric power supply for
each press model to assist you with planning and de‐
cision-making.
4.2 Water supply and water treatment

Planning and any other work that concern the fresh
water supply of the printing press must be initiated
by the user or the management of the print shop,
and may only be carried out by qualified staff.
Note
Relevant national provisions must also
be observed!
Contact your local water supply company to find out

whether the water requires special treatment for
press operation.
If certain substances in the water (e.g. carbonate, ox‐
ide, metallic salt, etc.) exceed the admissible limits, a
water treatment system must be installed to avoid mal‐
functions.
One criterion for describing water quality is the water
hardness. Installing a water treatment system may
be necessary for a water hardness from approximate‐
ly 12°dH (8.1 mmol/USgal). Water hardness of more
than 18°dH (12.1 mmol/USgal) always requires the in‐
stallation of a water treatment system.
Reference values
● Water hardness: 8°...12° dH (5.4...8.1 mmol/US‐
gal)
● pH value: 4.8...5.5
Additional information about water hardness can be
found in the appendix, chapter Water hardness.
00.999.5895/ B.2.15
4.3 Compressed-air supply and compressed-air treatment

The compressed air required for operating the print‐
ing press is usually generated and conditioned in a
compressor station which is delivered as a part of
the printing press. Specifications can be found in the
chapter Pneumatic compressor ScrollStar, and in the
main chapter Specifications.
When planning the layout of the pressroom, make
sure that a sufficient and suitable fresh air supply is
available for compressed-air treatment.
Should a compressor station with compressed-air
treatment unit and compressed-air system already ex‐
ist in the pressroom, connecting the pneumatic sys‐
tem of the press to it may be possible. In this case,
the compressor station is not required.
More information can be found in the chapter Air sup‐
ply via the central air supply system.
4.4 Suction air and blast air supply

The suction and blast air required at the printing
press is generated and conditioned in the AirStar air
supply cabinet, which is delivered as a part of the
printing press.
When planning the layout of the pressroom, make
sure that an adequately dimensioned and suitable
fresh air supply is available for suction air and blast
air treatment and for cooling the additional devices.
More information can be found in the chapter AirStar
air supply cabinet.
B.2.16 00.999.5895/
5 Printing Office Planning Department of Heidelberger Druckmaschinen AG

LS.906.3203-000UTKENU_01
5.1 Printing Office Planning Department of Heidelberger Druckmaschinen AG

Heidelberger Druckmaschinen AG offers a special
service for planning new printing offices and for con‐
verting or extending existing printing offices all
around the world.
Heidelberg Printing Office Planning will be pleased to
assist you with the following tasks:
● Preliminary planning of buildings
● Functional planning
● Work and material flow (logistics)
● Domestic service facilities
● Supply systems for the press (electricity, water,
air, etc.).
Construction planning, including design drawings, de‐
signs, detailed drawings, relevant cost calculations,
etc. must be carried out by architects in cooperation
with engineers specialized in statistics, heating, ven‐
tilation and air-conditioning, electrics, etc.
Heidelberg Printing Office Planning is not authorized
to carry out these tasks.
Address:
Heidelberger Druckmaschinen AG
Printing Office Planning
Kurfürsten-Anlage 5260
D-69115 Heidelberg
Germany
Tel. +49-(0)6221/92-0
00.999.5895/ B.2.17
B.2.18 00.999.5895/
Elevated printing press
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3

1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
1.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
1.3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.3
1.4 Required accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.4
2 Nonstop Preset Plus feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.5

2.2 Pile heights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.5
3 Strip foundations for elevated printing presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6

3.1 Possible versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6
3.2 Material requirements and weight calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.6
3.3 Production and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.7
4 Motor mounting base for elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.8

4.2 Material requirements and weight calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.8
4.3 Design of the motor mounting base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.9
4.4 Installation of the prefabricated motor mounting base . . . . . . . . . . . . . . . . . . . . . . . . . B.3.10
5 Oil drip pans for elevated presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.11

5.1 Oil drip pans for elevated presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.11
00.999.5895/ B.3.1
B.3.2 00.999.5895/
1 General information
SC.906.3401-000UTKENU_05
1.1 General Information

Elevating the printing press permits higher printing
SC.906.3403-000GRAUND_00
material piles to be used in feeder and delivery.
1 2 The maximum pile weight at the feeder and delivery
must not exceed the following value:
● 2000 kg (4410 lbs).
With the elevated printing press CD 102 or CX 102,
pile feed is possible laterally at the feeder (Fig. 1/1)
and optionally at the front side. The pile withdrawal
at the delivery is only possible from the side (Fig. 1/2).
Fig. 1 Pile feed and removal

Possible height
Printing presses of the CD 102 product line (with Pre‐
set Plus feeder) or CX 102 can be elevated by
500 mm (19.69 in).
1.2 Requirements
● A safe installation of the strip foundations re‐
quires adequate foundations to exist all over the
potential installation area of the printing press.
Inspection by a structural engineer is absolutely
necessary.
● Bottom plates for the floor space between the
strip foundations are not included in the delivery
of elevated printing presses. A suitable floor cov‐
ering must be laid in this area. This includes for
example tiles or an epoxy-coated floor covering.
Dimensions of the elevated printing press

The dimensions of the elevated printing presses in
various machine versions, and the specifications of
the minimum surface and working space required
can be found in the main chapter Specifications.
1.3 Installation
The printing units are installed on premanufactured
strip foundations. Both, feeder and delivery, are posi‐
tioned on supports on the floor of the machinery hall.
Additional information can be found in the chapter
Strip foundations for elevated printing presses.
The main driving motor is installed on a separate mo‐
tor mounting base that is drilled and bolted together
on site. Additional information can be found in the
chapter Motor mounting base for elevated printing
presses.
A gallery surrounds the printing press. It is used for
walking on the printing press and for rendering the
00.999.5895/ B.3.3
press safe. It provides space for installing the Prinect

Press Center and a Prinect peripheral unit (e.g. Pri‐
nect Image Control).
1.4 Required accessories

An elevated Speedmaster CD 102 or CX 102 re‐
quires various components that are different than the
ones for the standard installation.
The following parts are delivered along with the
press in the standard configuration:
● "Raised feeder" subassembly,
● "Raised delivery" subassembly.
The following items are also delivered when a raised
press is ordered or when an existing press is to be
raised:
● Gallery with railings, stairs, platforms on feeder
and delivery with space for the installation of
the Prinect Press Center and a Prinect peripher‐
al unit (e.g. Prinect Image Control).
The following items have to be ordered by the cus‐
tomer and manufactured by a concrete factory accord‐
ing to Heidelberg instructions:
● Strip foundation segments for elevating the
press by 500 mm (19.69 in);
● Motor mounting base for the installation of the
main drive.
Please refer to the chapters Strip foundations for ele‐
vated printing presses and Motor mounting base for
elevated printing presses.
Note
Only Heidelberg Service are allowed to
install the printing press with main drive
on the strip foundations and the motor
mounting base, to install the gallery,
and to start up the printing press.
B.3.4 00.999.5895/
2 Nonstop Preset Plus feeder

SC.906.3409-000UTKENU_01

The nonstop Preset Plus feeder permits the pile to
FS.906.3414-000GRAUND_00
be changed automatically. The automatic nonstop
pile change permits an empty pallet to be replaced
with a full one without interrupting the running produc‐
tion.
The nonstop rods move from their home position
against the direction of paper travel into the grooves
of the nonstop pallet. The auxiliary pile lifting unit
takes over the pile when the nonstop rods are in their
2 working position (Fig. 2/2). The main pile moves
down. You can change the pallet. The new main pile
(Fig. 2/3) is aligned. Main pile and auxiliary pile are
3 merged. The nonstop rods are withdrawn from the
1 pile and move to their home position (Fig. 2/1).
Based on the entered printing material properties
and the preselected production speed, the control sys‐
tem calculates the residual pile height required for au‐
tomatic pile change.
Fig. 2 Nonstop Preset Plus feeder
2.2 Pile heights

A smooth pile change in automatic nonstop opera‐
tion of the Preset Plus feeder requires the specifica‐
tions in the following table to be observed.
Note
Ensure that there is a sufficiently high
residual pile in the Preset Plus feeder
before pile change is started. A new
main pile must be available in time. The
preselected production speed must cor‐
respond to the actual printing speed.
Pile heights for printing presses elevated by 500 mm
(19.69 in)
Stock thickness [mm] ([in]) Pile height (1) [mm] ([in]) at printing speed
15000 [sheets/h] 13000 [sheets/h] 11000 [sheets/h]
0.3 (0.012) 1190 (46.85) 1210 (47.64) 1230 (48.43)
0.4 (0.016) 1150 (45.28) 1170 (46.06) 1190 (46.85)
0.5 (0.020) 1110 (43.70) 1140 (44.88) 1170 (46.06
0.6 (0.024) 1070 (42.13) 1100 (42.52) 1130 (44.49)
0.8 (0.031) 990 (38.98) 1030 (40.55) 1070 (42.13)
Tab. 1 Pile heights for printing presses elevated by 500 mm (19.69 in)
(1) The specified values refer to the pure pile height
without automatic nonstop pallet.
00.999.5895/ B.3.5
3 Strip foundations for elevated printing presses

SC.906.3402-000UTKENU_04
3.1 Possible versions

Strip foundations 500 mm (19.69 in) high can be com‐
posed of segments, or be built on site as continuous
strip foundations.
● Strip foundation segments: The foundation of
this version is composed of segments. The strip
foundation segments are produced in a con‐
crete factory according to the specifications
from Heidelberg.
● Continuous strip foundations: This version is pro‐
duced (reinforcement, forming and casting) di‐
rectly in the pressroom.
Nature and condition of the flooring at the future
place of installation of the printing press must be tak‐
en into account when deciding on strip foundation seg‐
ments or continuous strip foundations. For stability
reasons, we recommend continuous strip founda‐
tions produced directly in the pressroom.
3.2 Material requirements and weight calculation

Material requirements
We recommend heavy-duty concrete of concrete
property class C30/37 to EN 206/1 for all foundation
work.
(0.067...0.101 lbs/cu in)
cu in).
Weight calculation
Table 2 shows the mass of each meter of a strip foun‐
dation made from the above-mentioned concrete type.
Weight of the strip foundations

Height [mm] ([in]) Width [mm] ([in] Mass per meter
[kg/m] ([lbs/ft])
500 (19.69) 350 (13.78) 440 (295)
Tab. 2 Weight of the strip foundations
B.3.6 00.999.5895/
Note
For statical calculations it must be con‐
sidered that according to the type of ce‐
ment used and according to the propor‐
tion of gravels, the density and the
mass of the foundation strips can vary.
3.3 Production and installation

You must observe the following specifications when
you produce and install strip foundations:
● Dimensions of the strip foundation: see chapter
Dimensions of the foundation.
● A safe installation of the strip foundations re‐
quires adequate foundations to exist all over the
potential installation area of the printing press.
Inspection by a structural engineer is absolutely
necessary.
● The weight of the strip foundations must be tak‐
en into account, particularly with critical floor
loads and ceiling load capacity.
● We recommend heavy-duty concrete of con‐
crete property class C30/37 to EN 206/1 for all
foundation work.
● Premanufactured strip foundation segments
must be arranged longitudinally next to each oth‐
er without leaving any gaps.
● The diagonal height deviation for both strip foun‐
SG.904.3400-000GRAUND_00
max. 10 mm dations must not exceed 10 mm (0.39 in).

(max. 0.39 in)
● Minor differences of the strip foundation levels
can be eliminated with a thin layer of mortar.
Fig. 3 Maximum diagonal height deviation of the

two strip foundations
● To provide for an easy installation of cables and
hoses, the strip foundations should have circu‐
lar openings.
Distance of the openings Diameter of the openings

from the floor [mm] ([in]) [mm] ([in])
200 (7.87) 200 (7.87)
● The hardening time of fresh concrete is usually
28 days. Please take the time for hardening into
account when planning the printing press instal‐
lation.
00.999.5895/ B.3.7
4 Motor mounting base for elevated printing press

SC.906.3404-000UTKENU_04

● Due to technical reasons, the motor mounting
base cannot be mounted before the installation
of the printing units.
● Installing the main driving motor on a steel sup‐
port frame is not permitted!
Manufacture
Due to technical reasons, the motor mounting base
must be prefabricated completely as a single seg‐
ment in a concrete factory. The Heidelberg specifica‐
tions must be observed.
Height of the motor mounting base

The height of the motor mounting base and the
height of the strip foundations must be identical.
The motor mounting base of a printing press of the
CD 102 (with Preset Plus feeder) or CX 102 product
line must therefore be of the following height:
500 mm (19.69 in).
4.2 Material requirements and weight calculation

Material requirements
We recommend heavyweight concrete of concrete
property class C30/37 to EN 206/1 for all foundation
work.
(0.067...0.101 lbs/cu in)
cu in).
Weight calculation
The mass of the motor mounting base when manu‐
factured with the type of concrete specified above is
shown in the following table:4
B.3.8 00.999.5895/
Weight of the motor mounting base

Height [mm] Length Width Mass
([in]) [mm] ([in]) [mm] ([in]) [kg] ([lbs])
500 (19.69) 1000 800 (31.50) 980 (2161)
(39.37)
Tab. 4 Weight of the motor mounting base
Note
For statical calculations it must be con‐
sidered that according to the type of ce‐
ment used and according to the propor‐
tion of gravels, the density and the
mass of the motor mounting base can
vary.
4.3 Design of the motor mounting base
SG.904.3402-002GRAENU_00
500 (19.69)
30 (1.18)
O.S.
Threaded insert
M20 Bored hole
Ø 25 (1.0)
800 (31.50)
300
(11.81) D.S.
150 (5.9)
150 (5.9)
300 (11.81)
1000 (39.37)
150 (5.91)
Fig. 4 Dimensions and installation of the motor mounting base. All dimensions are in mm (in).
Besides having the correct outer dimensions, the mo‐
tor mounting base must fulfill a number of other fac‐
tors.
● The motor mounting base must be fastened to
the floor of the machinery hall using four screws
(M 20 for example) and shear connectors. For
00.999.5895/ B.3.9
this purpose, one bored hole (diameter: 25 mm

(1.0 in)) must be provided on each of the four
corners of the motor mounting base.
● The motor mounting base must be designed
such that it is level according to Fig. 4.
● In order to be able to transport the motor mount‐
ing base, include four threaded inserts (M 20,
for example) at the top when you cast the con‐
crete. To transport the motor mounting base
you can use lifting screws and a lifting gear, for
example.
4.4 Installation of the prefabricated motor mounting base

● At the future location of the motor mounting
base, four holes must first be drilled in the floor
and be provided with suitable shear connectors
(for example M 20).
● The locations and distances of the boreholes in
the shop floor must correspond to the ones of
the through-holes in the motor mounting base.
● The motor mounting base must be screwed
down on the shear connectors in the shop floor
by means of four screws (e.g. M 20) and the rel‐
evant washers (minimum quality: 8.8).
Note
The main drive is generally mounted on
the motor mounting base by Heidelberg
Service.
B.3.10 00.999.5895/
5 Oil drip pans for elevated presses

SC.906.3403-000UTKENU_05
5.1 Oil drip pans for elevated presses

During printing press operation small amount of lubri‐
cants are released (especially press oil). Any ma‐
chine oil seeping into the strip foundations will make
the concrete brittle over time, and reduce its strength.
Cover plates must therefore be used to protect partic‐
ularly exposed areas of the strip foundations against
oil.
● Heidelberg offers prefabricated oil drip pans for
standardized strip foundations.
All four sides of each oil drip pan are beaded.
The frame height is 25 mm (1 in) or 40 mm
(1.57 in).
At the front, the oil drip pans are screwed to
each other with pipe nipples through which the
oil can flow.
Both the first and the last oil drip pan are each
equipped with a drain tube and a stopcock. This
permits the draining of the collected machine oil
into a canister or some similar container.
● The oil drip pans can, however, also be pro‐
duced by a tinsmith according to the following
specifications and the following illustrations:
○ Corrosion-proof plates (e.g. galvanized
steel plate) or special steel plates should
be used as the material for cover plates
and collection containers.
○ To reduce the risk of injury during cleaning
work or the like, all plate edges must be
trimmed and flattened down.
● Oil drip pans for the floor space between the
strip foundations are not included in the delivery
of elevated printing presses. A suitable floor cov‐
ering must be provided in this area. This in‐
cludes for example tiles or an epoxy-coated
floor covering.
00.999.5895/ B.3.11
SC.906.3402-000GRAENU_00
Preset Plus delivery Preset Plus feeder
Last printing unit / Intermediate printing units /

Last coating unit Intermediate coating units First printing unit
1738 (68.43) 1220 (48.03) 1220 (48.03) 1220 (48.03) 1210 (47.64)
(19.88)
505
1755 (69.09)
745 (29.33)
9 (0.35)
1000 mm
(39.37 in)
Fig. 5 Oil drip pans for elevated printing presses of the CD 102 (Preset Plus) or CX 102 product line. All
dimensions in mm (in) .
B.3.12 00.999.5895/
Electrical installation of the printing press
1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.3

2 Specifications of the electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.4

2.2 Nameplate for the electrical equipment of the printing press . . . . . . . . . . . . . . . . . . . . B.4.4
2.3 Indicator plate for the connection of the printing press to the electric mains . . . . . . . . B.4.5
2.4 Location of nameplate and indicator plate on/in the central control cabinet . . . . . . . . B.4.5
3 Basic regulations for the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7

3.1 Types of power supply systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.7
3.4 EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.8
3.5 Power supply tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.10
3.6 Mains impedance values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.10
3.7 Power cable requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.11
3.8 Notes on laying the cables for the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.11
3.9 Mains cable entry into the central control cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.12
3.10 Checking the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.12
4 Basic recommendations and notes on the mains connection . . . . . . . . . . . . . . . . . . . . . . . . B.4.14

4.2 Selecting the material for power cables and PE conductors . . . . . . . . . . . . . . . . . . . . B.4.14
4.4 Switching on, starting up and running up the press . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.14
4.5 Load characteristics, harmonics and flickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.14
5 Mains connection of the printing press to the three-phase mains . . . . . . . . . . . . . . . . . . . . . B.4.16

5.2 Notes on the mains connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.17
5.3 Overview of the standard mains connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.18
6 Cross sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.23

6.1 Cross sections of the line terminals on the main switch . . . . . . . . . . . . . . . . . . . . . . . B.4.23
6.2 Cross sections of the conductor terminals at the series transformer . . . . . . . . . . . . . . B.4.23
00.999.5895/ B.4.1
B.4.2 00.999.5895/
1 General Information
SC.906.3800-000UTKENU_05

This chapter contains information about the electrical
installation of the press.
Note
Planning and any other work that con‐
cern the electrical installation of the
printing press must be initiated by the
user or the management of the print‐
shop, and may only be carried out by
qualified experts when the mains volt‐
age is switched off.
The specifications in the IEC/
EN 60204-1 standard, in particular,
must be observed.
be observed!
This chapter must be made available to the commis‐
sioned skilled personnel for planning of the installa‐
tion work to be done.
00.999.5895/ B.4.3
2 Specifications of the electrical equipment

SC.906.3801-000UTKENU_05

The press-specific specifications of the electrical
equipment of a printing press are shown on the name‐
plate.
The nameplate is attached to the central control cabi‐
net ZSG, which is a part of each printing press.
In the central control cabinet ZSG there is an addition‐
al indicator plate that specifies the connection of the
printing press to the electric mains.
2.2 Nameplate for the electrical equipment of the printing press
SG.904.3802-003GRAUND_00
2
1
TYPE XX 3 HDM-NO. XX.XXX.XXXX
M.NO. XXXXXX 5
U. XXX V 6 3 ~ xx Hz
I/P 4 XXX A XXX kW
Icu XX kA 7 9
8
Wiring diagramm - NO. XX.XXX.XXXX
XX.XXX.XXXX
Fig. 1 Nameplate for the electrical equipment of the printing press

1 Press version
2 Part number of the central control cabinet ZSG
3 Serial number
4 Mains voltage
5 Voltage type and mains frequency
6 Current
7 Energy demand
8 Rated ultimate short-circuit breaking capacity (1)
9 Part number of the wiring diagram
(1) The term "rated ultimate short-circuit breaking ca‐
pacity" Icu defines the maximum short-circuit current
the selected circuit-breaker is able to interrupt. Fur‐
ther information about the topic Rated ultimate short-
circuit breaking capacity can be found in the IEC/
EN 60947 Standard Specification.
B.4.4 00.999.5895/
Note
When you connect to a mains voltage
that differs from the voltage on the
nameplate (less/more than 400 V), you
must observe the current values and
Icu values listed in the Specifications.
2.3 Indicator plate for the connection of the printing press to the electric mains
In the central control cabinet ZSG next to the main
SG.906.3803-000GRAUND_00
switch, there is an indicator plate in four languages.
Beim Anschließen der Druckmaschine an das Stromnetz müssen This plate tells you that you must always observe the
unbedingt die Vorgaben und Informationen in der Technischen
Dokumentation beachtet werden. requirements and information in the technical docu‐
mentation when you connect the printing press to the
The specifications and informations in the Technical Documentation electric mains.
must be strictly observed and respected when connecting the
printing press to the power supply system.
Observer impérativement les consignes et informations de la

Documentation Technique lors de la connexion de la presse au
réseau électrique.
Al conectar la máquina de imprimir a la red eléctrica deben

observarse las indicaciones e informaciones de la
Documentatión Técnica.
10.120.0600
Fig. 2 Indicator plate for the connection of the print‐

ing press to the electric mains.
2.4 Location of nameplate and indicator plate on/in the central control cabinet
SG.904.3800-003GRAUND_00
Fig. 3 Plates on/in the central control cabinet ZSG: front left ZSG, rear right ZSG
The following plates can be found on/in the central
control cabinet ZSG:
00.999.5895/ B.4.5
1 Indicator plate for the connection of the printing

press: Inside the ZSG in the vicinity of the main
switch.
2 Nameplate for the electric equipment of the print‐
ing press: Outside the ZSG above the cable en‐
try.
B.4.6 00.999.5895/
3 Basic regulations for the mains connection

SC.906.3802-000UTKENU_09
3.1 Types of power supply systems

To operate the printing press and its peripheral equip‐
ment, two different power supply systems are re‐
quired:
● A three-phase AC system with a protective
ground (PE) for the power supply of the printing
press. The phase angles must be 120°. The
three-phase system must fulfill the require‐
ments described below.
● An AC system (lighting system) with one or two
phases and a protective ground conductor for
the power supply to certain peripheral equip‐
ment. The AC system must fulfill the require‐
ments described below.
3.2 Layout of the mains connection

Connected load
The layout of the mains connection depends on the
power required by printing press and peripheral equip‐
ment.
The layout must always be made in agreement with
Heidelberg Service.
Reactive power
The power factor of the printing press during nominal
operation is specified in the main chapter Specifica‐
tions. It can also be calculated with the data on the
nameplate.
Typical calculation:
Power demand: P = 115 kW
Mains voltage: U = 400 V
Nominal current of the printing press: In = 190 A
Power factor λ = (P * 1000) / (U * In * √3) =
(115 kW * 1000) / (400 V * 190 A * √3) = 0.87
The value can be improved by an "inductor-capaci‐
tor" compensation.
3.3 Fuses and protective measures

● In all current-carrying feeder lines, appropriate
fuses must be installed next to the power sup‐
ply tap. Since the inrush current of the series
transformer can briefly rise to a multiple of the
nominal current, it must be ensured that these
fuses are not released by the magnetizing cur‐
rents that occur when the press is switched on.
The recommended fuse values listed in the
main chapter Specifications are selected such
that the fuses do not trip during normal operation.
00.999.5895/ B.4.7
● The protective ground conductor must be an in‐

dependent conductor.
● The PE conductor can be laid in a cable togeth‐
er with the outside conductors.
● The PE conductors must be copper cables.
● To IEC/EN 60204-1, the cross section of the PE
conductor must be at least 10 mm2
(0.016 sq in).
● The neutral conductor currents of the customer
system must not generate any noticeable poten‐
tial differences between the protective ground
conductor connecting point of the printing press
and the equipotential bonding strip of the build‐
ing.
● Shape, arrangement, color or marking of the PE
conductor must be unambiguous.
The PE conductor must be green-and-yellow
over its entire length if it is solely identified by
its color.
3.4 EMC requirements

Printing press and peripheral units
To prevent electromagnetic interference, the electri‐
cal and electronic subassemblies of Heidelberger
Druckmaschinen AG are designed and tested accord‐
ing to the applicable EMC directives. They fulfill the
protective requirements to IEC/EN 61000-6-2 and
IEC/EN 61000-6-4.
In general, the printing presses and peripheral units
are designed for industrial use.
For use in residential areas, further measures (such
as additional interference suppression filters) may be
required in individual cases to limit the interference
transmission.
B.4.8 00.999.5895/
External equipment
Caution - Damage and malfunction of
electrical devices due to electromagnet‐
ic interference!
Third-party equipment used on the print‐
ing press must not cause any malfunc‐
tions in the electronic system of the print‐
ing press or of the third-party equipment.
External equipment may only be put in‐
to circulation and used if it fulfills the
EMC requirements according to IEC/
EN 61000-6-2 and IEC/EN 61000-6-4,
if this compliance has been certified by
a properly authorized position at the
manufacturer's, and if the equipment is
marked with the CE mark.
Prior to installing external equipment
you must have checked the necessity
of EMC measures. EMC measures
must always be agreed with Heidelberg
Service.
The following measures could be considered:
● Installation of external controls outside the cen‐
tral control cabinet (ZSG) in a separate,
screened casing.
● Power supply of all non-Heidelberg equipment
via a separate feeder line from the mains.
● Appropriate filtering measures for the power sup‐
ply.
● Electrical isolation for the signal lines to the
HDM control system.
● Interference suppression of the grounding con‐
tacts of one- and three-phase loads using suita‐
ble RC elements.
● Interference suppression of the protective coils
and control contacts:
○ by RC elements for AC voltage;
○ by interference suppression diodes for DC.
● Laying three-phase/AC lines separately from da‐
ta/control cables.
● Through use of shielded data and control lines
for connecting units to the STR interface adapt‐
er (please also refer to the Interface adapter
chapter).
Connecting the shield at both cable ends.
● If printing press and external equipment are in‐
stalled at a distance and, at the same time, are
connected to different power supply systems, ad‐
equate equipotential bonding must be provided
between the two components in order to pre‐
vent equalizing current from flowing on the shield.
00.999.5895/ B.4.9
To IEC/EN 60204-1, the cross section of the PE

(0.016 sq in).
Using mobile telephones and other electronic equip‐

ment in the environment of the printing press
Due to the sometimes high interference radiation of
mobile phones and other electronic equipment, such
units may only be used at a minimum distance of
0,5 m (1.64 ft) from the printing press and the control
panels.
3.5 Power supply tolerances

● The following fluctuations are tolerated in the
power supply system:
○ Voltage:
Max. +/- 10%
○ Frequency:
Continuous max. +/- 1%
Peak max. +/- 2%
● The total difference between the nominal mains
voltage (point of supply from the public utility)
and the terminal voltage on the printing press
should not exceed 10%.
● Agreement with Heidelberg Service must be
reached if the voltage differences exceed the
above-mentioned tolerance ranges.
3.6 Mains impedance values

To ensure the shutdown of the electrical safety equip‐
ment provided for by the manufacturer, the user
must ensure that the following mains impedance val‐
ues are not exceeded:
Current [A] Maximum mains impe‐

dance [mΩ]
< 25 500
25...32 400
32...50 300
50...80 200
80...160 100
> 160 50
Tab. 1 Mains impedance values
The electrical connection specifications of the print‐
ing press can be found in the main chapter Specifica‐
tions.
B.4.10 00.999.5895/
3.7 Power cable requirements

● The print shop user must provide and install the
cables between the power supply system and
the main switch in the central control cabi‐
net (ZSG).
● Power cables and protective ground conductors
must be selected such that they will be suitable
for the occurring operating conditions, and are
sturdy enough to withstand external influences.
● Power lines and PE conductors must be copper
cables.
● The minimum cross section of power conduc‐
tors and protective ground conductors must be
dimensioned for the printing press require‐
ments. The following factors should be consid‐
ered:
○ Power demand and load current
○ Characteristic data of the back-up fuse
○ Short-circuit capability
○ Fusing characteristics of the connection to
the power supply
○ Setting data of the main switch fusing
○ Insulation type
○ Installation method
○ Cable length
○ Cable grouping and heat generation
○ Ambient temperature
The minimum cross sections can be found in
the IEC/EN 60204-1 standard.
● To IEC/EN 60204-1, the cross section of the PE
(0.016 sq in).
● The cross sections of the conductor terminals in
the ZSG central control cabinet must be ob‐
served (please refer to the chapter Cross sec‐
tions of the conductor terminal).
3.8 Notes on laying the cables for the mains connection

● Lay the power cables in a suitable way to the
loads. Auxiliary equipment: Power cable ducts,
cable racks, etc.
● Make all connections expertly.
Do not solder the connections. Use connector
sleeves for the splice protection of stranded con‐
ductors.
● To prevent unacceptable tensile force on the ca‐
ble ends, the cable ends must be fixed in a suit‐
able way (by cable clamps, for example).
● Lay the mains cable in an adequate length from
the cable entry into the central control cabinet
00.999.5895/ B.4.11
(ZSG) up to the mains terminals in the central

control cabinet.
● Only skilled personnel commissioned by the op‐
erator may lay the mains cable in the control cab‐
inet and connect the power supply!
3.9 Mains cable entry into the central control cabinet

The mains cables are inserted in equipment zone A
MS.907.3818-000GRAUND_00
of the central control cabinet ZSG. There are two op‐
tions for inserting the mains cable into the central con‐
trol cabinet.
One option is to insert the mains cables from below
through an opening in the base of the central control
cabinet. The second option is to insert the mains ca‐
ble through the top cover of the central control cabinet.
1 Cable entry variant 1

Figure 4 shows the central control cabinet. The open‐
ing (Fig. 4/2) for inserting the mains cable is at the
bottom in the base.
Cable entry variant 2

Figure 5 shows the central control cabinet. The open‐
ing (Fig. 5/3) for inserting the mains cable is in the
2 top cover. There are prepunched boreholes in the cov‐
er of the central control cabinet and in the cover
plate (Fig. 5/2). Break out the boreholes as required.
Fig. 4 Mains cable from below If the boreholes in the cover plate are too large, drill
the necessary boreholes at the other side. The
MS.907.3817-000GRAUND_00
2 square cover plate (Fig. 5/2) can be reattached in dif‐

ferent positions.
3 Note
Remove the cover plate and do not use
it again if you want to use US union
joints. Further information can be found
in the Mechanical/electrical service
manual.
1
Fig. 5 Mains cable from above
3.10 Checking the mains connection

During and after the installation work for the mains
connection, the following tests must be carried out by
B.4.12 00.999.5895/
the skilled personnel commissioned by the print shop

operator. This includes:
● Verifying that there is a clockwise rotating field.
● Verifying that the mains voltages are within the
voltage tolerance values.
● Verifying that the protective ground (PE) conduc‐
tor has an appropriate cross section.
● Verify that there is a proper and sufficient con‐
nection between the protective earth system of
the printing press and the protective earth (PE)
of the higher-level mains.
00.999.5895/ B.4.13
4 Basic recommendations and notes on the mains connection

SC.906.3803-000UTKENU_04
4.1 Layout of the mains connection

● We recommend connecting the entire electrical
equipment of a press via a single connection to
power supply (distributor). The installation will
then be comprehensible and reconstructible.
● All lines must be laid continuously from terminal
to terminal without intermediate connectors.
4.2 Selecting the material for power cables and PE conductors

● Power lines and PE conductors must be copper
cables.
● To keep the conduction loss between the power
supply system (transfer point of the power utili‐
ty) and the press as low as possible, choose as
large a conductor cross section as possible.
● In order not to exceed the permissible potential
drop between the power supply system and the
power supply area, you may have to plan for larg‐
er conductor cross sections.
4.3 Fuses and protective measures

It is generally not possible to connect the printing
press via RCDs (residual-current protective devices),
as the installed electronic equipment and filtering
measures cause the RCDs to malfunction.
4.4 Switching on, starting up and running up the press

When switching on, starting up and running up the
press, the load current is a maximum of 20 % above
the nominal current.
The fuse protection in the central control cabi‐
net (ZSG) is accordingly designed and may be modi‐
fied only in special cases following consultation with
Heidelberg Service.
4.5 Load characteristics, harmonics and flickers

● During operation (production) the load currents
can briefly lie a maximum of 20 % above the
nominal currents.
● To assess the harmonics and flickers in the
load case, the customer's entire system must al‐
ways be analyzed, supplied via a single power
connection point.
The dimensioning of printing presses and periph‐
eral equipment is always based on the IEC/
EN 61000-3-12 standard for harmonic currents
and IEC/EN 61000-3-11 for voltage changes,
voltage fluctuations, and flickers.
B.4.14 00.999.5895/
Further information on the printing press or pe‐

ripheral units is available from Heidelberg Serv‐
ice on request.
● Since a printing press contains ohmic, inductive
and capacitive consumers, typical harmonic cur‐
rents and flickers may occur to a certain extent.
Should such interference values occur more fre‐
quently because of a particularly high-impe‐
dance connection to the power supply, connec‐
tion to a power supply connection point of a low‐
er impedance is helpful.
00.999.5895/ B.4.15
5 Mains connection of the printing press to the three-phase mains

SC.906.3804-000UTKENU_07

Caution - Electrical shock when touch‐
ing voltage-carrying parts!
Any electrical installation work may on‐
ly be carried out by qualified experts
and when the mains is switched off.
The mains connection must be installed
according to the specifications in the
IEC/DIN EN 60204-1 standard.
The connection elements must be able
to withstand the occurring electric, ther‐
mal, and mechanical stress.
be observed!
The chapters Basic regulations for the
mains connection and Basic recommen‐
dations and notes on the mains connec‐
tion must be observed when the mains
connection is prepared.
General information
● The printing press is generally connected to the
three-phase mains via the central control cabi‐
net (ZSG).
● The operating voltage of the printing press is
A.C. 400 V.
● A direct connection is possible with a mains volt‐
age of AC 380 V, AC 400 V and AC 415 V.
● For mains voltages of less than AC 380 V and
greater than AC 415 V, Heidelberg supplies an
additional series transformer that must be instal‐
led by the print shop operator.
● Copper cables must be used for connections to
the series transformer and from the series trans‐
former to the ZSG central control cabinet. The
copper lines between series transformer and
central control cabinet are not included in the
scope of delivery.
Power supply for the peripheral equipment

Besides the printing press, the central control cabinet
(ZSG) supplies current to the following units:
● Prinect Press Center with/without Prinect Axis
Control;
● AirStar
● ScrollStar/ScrollStar Plus II
● HydroStar and CombiStar
● WashStar
● CleanStar
B.4.16 00.999.5895/
● Various other peripheral units (e.g. powder

spray device, varnish supply unit, etc.).
5.2 Notes on the mains connection

1 Mains cable
FS.902.0017-001GRAUND_00
2 Terminal cover
3 Rails for attaching the terminal cover
4 4 Main switch
Ensure that all mains cables (Fig. 6/1) are connected
in a finger-safe way, each having a terminal cover
3 (Fig. 6/2) in line with protection type IP2x.
Fig. 6 Main switch with terminal cover
00.999.5895/ B.4.17
5.3 Overview of the standard mains connections
Nominal voltages and frequencies Mains connec‐

of the three-phase mains tion version
AC 200 V 50 Hz A2
60 Hz B2
AC 208 V 50 Hz A2
60 Hz B2
AC 220 V 50 Hz A2
60 Hz B2
AC 230 V 50 Hz A2
60 Hz B2
AC 240 V 60 Hz B2
AC 350 V 50 Hz A2
AC 380 V 50 Hz A1
60 Hz B1
AC 400 V 50 Hz A1
AC 415 V 50 Hz A1
AC 440 V 50 Hz A2
60 Hz B2
AC 480 V 60 Hz B2
AC 600 V 60 Hz B2
Tab. 2 Overview of standard power supply connec‐
tions
Note
Please contact the Heidelberg Service
to implement the correct mains connec‐
tion if the table above does not permit
any allocation to be made.
Description of the mains connection versions

● Standard mains connection with mains frequen‐
cy 50 Hz, variants A1 and A2:
see section standard mains connection, var‐
iants A1 and A2.
● Standard mains connection with mains frequen‐
cy 60 Hz, variants B1 and B2:
see section standard mains connection, var‐
iants B1 and B2.
Example taken from the opposite table

The local voltage of the three-phase mains is as‐
sumed to be AC 350 V at a mains frequency of 50 Hz.
The line "AC 350 V/50 Hz" provides:
Mains connection, variant A2.
B.4.18 00.999.5895/
5.3.1 Standard mains connection, variants A1 and A2

Interconnection diagram for 50 Hz mains frequency
SG.906.3805-000GRAENU_00
Responsibility of
customer 2 1 2 1
3 3
4 4
Responsibility of
Heidelberg Service
Version A1 Version A2
Fig. 7 Layout of the mains connection according to variants A1 and A2

1 Mains
2 Fuses
3 Connecting cable to the central control cabinet
ZSG and/or to the series transformer
4 Central control cabinet ZSG with main power
supply area
5 Series transformer (1)
(1): The connecting cables between series transform‐
er and central control cabinet ZSG are not included
in the scope of delivery.
The series transformer provides the voltages
3 AC 400 V/50 Hz for the central control cabinet and
the units.
Wiring diagram for mains connection version A1
Valid for the following electrical ratings:
● AC 380...415 V/50 Hz
00.999.5895/ B.4.19
SG.904.3808-002GRAENU_00
Mains power supply area
Mains (Central control cabinet ZSG)
PE
Back-up fuses
L1
L2
L3
Responsibility of customer Responsibility of Heidelberg Service
Fig. 8 Wiring diagram for mains connection version A1

● AC 200...230 V/50 Hz
● AC 350 V/50 Hz
● AC 440 V/50 Hz
SG.904.3812-002GRAENU_00
Mains power supply area
PE
Back-up fuses
L1
L2
L3
3 AC 400 V/50 Hz
Series transformer
5.3.2 Standard mains connection, variants B1 and B2

Interconnection diagram for 60 Hz mains frequency
B.4.20 00.999.5895/
SG.906.3806-001GRAENU_00
Responsibility of cus-
2 1 2 1
tomer
3 3
4 4
Responsibility of
Heidelberg Service 6 6
Version B1 Version B2
Fig. 10 Layout of the mains connection according to variants B1 and B2

1 Mains
2 Fuses
3 Connecting cable to the central control cabinet
ZSG and/or to the series transformer
4 Central control cabinet ZSG with main power
supply area
5 Series transformer (1)
6 Control transformer for mains frequency 60 Hz,
integrated in the central control cabinet ZSG
(1): The connecting cables between series transform‐
er and central control cabinet ZSG are not included
in the scope of delivery.
The series transformer provides the voltages
3 AC 400 V/60 Hz for the central control cabinet. The
control transformer provides the voltages 3 AC 480 V/
60 Hz for the units.
Circuit diagram for mains connection version B1
● AC 380 V/60 Hz
00.999.5895/ B.4.21
SG.904.3807-003GRAENU_00
Mains power supply area Control transformer
3 AC 480 V/
60 Hz
PE
L1 Back-up fuses
L2
L3
3 AC 400 V/
60 Hz
Fig. 11 Circuit diagram for mains connection version B1

Circuit diagram for mains connection version B2
● AC 200...240 V/60 Hz
● AC 440...600 V/60 Hz
SG.904.3813-003GRAENU_00
Mains power supply area Control transformer
Mains
(Central control cabinet ZSG) 3 AC 480 V/
60 Hz
Series transformer
PE
L1 Back-up fuses
L2
L3
3 AC 400 V/60 Hz
Fig. 12 Circuit diagram for mains connection version B2
B.4.22 00.999.5895/
6 Cross sections of the conductor terminals

SC.906.3805-000UTKENU_02
6.1 Cross sections of the line terminals on the main switch

The supply cable is connected directly to the main
switch with circular conductor (please refer to the
chapter Connection of the printing press to the three-
phase mains).
Table 3 lists the possible cross sections of the cables
at the main switch.
Number of printing units Cross sections of the line terminals on the main switch
[mm2] [AWG/kcmil]
≤ 6 printing units 1 × 4...185 1 × 11 AWG...350 kcmil
2 × 4...70 2 × 12 AWG...2/0 AWG
≥ 7 printing units 1 × 35...240 1 × 2 AWG...500 kcmil
2 × 16...120 2 × 6 AWG...250 kcmil
Tab. 3 Cross sections of the line terminals on the main switch
6.2 Cross sections of the conductor terminals at the series transformer

● The series transformer may only be used as the
power supply for the central control cabinet and
the Heidelberg-approved electrical consumers
connected to it.
● Do not connect any additional consumers (such
as non-Heidelberg units) to the series transform‐
er.
● A maximum of two current conductors can be
connected to each terminal of the series trans‐
former. Clamp the cables such that they cannot
work loose during operation.
● The instructions in chapter Basic instructions for
mains connections which apply to the require‐
ments for the power lines and the type and check‐
ing of the mains connection apply.
The required connected load of the printing press is
specified in the main chapter Specifications. Please
observe the relevant regulations when laying the con‐
nection cables.
Note
The following table is only significant
when the printing press is connected
via a series transformer.
Nominal voltages and Cross sections of the terminals on the series transformer [mm2] ([sq in])
frequencies of the three-
primary side secondary side
phase mains
Printing presses with up to 4 printing units and a coating unit
AC 200...240 V 3 × 2 × 150 (3 × 2 × 0.23) 3 × 150 (3 × 0.23)
AC 350 V 3 × 150 (3 × 0.23) 3 × 150 (3 × 0.23)
00.999.5895/ B.4.23
Nominal voltages and Cross sections of the terminals on the series transformer [mm2] ([sq in])
frequencies of the three-
primary side secondary side
phase mains
Printing presses with 5 and more printing units
AC 200...240 V and 3 × 4 × 2 × M12 3 × 2 × 2 × M12
AC 350 V
Tab. 4 Cross sections of the conductor terminals at the series transformer
"3 × 2 × 150 (3 × 2 × 0.23)" means:
The terminals L1, L2 and L3 exist twice, each with a
cross section of 150 mm2 (0.232 sq in).
Note
Copper cables must be used as power
lines to the series transformer and from
the series transformer to the central con‐
trol cabinet ZSG.
Note
"M12" stands for the borehole of the ca‐
ble lug for the connection cable. The
electrician determines the cable cross
section according to the local require‐
ments.
Conductor terminals and possible cable cross sections
The cross sections of the conductor terminals permit
the following cable cross sections (stranded wires) to
be used:
Cross section of the con‐ Possible conductor cross

ductor terminals section [mm2] ([sq in])
[mm2] ([sq in])
70 (0.108) 10...95 (0.015...0.147)
150 (0.232) 35...185 (0.054...0.286)
240 (0.372) 70...240 (0.108...0.372)
Tab. 5 Conductor terminals and possible cable
cross sections
B.4.24 00.999.5895/
Air supply cabinet AirStar
1 Air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.3

1.2 Process air supply of the AirStar for the printing process . . . . . . . . . . . . . . . . . . . . . . B.5.4
2 Air-cooled AirStar air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.6

2.3 Air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.7
3 Water-cooled AirStar air supply cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.8

3.4 Extracting the process air from the printing process . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.9
3.5 Connection of external refrigeration cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.9
4 Installation instructions for the AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.11

4.2 Minimum distances at the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.11
5 Installation of the air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.14

5.1 Installation site requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.14
5.2 Pressure drop when using exhaust hoods on the air-cooled AirStar . . . . . . . . . . . . . . B.5.14
5.3 Different diameter of air pipes >10 m (>33 ft) to the printing press . . . . . . . . . . . . . . . B.5.16
00.999.5895/ B.5.1
B.5.2 00.999.5895/
1 Air supply cabinet AirStar

SC.906.4052-000UTKENU_00

The AirStar air supply cabinet supplies the press with
the suction and blast air that is necessary during the
printing process. Suction air and blast air are sup‐
plied at different levels of positive and negative pres‐
sure to components like carrier air and sheet separa‐
tion blower, lifting suckers and forwarding suckers,
sheet slow-down device, etc.
Two types of the air supply cabinet AirStar are availa‐
ble:
● Air-cooled AirStar: The waste heat of the air sup‐
ply units is extracted via the air by a fan.
Once the electrical connection and the connec‐
tion of the air supply lines have been establish‐
ed by the Heidelberg Service, the air-cooled Air‐
Star is ready for operation.
● Water-cooled AirStar: The waste heat of the air
supply units is extracted via an integrated air-wa‐
ter heat exchanger.
In addition to its electrical connection and its con‐
nection of the air supply lines, the cooling circu‐
lation of the water-cooled AirStar must be con‐
nected to an external re-cooling system.
The planning and installation of this re-cooling
system must be authorized by the print shop
management and may only be performed by
qualified personnel.
Both types are equipped with the same units for gen‐
erating suction and blast air for the presses.
Advantages of water-cooled air supply cabinets
Compared with the air-cooled variant, the water-
cooled AirStar air supply cabinet has the following ad‐
vantages:
● The waste heat can better be seized and easier
be fed to a waste heat recovery system.
● Less air eddies in the pressroom due to a lower
amount of air needed (the cooling air is circulat‐
ed in the cabinet).
● This results in less dirt accumulation in the cabi‐
net caused by air containing powder particles,
and hence a longer service life.
● The waste heat can be dissipated with cooling
water through pipes with a small cross section.
This is especially advantageous when pipes are
installed in pressrooms with low ceilings.
Power supply
The AirStar air supply cabinet is fed with electric pow‐
er via the central control cabinet ZSG. The connec‐
tion is generally established by Heidelberg Service.
00.999.5895/ B.5.3
1.2 Process air supply of the AirStar for the printing process
The following information applies to the air-cooled
and to the water-cooled version of the AirStar.
Assignments of the connecting sockets of the air sup‐
SC.906.4050-000GRAUND_00
ply cabinets AirStar A1-R1 and A1-R2
Figure 1 shows the assignments of the connecting
sockets of the air supply cabinets.
P3 P5 P1-2 P1-1 V1 V5
Fig. 1 AirStar A1-R2-L connecting socket
Socket designation Type of air AirStar A1-R1 AirStar A1-R2

V5 Vacuum + +
V1 Vacuum + +
P1-1 Pressure + +
P1-2 Pressure - +
P5 Pressure + +
P3 Pressure + +
Tab. 1 Connecting socket assignments of the air supply cabinets AirStar A1-R1 and A1-R2
Specifications of the process air supply
Socket designation Outside diameter of Max. pressure Max. temperature in‐ Connecting point
the connection abs (1) [bar] ([psi]) crease by compres‐
pieces dS [mm] ([in]) sion [°C] ([°F])
V5 32 (1.26) 0.35 (5.08) 20 (68) Feeder

V1 55 (2.17) 0.40 (5.80) 40 (104) Delivery
P1-1 125 (4.92) 1.25 (18.13) 25 (77) Central air distributor
P1-2 125 (4.92) 1.25 (18.13) 25 (77) Central air distributor
P5 40 (1.57) 2.0 (29.01) 40 (104) Feeder
P3 40 (1.57) 1.45 (21.03) 60 (140) Feeder
Tab. 2 Technical specifications of the process air supply
(1): The maximum values of the individual pressure
levels result from the settings of the pressure and vac‐
uum regulation valves.
B.5.4 00.999.5895/
Socket designation Connecting point Consumer

V5 Feeder Lifting and forwarding suckers
V1 Delivery Sheet slow-down device
P5 Feeder Carrier air and sheet separation blower
P3 Feeder Lateral, diagonal and rear edge blowers
Tab. 3 Consumers on feeder and delivery
Total air required on the central air distributor
AirStar type Total air volume required at the cen‐

tral air distributor (regulated:
1.19 bars (17.26 psi)) [m3/h] ([cu ft/
min])
A1-R1 900 (530)
A1-R2 1800 (1060)
Tab. 4 Total air required on the central air distributor
Absolute pressure
The absolute pressure pabs in Table 2 is defined as
the sum of the ambient pressure p0 and the relative
pressure prel:
● Definition of absolute pressure pabs.:
pabs. = p0 + prel.
● Definition of relative pressure prel.:
prel. = pabs. - p0
Standard volumetric flow
The standard volumetric flow refers to the following
standard values:
● Ambient pressure p0: 1013 mbars (14.69 psi)
● Ambient temperature T0: 20°C (68°F)
● Atmospheric pressure 1.2 kg/m3 (0.04 lbs/cu in)
Note
The maximum process air temperature
is measured at the connecting socket
of the AirStar.
00.999.5895/ B.5.5
2 Air-cooled AirStar air supply cabinet

SC.906.4053-000UTKENU_00

Depending on the version of the printing press, Hei‐
SC.906.4051-000GRAUND_00
delberg supplies the matching air supply cabinet Air‐
Star, type A1-R1-L, or A1-R2-L
The built-in units that generate the suction and blast
air in the AirStar produce heat.
In the air-cooled AirStar, fans cool the units and re‐
move the produced heat from the cabinet via an air
stream.
The air-cooled AirStar A1-R1-L and A1-R2-L units
1 consist of the following components:
● Base module to generate blast air and suction
air, with integrated electric module for open-
loop control and closed-loop control (Fig. 2/1).
To maintain the temperature in the pressroom at a
constant level, you must collect the exhaust air in a
suitable form and lead it out of the pressroom.
Fig. 2 Air-cooled air supply cabinet A1-R2-L
2.2 Overall air throughput

The total air consumption of the air-cooled AirStar is
described below. The individual air volumes can be
found in the tables in the main chapter Specifications.
General information
● Process exhaust air is the suction air and blast
air for the printing process.
● The exhaust air consists of:
○ cooling air used for cooling the units;
○ exhaust air from vacuum generation (suc‐
tion air);
○ blast air which is not required depending
on the operating status of the press and
which is carried off via the pressure relief
valves.
● The cooling air represents the biggest share in
the overall air consumption. The share of the
process exhaust air is relatively small. It de‐
pends on the operating status of the press.
B.5.6 00.999.5895/
2.3 Air cooling

Exhaust air removal
SC.906.4053-000GRAUND_00
The air-cooled version of the AirStar air supply cabi‐
net can be optionally equipped with an exhaust hood
(Fig. 3/1). The exhaust hood is installed on the roof
of the AirStar. It leads the exhaust air blown off
1 through the cabinet top into an exhaust pipe via an
exhaust air nozzle.
The exhaust hood can be obtained from Heidelberg.
Air friction in the exhaust hood and in the exhaust
pipe leads to pressure losses. To prevent a stagna‐
tion of the cooling air, one or more suction fans must
be installed in the connecting socket of the exhaust
hood or in the exhaust pipe.
The suction fan must start as soon as the press is
switched on at the main switch on the central control
cabinet.
Any planning for removing the cooling air through an
exhaust air duct, including the installation of the asso‐
ciated suction fans, must be initiated by the user and/
or the management of the print shop. The installation
must be planned and carried out by skilled personnel.
The rough calculation of the pressure drop in the
hose and pipe system, and its compensation, are de‐
Fig. 3 Air removal with optional exhaust hood Air‐
scribed in chapter Installation of the air supply cabi‐
Star A1-R3-L
net AirStar, section Pressure drop when using ex‐
haust hoods on the air-cooled AirStar.
2.4 Process air supply for the printing process

The specifications of the air-cooled variant of the Air‐
Star air supply cabinet can be found in the chapter
AirStar air supply cabinet, section Process air supply
of the AirStar for the printing process.
00.999.5895/ B.5.7
3 Water-cooled AirStar air supply cabinet

SC.906.4054-000UTKENU_00

A characteristic feature of the water-cooled AirStar
SC.906.4052-000GRAUND_00
air supply unit is that the cooling air is circulated in a
closed refrigeration cycle inside the air supply cabi‐
net. The heated cooling air is not released into the en‐
vironment, as it is the case with the air-cooled AirStar.
2 The water-cooled AirStar A1-R1-W and A1-R2-W con‐
sist of the following components:
● Base module to generate blast air and suction
air, with integrated electric module for open-
1 loop control and closed-loop control (Fig. 4/1);
● Water-cooling module with fan and air/water
heat exchanger (Fig. 4/2).
Fig. 4 Water-cooled air supply cabinets AirStar A1-

R2-W
Re-cooling
A separate re-cooling system is required for re-cool‐
ing the cooling water in the cooling module.
The task of the re-cooling system is to dissipate the
heat from the cooling water of the cooling module.
The user must initiate the planning work for the sepa‐
rate re-cooling system. The installation must be plan‐
ned and carried out by skilled personnel.
3.2 Overall air throughput

Due to the internal air circulation, the overall air con‐
sumption of the water-cooled AirStar is considerably
smaller than that of the air-cooled AirStar.
Cooling air (electronics cooling) and suction air from
the printing press are delivered via the cabinet roof.
This air volume is relatively small and does not need
to be considered in the calculation of the air flow rate
for the pressroom. An exhaust hood is therefore not
necessary for the water-cooled air supply cabinet Air‐
Star.
3.3 Process air supply for the printing process

The specifications of the water-cooled variant of the
AirStar air supply cabinet can be found in the chapter
AirStar air supply cabinet, section Process air supply
of the AirStar for the printing process.
B.5.8 00.999.5895/
3.4 Extracting the process air from the printing process

Extracting the process exhaust air (blast air) that is
brought in during the printing process from the print‐
ing press is not planned.
The standard volumetric flow of the process air must
be included in the air consumption calculations for
the pressroom if the AirStar is not installed in the
pressroom but, for example, in a separate equipment
room.
3.5 Connection of external refrigeration cycle

Note
Prior to connecting the water-cooled Air‐
Star, flush the re-cooling system at the
customer side. To prevent foreign bod‐
ies from penetrating the heat exchang‐
er, a filter element with a mesh width of
0.08 mm (0.003 in) must be installed in
the cooling water pipe at the customer
side.
SC.906.4054-000GRAUND_00
1
2 700/27.6
130/5.1
220/8.7
150/5.9
Fig. 5 AirStar connection of external refrigeration cycle (dimensions in mm/in)

1 Return flow
2 Feed line
The positions of the connections (Fig. 5/1 and 2) are
the same for all water-cooled AirStar air supply cabi‐
nets.
The connection to the external refrigeration cycle is
prepared via flat-sealing union joints with inside
thread. The distance between roof opening and flat
packing for feed line (Fig. 5/2) and return flow
(Fig. 5/1) is 10 mm (0.39 in).
00.999.5895/ B.5.9
Cooling water connections of the AirStar

Feed line 1"
Return flow 1"
Thread Inside thread
Tab. 5
B.5.10 00.999.5895/
4 Installation instructions for the AirStar

SC.906.4009-000UTKENU_04
4.1 Installation instructions

The installation site of the AirStar air supply cabinet
must be chosen such that it is easily and at any time
accessible for service and maintenance work.
Installation of hoses
The air hoses should be installed in straight lines in
order to keep the flow losses as low as possible. In
general, each 90° hose elbow increases the air resist‐
ance.
The hoses should be installed such that there is no
danger of tripping, The hoses must not be bent.
Always shorten the hoses during installation accord‐
ing to local requirements.
4.2 Minimum distances at the installation site

To be able to carry out service and maintenance
work on the air supply cabinet AirStar, the minimum
distances to surrounding objects shown in Fig. 6
must be observed.
The specified distances are always related to the
LS.906.4014-003GRAUND_00
standard installation.
1 Distance to the wall:
2 Min. 700 mm (27.56 in)
2 Distance to the ceiling:
Air-cooled AirStar with exhaust hood:
min. 1500 mm (59.05 in)
Water-cooled AirStar: min. 500 mm (19.68 in)
3 Distance to the printing press:
Min. 500 mm (19.68 in)
Rotating the service side is a useful option when a
minimum distance of 700 mm (27.56 in) to the wall is
not possible. The minimum distance to the wall must
3
1 be 200 mm (7.87 in) in this case. The connecting sock‐
ets will still point towards the printing press after this
rotation. Further information see AirStar service man‐
ual.
Note
The areas of the inlets and outlets for
cooling and process air on both sides
and on the top of the AirStar must re‐
main free. They must not be obstructed
by objects that impede the free flow of
Fig. 6 Minimum distances for installing the AirStar air through the inlets and outlets.
00.999.5895/ B.5.11
4.3 Standard installation

The standard installation of the AirStar air supply cab‐
inet is planned in the area of the first and second print‐
ing unit on D.S.
The standard position of the air supply cabinet is
shown in the floor plans. The floor plans are a part of
the main chapter Specifications.
The position of the air supply cabinet may differ from
the position shown in the floor plans. A different instal‐
lation depends particularly on the remaining length of
the serial connection hoses and the electrical serial
connection cable (flexibility).
Basic flexibility
The basic flexibility of the AirStar air supply cabinet
is based on the flexibility of the standard connection
hoses and the electrical standard connection cable.
Usually, the maximum length is 1.0 m (3.3 ft). The ba‐
sic flexibility can change as the configuration and oth‐
er circumstances change.
SC.906.4010-002GRAUND_00
A.S.
D.S.
C.E.
L.I. 3
1 2
Fig. 7 Basic flexibility of the AirStar without extension package

1 AirStar
2 Central control cabinet
3 Basic flexibility
Elevated installation
If a printing press is elevated, more hose length will
be required for the internal laying. The flexibility of
the serial connection hoses will therefore be reduced
by the height of the foundation.
B.5.12 00.999.5895/
4.4 Flexible installation of peripheral units

The flexible installation of peripheral units permits
the AirStar air supply cabinet to be installed outside
the standard installation area.
For this purpose, the following extension kits are avail‐
able:
● +10 m (32.8 ft),
● + 20 m (65.6 ft).
The following installation versions are possible:
● remote installation
● two-row installation
● elevated installation
● lower installation.
Note
The maximum height difference is 5 m
(16.4 ft) in each case.
The installation version + 20 m (65.6 ft) requires a per‐

manent piping. Planning and installation of this per‐
manent piping must be initiated by the operator, i.e.
the print shop management, and may only be per‐
formed by qualified staff. For further information on
permanent piping please refer to chapter Permanent
piping.
Further information about the flexible installation of
peripheral units can be found in chapter Flexible in‐
stallation of peripheral units. In addition, please con‐
tact the Heidelberg Service department.
00.999.5895/ B.5.13
5 Installation of the air supply cabinet AirStar

SC.906.4006-000UTKENU_06
5.1 Installation site requirements

The following requirements must be satisfied for the
air-cooled and for the water-cooled AirStar air supply
cabinet:
● Air temperature in room:
min. 10 °C (50 °F);
max. 40 °C (104 °F).
● Ideal ambient air humidity: 50...58 %.
site must be returned to the room in a suitable
form.
● Air velocity of the ambient air for installation in
the pressroom: <0.2 m/s (<0.66 ft ps).
● Air velocity of the ambient air for installation in a
special equipment room:
<1.0 m/s (<3.28 ft ps).
5.2 Pressure drop when using exhaust hoods on the air-cooled AirStar
The effects of air friction lead to a pressure drop in
hose and pipe systems.
When installing an exhaust-air hood on the air-
cooled AirStar air supply unit, the pressure loss must
be compensated by the installation of an additional
suction fan in the exhaust air duct.
The data required for a rough calculation of the pres‐
sure drop and for determining the suction fan output
can be taken from the tables in the main chapter
Specifications and the following example calculation.
Calculation example
SG.904.4008-002GRAUND_00
The following example, which applies to the type of

installation shown in Fig. 8, is calculated first using
SI units, then using ANSI units.
1 Exhaust hood
1
4 2 2 Exhaust pipe
3 90° bend
4 Suction fan
● Utilization of the AirStar air supply cabinet with
exhaust hood.
● Pipe length between air cabinet installation site
and wall breakthrough:
3 l = 20 m (65.6 ft).
● Number of 90° bends in the air pipe:
n = 4.
Fig. 8 Pressure drop in the pipe system with the
example of the AirStar ● Cooling air volumetric flow:
dV/dt = 2400 m3/h (1415 cu ft/min)
B.5.14 00.999.5895/
● Overall efficiency of the suction fan:

η = 0.4.
Calculation example (metric units):
Calculation of the pressure drop

The total pressure drop Δp in the pipe system is ob‐
tained by adding the partial drop values in the ex‐
haust hood (p1), in the exhaust pipe (p2) and in the
90° bends (p3).
Δp = p1 + p2 + p3
= 30 Pa + (20 m × 0.8 Pa/m) + (4 × 7 Pa)
= 74 Pa = 74 kg/ms2
At a volumetric flow of 2400 m3/h, the compressor
must compensate for a pressure drop of 74 Pa in the
pipe system.
Calculation of the suction fan output

The pneumatic output Ppneu of the suction fan is ob‐
tained from the total pressure loss Δp.
Note
The pneumatic output Ppneu is not identi‐
cal with the electric power Pel on the
nameplate of the suction fan. The pneu‐
matic output of the fan is much lower
than its electric power.
Ppneu = dV/dt × Δp
= 2400 m3/h × 74 kg/ms2
= 0.667 m3/s × 74 kg/ms2
= 49.3 kg×m2/s3 = 49,3 W
Pel = Ppneu / η = 49.3 W / 0.4 = 123 W = 0.123 kW
Calculation example (ANSI units):
Calculation of the pressure drop

The total pressure drop Δp in the pipe system is ob‐
tained by adding the partial drop values in the ex‐
haust hood (p1), in the air pipe (p2), and in the
90° bends (p3).
Δp = p1 + p2 + p3
= 0.63 lbf/sq ft + (65.6 ft × 0.0052 lbf/sq ft)
+ (4 × 0.15 lbf/sq ft)
= 1.57 lbf/sq ft
At a volumetric flow of 1415 cu ft/min, the suction fan
must compensate for a pressure drop of 1.57 lbf/sq ft
in the pipe system.
Calculation of the suction fan output

The pneumatic output Ppneu of the suction fan is ob‐
tained from the total pressure loss Δp.
00.999.5895/ B.5.15
Note
The pneumatic output Ppneu is not identi‐
cal with the electric power Pel on the
nameplate of the suction fan. The pneu‐
matic output of the fan is much lower
than its electric power.
Ppneu = dV/dt × Δp
= 1415 cu ft/min × 1.57 lbf/sq ft
= 23.58 cu ft/s × 1.57 lbf/sq ft
= 37.02 lbf×ft/s
= 0.067 hp
Pel = Ppneu / η = 0.067 hp / 0.4 = 0.168 hp
Power of the suction fan
In this example, at an efficiency of η = 0.4, a suction
fan with an electrical power of Pel = 0.123 kW
(0.168 hp) would have to be installed in the exhaust
air duct after the exhaust hood.
● To ensure correct dimensioning, the selection
of suitable suction fans must be made on the ba‐
sis of the characteristic curves from their manu‐
facturers.
● There is a small clearance between the upper
edge of the cabinet top and the bottom edge of
the exhaust hood. If air escapes from this clear‐
ance, the blower output of the suction fan in the
exhaust air duct is insufficient. In this case, a
stronger suction fan must be used to ensure ad‐
equate cooling of the AirStar.
5.3 Different diameter of air pipes >10 m (>33 ft) to the printing press
The air-cooled and the water-cooled AirStar air sup‐
ply cabinet are both available for installation at a dis‐
tance of up to 10 m (33 ft) from the printing press.
If the AirStar is installed at a place more than 10 m
(33 ft) away from the press, the diameter of the air
pipes must be increased over the full length of the air
pipes between the AirStar and the press in order to
prevent excessive pressure loss.
Note
Extending the standard air pipes with
air pipes of a larger diameter is not per‐
mitted!
The new inside diameter of an air pipe is determined
as follows on the basis of the so-called equivalent
length:
x = l + (n × 1 meter) [m]
or
x = l + (n × 3.3 feet) [ft]
Whereby:
B.5.16 00.999.5895/
x ... supplementary length [m] or [ft];

l ... actual distance between AirStar and printing
press in [m] or [ft];
n ... number of 90° bends in the air pipe.
Note
Table 6 applies to air pipes with a
smooth inside surface.
Using the outside diameter of the cabinet connecting

socket ds and the calculated equivalent length x, Ta‐
ble 6 shows the related air pipe inside diameter dL:
Outside diameter of socket dS Equivalent length x [m] ([ft]) Inside diameter of air pipe dL [mm] ([in])
[mm] ([in])
15 (49.2) 35 (1.38)
20 (65.6) 38 (1.50)
32 (1.26)
25 (82.0) 40 (1.57)
30 (98.4) 42 (1.65)
15 (49.2) 44 (1.73)
20 (65.6) 46 (1.81)
40 (1.57)
25 (82.0) 48 (1.89)
30 (98.4) 50 (1.97)
15 (49.2) 60 (2.36)
20 (65.6) 65 (2.56)
55 (2.17)
25 (82.0) 67 (2.64)
30 (98.4) 70 (2.76)
15 (49.2) 70 (2.76)
20 (65.6) 75 (2.95)
65 (2.56)
25 (82.0) 79 (3.11)
30 (98.4) 82 (3.23)
15 (49.2) 135 (5.31)
20 (65.6) 144 (5.67)
125 (4.92)
25 (82.0) 152 (5.98)
30 (98.4) 158 (6.22)
Tab. 6 Calculating the inside diameter for air pipes
● If the calculated equivalent length x (Table 6) is
between two values in the table above, you
must use the next higher equivalent length.
● When using pipes instead of air hoses, the stand‐
ard diameter for the next largest non-metric
pipe in each case must be selected after calcu‐
lating dL.
00.999.5895/ B.5.17
Calculation example for above table:

● Distance between the place of installation of the
AirStar and the printing press:
l = 20 m (65.6 ft).
● Number of 90° bends in the air pipe:
n = 3.
● Diameter of the cabinet connecting socket:
dS = 40 mm (1.57 in).
In the metric system:

● The following applies:
x = l + (n × 1 meter)
= 20 m + (3 × 1 meter) = 23 m
In the ANSI system:

● The following applies:
x = l + (n × 3.3 ft)
= 65.6 ft + (3 × 3.3 ft) = 75.5 ft
● With an equivalent length of x = 25 m
(x = 82 ft), the table above shows the required
air pipe diameter dL = 48 mm (1.89 in)
Air pipe requirements
● For temperature and pressure resistance: See
table in chapter AirStar air supply cabinet, Sec‐
tion Process air supply of the AirStar for the print‐
ing process.
● The air pipes must be resistant against the gen‐
erated air pressure and against the prevailing
temperatures (see also note below).
● Smooth inner wall to reduce the flow resistance.
If necessary, utilization of suitable pipes.
● Short air pipe length.
● Straight installation.
● Chemical resistance against commonly used sol‐
vents and cleaners.
● Avoid using thin-walled air pipes. Background:
The compression of the air produces sound
waves that are propagated via the pipe walls.
● Bending radius when placing:
more than five times the inside diameter of the
air pipe.
● The inner diameter is to be maintained at 90° el‐
bows as well. The air pipes should not kink.
Note
Frequently, the manufacturers of air ho‐
ses state temperature and pressure sta‐
bility independently of each other.
The air pipes must be temperature-re‐
sistant and pressure-resistant to the
maximum temperatures occurring.
B.5.18 00.999.5895/
Pneumatic compressor ScrollStar
1 Pneumatic compressor ScrollStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3

1.2 ScrollStar overall air throughput . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3
1.3 Requirements placed upon the place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.3
2 Installation instructions for the ScrollStar ....................................... B.6.5

2.2 ScrollStar: Minimum distances at the place of installation . . . . . . . . . . . . . . . . . . . . . . B.6.5
3 Air supply via central air supply systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.8

3.2 Compressed air supply (high pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.8
00.999.5895/ B.6.1
B.6.2 00.999.5895/
1 Pneumatic compressor ScrollStar

LS.906.4001-000UTKENU_06

The standard configuration of a printing press in‐
cludes a compressor station for providing the pneu‐
matic components with compressed air. Consumers
are, for example, pneumatically controlled valves or
pneumatic cylinders.
The compressor station consists of the following com‐
ponents:
● compressor
● air-drying unit
● compressed-air reservoir
● pressure control
Power supply
The compressor station ScrollStar is supplied with
power via the central control cabinet ZSG. The con‐
nection is generally done by Heidelberg Service.
1.2 ScrollStar overall air throughput

The ScrollStar (Fig. 1) contains a compressor that pro‐
MS.906.4000-003GRAUND_00
vides a pressure of 10 bars (145 psi) at a maximum

air volume of 15 m3/h (530 cu ft/h). The ScrollStar is
not necessary if a central compressed-air supply sys‐
1
tem is installed in the print shop.
1 Cooling air output
2 Cooling air intake
3 Compressed-air hose outlet
4
3 2 4 Condensate hose outlet
5 5 Electrical cable entry
The volume of cooling air is approx. 720 m3/h
(425 cu ft/min). Collecting the warmed cooling air
and extracting it out of the pressroom is not provided.
Fig. 1 Overall air throughput of the ScrollStar
1.3 Requirements placed upon the place of installation

min. 10 °C (50 °F);
max. 40 °C (104 °F).
● Ambient air humidity: 50...58 %.
site must be returned in a suitable form.
● Air velocity of the ambient air for installation in
the pressroom:<0.2 m/s (<0.66 fps).
● Air velocity of the ambient air when installing in
a special equipment room:
00.999.5895/ B.6.3
<1.0 m/s (<3.28 fps).
B.6.4 00.999.5895/
2 Installation instructions for the ScrollStar

SC.906.4012-000UTKENU_03

The location of the ScrollStar must be selected such
that it is easily accessible at any time for service and
maintenance work.
The air hoses should be installed in straight lines in
order to keep the flow losses as low as possible. In
general, each 90° hose elbow increases the air resist‐
ance.
2.2 ScrollStar: Minimum distances at the place of installation

MS.906.4006-002GRAUND_00
work on the ScrollStar, the minimum distances to sur‐

rounding objects shown in Fig. 2 must be observed.
● Distance at the connection/maintenance side:
min. 800 mm (31.50 in).
● Distance at the rear: min. 200 mm (min. 7.87 in).
1 Connection / service side
2 Rear
min. 200 mm
(7.87 in)
1
800 mm
(31.50 in)
Fig. 2 ScrollStar: Minimum distances at the place

of installation

The standard installation position of the ScollStar is
next to the HydroStar or CombiStar on D.S.
The standard position of the ScrollStar is shown in
the floor plans. The floor plans are a part of the main
chapter Specifications.
The position of the ScrollStar may differ from the po‐
sition shown in the floor plans. A different installation
depends particularly on the remaining length of the
electrical series connecting cable (flexibility).
00.999.5895/ B.6.5
Basic flexibility
The basic flexibility of the ScrollStar results from the
flexibility of the electric series connecting cable. It usu‐
ally is 0.5...1.0 m (1.6...3.3 ft). The basic flexibility
can change as the configuration and other circum‐
stances change.
SC.906.4017-001GRAUND_00
A.S.
D.S.
C.E.
L.I. 3
2
Fig. 3 Basic flexibility of the ScrollStar without extension package

1 ScrollStar
2 CombiStar
3 Basic flexibility

With the flexible installation of peripheral units, it is
possible to install the ScrollStar beyond the standard
installation area.
The following extension packages are available:
● + 5 m (16.4 ft),
● + 20 m (65.6 ft).
B.6.6 00.999.5895/
Note

00.999.5895/ B.6.7
3 Air supply via central air supply systems

SC.906.4011-000UTKENU_04

Some print shops use central air supply systems with
one or several central compressor stations. These
systems supply compressed air to one or several com‐
pressed-air supply networks.
For reasons of uniform and manageable mainte‐
nance, the customer often wants the printing press to
be connected to such a central compressed-air sup‐
ply system.
The central air supply must be subdivided into two cat‐
egories with different air pressure:
● High pressure for the compressed air supply
(for properties see section Compressed air sup‐
ply (high pressure) in this chapter).
● Low pressure for the suction and blast air supply.
Suction and blast air is generated via the AirStar air
supply cabinet, that is delivered as a part of the print‐
ing press.
Note
More information can be found in the
chapter AirStar air supply cabinet.
3.2 Compressed air supply (high pressure)

Compressed air requirement
If compressed air is provided by a central air supply
system, the following minimum requirements must
be met.
The following technical specifications apply to all

press versions:
● Feeding point
Feeder on O.S.
● Operating pressure
7...10 barsrel. (102...145 psi rel. )
● Air volume
< 4 printing units: 12 m3/h (420 cu ft/h)
≥ 4 printing units: 18 m3/h (640 cu ft/h)
Configuration of the compressed air connection
● A special compressed air connecting hose (fi‐
brous hose) with the following technical specifi‐
cations is delivered along with Heidelberg press
versions without a compressor station.
○ Inside diameter:
13 mm (0.51 in)
○ Outside diameter:
B.6.8 00.999.5895/
17.6 mm (0.69 in)

○ Length:
11 m (36.1 ft)
○ Minimum bending radius:
100 mm (3.94 in)
○ Operating temperature:
0 °C...+40 °C (+32 °F...+104 °F)
The compressed air hose provided must be connect‐
ed in a suitable way to the compressed air supply
pipe installed in the pressroom. A screwed connec‐
tion is recommended.
● The compressed air hose must be installed in a
way to make it easily accessible for mainte‐
nance and repair. We do not recommend an in‐
stallation in supply ducts (underfloor ducts).
The compressed air hose can be installed in par‐
allel to current-carrying cables.
● The compressed-air hose must adequately be
connected to the printing press on D.S., be‐
tween feeder and printing unit 1.
● The pressure control valve on the printing press
is adjusted in the factory; this adjustment must
not be changed!
● The compressed air should have the following
properties:
○ Air suction temperature:
min. 3 °C (37.4 °F);
max. 40 °C (104 °F).
In normal operation, the air intake temper‐
ature should be at least 5 °C (41 °F) below
the ambient temperature. However, the
temperature should not be lower than the
minimum suction temperature.
○ Maximum oil content of air:
1 mg/m3 (per standard cubic meter of at‐
mospheric air).
○ Maximum water content of air:
5.9 mg/m3 at 7 bars (102 psi) excess pres‐
sure (corresponds to a dew point at
+3 °C (+37 °F)).
○ Solids content of air:
Particle size max. 5 μm
Particle density max. 5 mg/m3.
From a technical point of view, the required quality of
the compressed air can be obtained not only by us‐
ing an appropriate pneumatic compressor station but
also by installing an additional aftercooler, a refriger‐
ation dryer, and a filter station.
00.999.5895/ B.6.9
Safety and protective measures

A pressure switch on the press monitors the input
pressure. It responds if the air pressure drops below
6 bar (87 psi) for more than 5 seconds. An error mes‐
sage is then given.
Checking the compressed air connection

Once the compressed air connection has been instal‐
led, it must be checked for leaks (listening check).
This must be done at a time at which compressed air
is not consumed and/or no ambient noises disturb
the verification.
Repair work
Caution - Risk of serious injuries if re‐
pair work is not carried out properly!
Never perform any repair work on pneu‐
matic systems which are under pres‐
sure.
This can lead to serious injuries. There‐
fore, repair work should only be started
after the entire system or the defective
part has been depressurized.
Note
Compressed air hoses should not be re‐
paired if the leakage is alongside the
walls. In this case a replacement pipe
must be ordered and installed by Heidel‐
berg Service.
B.6.10 00.999.5895/
Dampening solution supply CombiStar
1 CombiStar combination unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.3

2 Installation instructions for the CombiStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.5

3 Dampening solution supply via central dampening solution supply systems . . . . . . . . . . . . . B.7.9
3.2 Dampening solution supply via central dampening solution supply systems . . . . . . . . B.7.9
00.999.5895/ B.7.1
B.7.2 00.999.5895/
1 CombiStar combination unit

FS.906.4202-000UTKENU_01

Functions and versions
The CombiStar is a combination unit on printing
presses to:
● supply the dampening system with conditioned
dampening solution;
● control the temperature of the inking units.
The CombiStar is available in two versions:
● CombiStar, air-cooled,
● CombiStar, water-cooled.
Power supply
The central control cabinet ZSG feeds power to the
CombiStar. The connection is generally done by Hei‐
delberg Service.
1.2 Connection of the external refrigeration cycle

Water-cooled version
SC.906.4505-001GRAUND_00
1
700/27.6
2
130/5.1
200/7.9
90/3.5
Fig. 1 CombiStar connection of external refrigeration cycle (dimensions in mm/in)

1 Return flow
2 Feed line
The positions of the connections (Fig. 1/1 and 2) are
the same for all water-cooled CombiStar units.
Connecting tubes with inside thread provide the feed
and return flow to and from the external refrigeration
cycle. The connecting tubes must be sealed by the fit‐
ter with hemp or teflon tape when they are connect‐
ed to the refrigeration cycle. The technical specifica‐
tions of the connections are listed in the Tables 1, 2
or 3.
00.999.5895/ B.7.3
The distance between roof opening and flat packing

for feed line (Fig. 1/2) and return flow (Fig. 1/1) is
10 mm (0.39 in).
Cooling water connection of the CombiStar (beta.c

130 G, beta.c 170 G)
beta.c 130 G
Version
beta.c 170 G
Feed line 1"
Return flow 1"
Tab. 1

220 G, beta.c 280 G)
beta.c 220 G
Version
beta.c 280 G
Feed line 1¼"
Return flow 1¼"
Tab. 2

400 G, beta.c 500 G)
beta.c 400 G
Version
beta.c 500 G
Feed line 1½"
Return flow 1½"
Tab. 3
B.7.4 00.999.5895/
2 Installation instructions for the CombiStar

SC.906.4205-000UTKENU_04
SC.906.5610-001GRAUND_00
1
Fig. 2 Free space above: to the left in air-cooled version (with/without exhaust hood) and to the right in water-
cooled version
The location of the CombiStar must be selected such
that it is easily accessible for service and mainte‐
nance work at all times.
The CombiStar must not be exposed to extreme heat.
It is necessary to ensure sufficient ventilation for ex‐
tracting the cooling exhaust air.
Free space above:
1 Air-cooled version (Fig. 2/1):
● With CombiStar without exhaust hood: min.
1500 mm (59.06 in),
● With CombiStar with exhaust hood: min.
3000 mm (118.11 in),
2 Water-cooled version (Fig. 2/2): min. 500 mm
(16.69 in).
With open doors, the minimum distance to the near‐
est obstacle must be 500 mm (19.69 in).
Alignment of the unit
The CombiStar must be positioned on a firm base
and must be aligned in two directions to ensure per‐
fect function.
Never close or cover the ventilation grids on the
doors of the CombiStar.
00.999.5895/ B.7.5
The CombiStar must be positioned at the same level

as the printing press (exception: when the extension
package +20 m (65.6 ft) is used).
The dampening solution and temperature control
hose must be laid in straight lines, in order to keep
the flow losses as minimal as possible.
Protect the hoses against heat. Install a heat insula‐
tion if necessary. Hoses equipped with Armaflex are
already heat-insulated.

The standard installation place of the CombiStar is
next to the AirStar on D.S.
The standard location of the CombiStar is shown in
The position of the CombiStar may differ from the po‐
serial connection hoses and the electrical serial con‐
nection cable (flexibility).
Basic flexibility
The basic flexibility of the CombiStar is based on the
flexibility of the standard connection hoses and the
electrical standard connection cable. It is usually
3.0...4.0 m (9.8...13.1 ft). The basic flexibility can
change as the configuration and other circumstances
change.
SC.906.4200-002GRAUND_00
A.S.
D.S.
C.E.
L.I. 3
1 2
Fig. 3 Basic flexibility of the CombiStar without extension package

B.7.6 00.999.5895/
1 CombiStar
2 AirStar
3 Basic flexibility

With the flexible installation of peripheral units, it is
possible to install the CombiStar beyond the stand‐
ard installation area.
For this purpose, the following extension kits are avail‐
able:
● + 5 m (16.4 ft),
● + 20 m (65.6 ft).
The following installation variants are available, de‐
pending on the extension kit:
Extension kit + 5 m (16.4 ft):
Extension kit + 20 m (65.6 ft):
Note
The maximum line length is 30 m
(98.4 ft).
Note
When the extension package +5 m
(16.4 ft) is used, the CombiStar must
be positioned at the same level as the
printing press.
When the extension package +20 m
(65.6 ft) is used, the height difference
must not exceed 5 m (16.4 ft).
The installation version + 20 m (65.6 ft) requires a per‐
manent piping. Planning and installation of this per‐
manent piping must be initiated by the operator, i.e.
the print shop management, and may only be per‐
formed by qualified staff. For further information on
permanent piping please refer to chapter Permanent
piping.
00.999.5895/ B.7.7

B.7.8 00.999.5895/
3 Dampening solution supply via central dampening solution supply systems

LS.906.4201-000UTKENU_02

Planning and any other work that concern the damp‐
ening solution supply of the printing press must be in‐
itiated by the user or the management of the print‐
shop, and may only be carried out by qualified experts.
Note
be observed!
● Heidelberg printing presses are always pre‐

pared for the connection to a central dampening
solution supply (building mains).
● This chapter must be made available to the com‐
missioned skilled personnel for planning of the
installation work to be done.
Note
The operator is responsible for circula‐
tion of the dampening solution in the
press. The operator must implement ap‐
propriate measures to support circula‐
tion of the dampening solution.
3.2 Dampening solution supply via central dampening solution supply systems
Type and design of the dampening solution supply
and disposal network
● When the press is connected to a central damp‐
ening solution supply (in-house network), the
dampening solution must maintain a feed flow
temperature of between 8...10°C (46 ...50 °F) at
the point where it enters the press. Please note
that longer supply lines in the pressroom may
cause the dampening solution to warm up.
● The temperature of the dampening solution in
the press must not rise by more than 1°C
(1.8°F).
● Please do not use distilled or demineralized wa‐
ter as dampening solution.
● The link to a central dampening solution supply
system requires special water treatment. Water
quality standard values are provided in greater
detail in the Water supply and treatment chapter.
● Please design and install a suitable disposal sys‐
tem for the dampening solution. Do not dispose
of dampening solution that can no longer be
used in the sewerage system.
Requirements for the fixed dampening solution feed

and return flow pipes
● Please select the dampening solution supply
pipes so that they will be suitable for the preva‐
00.999.5895/ B.7.9
lent operating conditions, and are sturdy

enough to withstand external influences. The
dampening solution supply pipe should be
made of stainless steel, galvanized steel or
PVC. The supply pipes may not be made of cop‐
per (Cu) or material containing copper (e.g.
brass).
Layout of the dampening solution connection
● Suitable safety devices (pipe separators) must
be installed between the fresh water connection
and the dampening solution processing unit to
avoid contaminating the fresh water supply with
dampening solution.
● The fixed dampening solution supply and return
pipes must adequately be grounded against stat‐
ic charge.
● The operator must provide a flexible supply
hose of the following properties that is to be laid
between the fixed dampening solution supply
and return lines and the printing press:
○ Inside diameter of the dampening solution
supply line: 25 mm (1 in)
○ Inside diameter of the dampening solution
return line: 25 mm (1 in)
○ Minimum bending radius: 100 mm (3.94 in)
○ Maximum operating pressure:
6 bars (87 psi)
○ Operating temperature: 8...20°C (46 ...
68°F)
○ Material: PVC fibrous hose, for example.
● Between the fixed dampening solution supply
line and the flexible dampening solution supply
hose, a coarse filter and a stopcock should be
installed.
● Always route the supply hoses separately from
the other supply lines (power, air, etc.) to the
printing press.
● Use a suitable hose clamp for fixing the supply
hose to the dampening solution connecting sock‐
et of the printing press.
● After installing the dampening solution flow and
return pipes and before connecting them to the
press, rinse them thoroughly.
Testing the dampening solution connection

● After installing the dampening solution connec‐
tion, a leakage test (visual inspection) must be
performed on the dampening solution flow and
return pipes and of all the hose couplings.
B.7.10 00.999.5895/
Washing fluid disposal WashStar
1 Installation instructions for the WashStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.3

1.3 Flexible peripherals installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.5
00.999.5895/ B.8.1
B.8.2 00.999.5895/
1 Installation instructions for the WashStar

SC.906.4500-000UTKENU_03

Installation site
SC.906.4502-000GRAUND_00
Note
The WashStar must be installed in a hor‐
izontal position.
● The installation site must guarantee a safe posi‐

1m tion of the device.
0,2 m ● Install the WashStar not more than 0.2 m
(0.7 ft) above and not more than 3,0 m (9.8 ft)
below the press level.
3m 0,2 m 0,1 m ● Make sure that there is enough space for opera‐
tion, maintenance and cleaning of the device.
● Hoses and electrical supply lines must be instal‐
led correctly.
● Avoid points presenting the danger of stumbling.
● Protect the WashStar against damage.
Fig. 1 Standard installation
Caution - Danger of damage or failure
of the device!
Do not use the WashStar on coating
units (or on printing units working with
varnish).
Hose sets
The lengths of the available hose sets are matched
to the press configuration.
The hose set includes feed and return hoses + con‐
necting cables for the level sensors.

The standard position of the WashStar is on D.S.
● On presses with one WashStar, the WashStar
is installed at the beginning of the cabinet row,
before the central control cabinet ZSG.
● On presses with two WashStars, the standard
position of both WashStars is approximately at
the press center.
The standard position of the WashStar is shown in
The position of the WashStar may differ from the po‐
serial connection hoses and the electrical serial con‐
nection cable (flexibility).
Basic flexibility
The basic flexibility of the WashStar is based on the
flexibility of the serial connection hoses and the elec‐
trical serial connection cable. It usually is:
00.999.5895/ B.8.3
● for printing presses with one WashStar 1.0...

1.5 m (3.3...4.9 ft);
● for printing presses with two WashStars 4.0...
6.0 m (13.1...19.7 ft).
The basic flexibility can change as the configuration
and other circumstances change.
SC.906.4500-002GRAUND_00
A.S.
D.S.
C.E.
L.I. 3
2
Fig. 2 Basic flexibility of the WashStar, printing press with one device
1 WashStar
2 Central control cabinet
3 Basic flexibility
SC.906.4501-002GRAUND_00
A.S.
D.S.
C.E.
L.I. 3 3
1 2
Fig. 3 Basic flexibility of the WashStar, printing press with two devices
1 WashStar I
B.8.4 00.999.5895/
2 WashStar II
3 Basic flexibility
1.3 Flexible peripherals installation

There is no prefabricated extension package availa‐
ble for the WashStar.
An extension of hoses and cables is possible as a
customizing solution. In addition, please contact the
Heidelberg Service department.
00.999.5895/ B.8.5
B.8.6 00.999.5895/
Exhaust air cleaning cabinet CleanStar
1 Exhaust air cleaning cabinet CleanStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3

1.2 Method of functioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3
1.3 Explosion prevention measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.3
2 Installation instructions for the CleanStar exhaust air cleaning cabinet . . . . . . . . . . . . . . . . . B.9.4

Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.9
Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.10
00.999.5895/ B.9.1
B.9.2 00.999.5895/
1 Exhaust air cleaning cabinet CleanStar

SC.906.4008-000UTKENU_02

Function
The exhaust air cleaning cabinet combines the ex‐
haust air streams from the individual suction points in
the delivery of the printing press, and filters the ex‐
haust air that is loaded with spray powder. The fil‐
tered air is blown out of the top of the exhaust air
cleaning cabinet.
Optionally, it can be routed from the pressroom into
the open air via an exhaust hood and a connected
pipe system.
Power supply
exhaust air cleaning cabinet. The connection is gen‐
erally done by Heidelberg Service.
1.2 Method of functioning

1 Intake of powder-loaded air
SG.906.4400-000GRAUND_00
4
2 Electrical connection
3 Clean air outlet
3
4 Exhaust-air hood (option)
The powder-loaded exhaust air is routed via the ex‐
haust air routing system into the filter compartment
with the filter element. The filter element consists of
a filter cartridge with a prefilter sieve. Coarse and fi‐
ber dust particles are separated at the prefilter sieve.
2 Next, the fine particulates are removed in the filter car‐
tridge.
Finally, the clean air is blown out via the roof of the
exhaust air cleaning cabinet.
In the standard version, the clean air is blown directly
into the pressroom. Optionally, an exhaust hood can
be used. Depending on the length of the exhaust
pipe, additional fans may be required in the exhaust
1 pipe.
Fig. 1 Exhaust air cleaning cabinet
1.3 Explosion prevention measures

Note
Powder and paper dust can be combus‐
tible and explosive. When handling
these substances, observe the instruc‐
tions given in the chapter Exhaust air
piping, section Explosion prevention
measures and zone structures.
00.999.5895/ B.9.3
2 Installation instructions for the CleanStar exhaust air cleaning cabinet

SC.906.4015-000UTKENU_00

The location of the exhaust air cleaning cabinet must
be selected such that it is easily accessible at any
time for service and maintenance work.
tracting the process exhaust air.
The minimum distance between the top and the ceil‐
ing must be 1500 mm (59.06 in) to allow the heat of
the CleanStar to be removed.
With open doors, the minimum distance to the near‐
est obstacle must be 500 mm (19.69 in).
The suction hoses should be installed in straight
lines in order to keep the flow losses as minimal as
possible. In general, each 90° hose elbow increases
the air resistance.

The standard installation of the exhaust air cleaning
cabinet is in the delivery zone on the drive side (D.S.).
The standard position of the exhaust air cleaning cab‐
inet is shown in the floor plans. The floor plans are a
part of the main chapter Specifications.
The position of the exhaust air cleaning cabinet may
differ from the position shown in the floor plans. A dif‐
ferent installation depends particularly on the remain‐
ing length of the serial connection hoses and the elec‐
trical serial connection cable (flexibility).
Basic flexibility
The basic flexibility of the exhaust air cleaning cabi‐
net is based on the flexibility of the standard connec‐
tion hoses and the electrical standard connection ca‐
ble. It is usually 0.5...1.5 m (1.6...4.9 ft). The basic
flexibility can change as the configuration and other
circumstances change.
B.9.4 00.999.5895/
SC.906.4025-000GRAUND_00
A.S.
D.S.
C.E.
L.I. 3
2
Fig. 2 Basic flexibility of the exhaust air cleaning cabinet without extension package
2 DryStar Combination
3 Basic flexibility

The flexible installation of peripheral units enables
the exhaust air cleaning cabinet to be installed out‐
side the standard installation area.
The following extension package is available for this
purpose:
● +5 m (16.4 ft).
Note

00.999.5895/ B.9.5
3 Exhaust air routing in presses with Preset Plus delivery

SC.906.4013-000UTKENU_03

The exhaust air routing in printing presses of the
CD 102 (with Preset Plus delivery) and the CX 102
product line depends on the press configuration.
The differences in exhaust air routing are given by
the selection of the DryStar dryer and the CleanStar.
There are 2 variants of connecting the exhaust air
cleaning system:
● CleanStar Compact with one or two exhaust air
collecting box(es) as interface to the exhaust air
supply of the print shop ("connection concept 1");
● CleanStar with exhaust air cleaning cabinet
and, depending on the configuration, with an ad‐
ditional exhaust air collecting box ("connection
concept 2").
In the standard version, the filtered exhaust air is
blown out of the exhaust air cleaning cabinet into the
pressroom. An optional exhaust hood may be used
for the exhaust air cleaning cabinet. This requires ad‐
ditional supporting fans to be installed in the exhaust
air duct.
Note
Removing the produced warm exhaust
air via the optionally available exhaust
hoods and an exhaust air piping from
the pressroom to the outside is recom‐
mended.
DryStar Ink
Printing presses that are equipped with a DryStar Ink
can be combined with the CleanStar Compact or the
CleanStar. The electronic system for the dryer is inte‐
grated in the electric module on the printing press.
B.9.6 00.999.5895/
3.2 Exhaust air routing for DryStar Ink
3.2.1 Exhaust air routing for DryStar Ink without additional exhaust air cleaning
The exhaust air of a printing press (Fig. 3) with Dry‐
SC.906.4421-001GRAUND_00
1 Star Ink and without CleanStar is removed by a G1G
blower.
1 G1G blower
2 Flange plate
4
2 3 Slide-in dryer
4 Pile in delivery
3
Fig. 3 Exhaust air routing for DryStar Ink without

additional exhaust air cleaning
3.2.2 Exhaust air routing for DryStar Ink with CleanStar Compact
SC.906.4437-000GRAUND_00
Star Ink and CleanStar Compact is removed with a Di‐

1 etz blower.
1 Dietz blowers
2 Powder suction removal
3
3 Pile in delivery
Fig. 4 Exhaust air routing for DryStar Ink with

CleanStar Compact
00.999.5895/ B.9.7
3.2.3 Exhaust air routing for DryStar Ink with CleanStar

SC.906.4438-000GRAUND_00
1 Star Ink and CleanStar is filtered and removed
through the exhaust air cleaning cabinet.
3 Pile in delivery

CleanStar
3.3 Exhaust air routing for DryStar Coating with CleanStar Compact
FS.906.5889-000GRAUND_00
1 Star Coating and CleanStar Compact is removed by

a Dietz blower to the exhaust air collecting box.
2 1 Exhaust air collecting box
2 Dietz blowers
3 Lateral suction devices
5 4 3
5 Pile in delivery
Fig. 6 Exhaust air routing for DryStar Coating with

CleanStar Compact
B.9.8 00.999.5895/
3.4 Exhaust air routing for DryStar Coating with CleanStar

FS.906.5897-000GRAUND_00
1 Star Coating and CleanStar is removed through the
4 3 2 4 Pile in delivery

CleanStar
3.5 Exhaust air routing for DryStar Combination with 2 slide-in units and CleanStar Compact
The exhaust air of a printing press (Fig. 8) with the
SC.906.4436-000GRAUND_00
1 DryStar Combination with 2 slide-in units and the

2 CleanStar Compact is routed through two Dietz blow‐
ers to the exhaust air collecting box.
2 Dietz blowers
6 5 4 3 3 Lateral suction devices
4 Suction removal slide-in unit 3
6 Pile in delivery
Fig. 8 Exhaust air routing for DryStar Combina‐

tion with 2 slide-in units and CleanStar Com‐
pact
00.999.5895/ B.9.9
FS.906.5901-000GRAUND_00
1 2 DryStar Combination with 2 slide-in units and the
CleanStar is routed through one Dietz blower to the
3
exhaust air collecting box and removed via the ex‐
haust air cleaning cabinet.
7 6 5 4 2 Exhaust air collecting box
3 Dietz blowers
Fig. 9 Exhaust air routing for DryStar Combina‐ 7 Pile in delivery
tion with 2 slide-in units and CleanStar
FS.906.5893-000GRAUND_00

2 CleanStar Compact is routed through three Dietz
blowers to the exhaust air collecting box.
2 Dietz blowers
6 Pile in delivery

pact
B.9.10 00.999.5895/
FS.906.5901-000GRAUND_00
3
3 Dietz blowers
00.999.5895/ B.9.11
B.9.12 00.999.5895/
Varnish supply unit CoatingStar
1 Varnish supply unit CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.3

1.2 Task and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.4
1.3 Structure and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.4
1.4 Requirements for the place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.5
2 Installation instructions for the CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.6

2.2 Minimum distances at the place of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.6
00.999.5895/ B.10.1
B.10.2 00.999.5895/
1 Varnish supply unit CoatingStar

FS.906.4018-000UTKENU_01

Planning and any other work that concern the var‐
nish supply of the printing press must be initiated by
the user or the management of the print shop, and
may only be carried out by qualified experts.
Note
be observed!
When using dispersion varnish: The CoatingStar

must be connected to the fresh water supply (build‐
ing mains) to wash the coating unit and the pipe sys‐
tem with temperature-controlled fresh water.
When using UV varnish: The "Washup" function is
not permitted when using UV varnish. In this case,
the CoatingStar must not be connected to the fresh
water supply.
Varnish residues can flow back into the water mains
and pollute it if there is a pressure drop in the water
mains. To avoid this pollution, install a pipe discon‐
nector between the fresh water supply and the con‐
nection to the varnish supply unit.
Note
Please refer to DIN 1988, Fresh water
regulation and the European Drinking
Water Directive for further information
about the fresh water connection of the
varnish supply unit.
Power supply
CoatingStar. The connection is generally done by Hei‐
delberg Service.
00.999.5895/ B.10.3
1.2 Task and functions

The CoatingStar conveys the varnish from the var‐
FS.906.5886-001GRAUND_00
nish container to the coating pan of the coating unit.
Varnish types
The CoatingStar permits the following varnish types
to be processed:
● Dispersion varnish,
● UV varnish,
● Effect varnish.
Functions
The CoatingStar offers the following functions:
● Varnish circulation
Delivering water-based dispersion varnish or
UV varnish from an external varnish tank to the
coating unit of the printing unit, and back.
● Prewashing (washing fluid circulation)
Fig. 1 CoatingStar varnish supply unit (front and ○ Dispersion varnish:
side view) Prewashing the coating unit and the pipe
system with water.
○ UV varnish:
Prewashing the coating unit and the pipe
system with UV washing fluid.
● Washup (rinsing with fresh water)
○ Dispersion varnish:
Washing the coating unit and the pipe sys‐
tem with temperature-controlled fresh wa‐
ter.
○ UV varnish:
Washing is not permitted with UV varnish.
The CoatingStar must not be connected to
the fresh water supply.
● Emptying the coating pan
Pumping the varnish back onto the varnish
tank, or pumping the washing fluid back into the
cleaning tank.
Caution - Risk of damaging the Coating‐
Star!
There can be blockings that affect the
function of the unit when dispersion var‐
nish and UV varnish are used alternate‐
ly. Observe the Coating Star operating
manual in alternate operation.
1.3 Structure and operation

The CoatingStar varnish supply unit consists of the
following three main function groups:
● Coating circuit
● Cleaning circuit
B.10.4 00.999.5895/
● Control cabinet and unit control system

The CoatingStar can alternatively be operated via:
● Prinect Press Center,
● Control panel on the coating unit,
● Remote control with cable,
● Device control.
1.4 Requirements for the place of installation

min. 15 °C (59 °F);
max. 40 °C (104 °F).
● Air humidity in room:
max. 90 %, no condensation.
00.999.5895/ B.10.5
2 Installation instructions for the CoatingStar

SG.906.4015-000UTKENU_03

The location of the CoatingStar must be selected
such that it is easily accessible at any time for serv‐
ice and maintenance work.
Lay the hoses for fresh water and compressed air
such that there is no danger of tripping. The hoses
must not be bent.
2.2 Minimum distances at the place of installation

FS.906.4014-001GRAUND_00 work at the CoatingStar, the following minimum dis‐
tances to surrounding objects must be observed.
● Distance (Fig. 2/1) on the connection/mainte‐
nance side:
min. 700 mm (27.56 in).
● Distance (Fig. 2/2) at the rear:
There need not be any space between Coating‐
Star and cable rack or gallery.
1 Connection / service side
2 Rear
Fig. 2 Minimum distances at the installation loca‐

tion

The standard installation place of the CoatingStar is
in the area of the coating unit on D.S.
The CoatingStar is always installed at ground level,
and on the level of the coating unit.
The standard position of the CoatingStar is shown in
B.10.6 00.999.5895/
The position of the CoatingStar may differ from the

position shown in the floor plans. A different installa‐
tion depends particularly on the remaining length of
the electrical series connecting cable (flexibility).
Basic flexibility
The basic flexibility of the CoatingStar results from
the flexibility of the electrical series connecting cable.
Usually, the maximum length is 1.0 m (3.3 ft). The ba‐
sic flexibility can change as the configuration and oth‐
er circumstances change.
SG.906.4015-001GRAUND_00
A.S.
D.S.
C.E.
L.I. 3
2
Fig. 3 Basic flexibility of the CoatingStar without extension package

1 CoatingStar
2 DryStar Combination
3 Basic flexibility

The flexible installation of peripheral units enables
the CoatingStar to be installed outside the standard
installation area.
The following extension package is available for this
purpose:
● + 5 m (16.4 ft),
Note
The CoatingStar must be installed at
the same level as the printing press.

00.999.5895/ B.10.7

B.10.8 00.999.5895/
IR dryer DryStar
IR dryer DryStar
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.3

2 IR Dryer DryStar Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.4

2.1 Description of DryStar Ink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.4
3 IR dryer DryStar Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.7

3.1 Description of DryStar Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.7
3.3 Dryer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.8
3.4 Air supply and air removal during the printing process . . . . . . . . . . . . . . . . . . . . . . . . B.11.9
3.5 Cooling circulation of sheet track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.9
4 IR Dryer DryStar Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.11

4.1 Description of DryStar Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.11
4.3 Dryer cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.13
4.6 Connecting external refrigeration cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.14
5 Installation instructions for the DryStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.15


Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.21
Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.22
00.999.5895/ B.11.1
IR dryer DryStar
7 Mains connection of the IR dryers to the three-phase mains . . . . . . . . . . . . . . . . . . . . . . . . . B.11.24

................................................................... B.11.24
7.3 Standard mains connection, variants A1 and A3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.25
7.4 Cross sections of the conductor terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.28
8 Ultraviolet drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30

8.1 General note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30
8.2 Technical preinstallation by Heidelberger Druckmaschinen AG . . . . . . . . . . . . . . . . . B.11.30
8.3 Interdeck drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.30
8.4 Requirements placed upon the UV drying system . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.31
8.5 Clarification of technical issues by the manufacturer of the UV dryers . . . . . . . . . . . . B.11.31
B.11.2 00.999.5895/
IR dryer DryStar
1 General information
LS.906.4400-000UTKENU_02

This chapter informs about the installation of IR dry‐
ers on the printing press.
Note
Planning and any other work that con‐
cern the installation of the IR dryers
must be initiated by the user or the man‐
agement of the printshop, and may only
be carried out by qualified experts.
be observed!
This chapter must be made available to the commis‐
sioned skilled personnel for planning of the installa‐
tion work to be done.
00.999.5895/ B.11.3
IR dryer DryStar
2 IR Dryer DryStar Ink

FS.906.4411-000UTKENU_01
2.1 Description of DryStar Ink

Function and versions
In its role as an accessory for the printing press the
DryStar Ink supports the drying process of the print‐
ed sheet.
The DryStar Ink is available in two versions:
● DryStar Ink air-cooled,
● DryStar Ink water-cooled.
In the air-cooled version of the DryStar Ink, the
waste heat of the sheet track is dissipated over a wa‐
ter/air heat exchanger to the ambient air.
In the water-cooled version of the DryStar Ink, the
waste heat of the sheet track is dissipated via a water/
water heat exchanger to an external cooling circuit.
Note
The resulting heated-up exhaust air
should not be blown into the press‐
room. Route the exhaust air via the ex‐
haust air collecting box and an addition‐
ally installed exhaust air duct with sup‐
porting blower to the outside.
Operator control
The DryStar Ink IR dryer is controlled via the Prinect
Press Center of the printing press.
Power supply
DryStar Ink IR dryer. The connection is generally
done by Heidelberg Service.
B.11.4 00.999.5895/
IR dryer DryStar
2.2 Main components
SC.906.4415-000GRAUND_00
1
Fig. 1 Main components of DryStar Ink

Fig. 1 shows the main components of the DryStar Ink.
1 Slide-in dryer (IR and suction device)
2 Cooling module
3 Electric module
The electric module contains all fuses, switching and
control devices. The electric module is the link be‐
tween the printing press and the DryStar Ink.
2.3 Air supply and air removal in the printing process

Additional air supply
The air supply for the radiator cooling is generated
by decentral blowers. The blowers are on the flange
plates. They provide the IR lamp with ambient air.
Exhaust air discharge

The exhaust air routing is described in the chapter
Exhaust air routing.
00.999.5895/ B.11.5
IR dryer DryStar
2.4 Cooling circulation of the sheet track

The delivery of the printing press is equipped with a
SC.906.4416-000GRAUND_00
water-cooled sheet track. The cooling circulation of
the sheet track is routed through the cooling module.
Figure 2 shows the cooling module with the connect‐
ing sockets (Fig. 2/1) for the cooling circulation of the
sheet guide plate.
1 The cooling module is available in two different ver‐
sions:
● with water/air heat exchanger,
● with water/water heat exchanger.
There is only an insignificant difference between the
external structures of the cooling module with water/
water heat exchanger and of the cooling unit shown
in Figure 2. There are two connections for the cus‐
tomer-installed cooling circulation on the bottom of
the cooling module.
An integrated blower cools down the water in the cool‐
Fig. 2 Cooling module ing module with water/air heat exchanger. In the ver‐
sion with a water/water heat exchanger, the water is
cooled by an external cooling circulation.
B.11.6 00.999.5895/
IR dryer DryStar
3 IR dryer DryStar Coating

SC.906.4413-000UTKENU_02
3.1 Description of DryStar Coating

DryStar Coating supports the drying process of the
printed and coated sheets.
The DryStar Coating is available in two versions:
● DryStar Coating air-cooled,
● DryStar Coating water-cooled.
In the air-cooled version of the DryStar Coating, the
waste heat of the sheet track is dissipated via a water/
air heat exchanger to the ambient air.
In the water-cooled version of the DryStar Coating
the waste heat of the sheet track is dissipated over a
water/water heat exchanger to an external cooling cir‐
cuit.
Note
haust hood and an additionally installed
exhaust air duct with supporting blower
to the outside.
Operator control
The DryStar Coating IR dryer is controlled via the Pri‐
nect Press Center of the printing press.
Power supply
The DryStar Coating IR dryer requires a separate
three-phase mains connection. Further information
about the mains connection of the DryStar Coating
IR dryer can be found in the chapter Mains connec‐
tion of the IR dryer to the three-phase mains.
00.999.5895/ B.11.7
IR dryer DryStar
3.2 Main components
SC.906.4420-000GRAUND_00
2
Fig. 3 Main components of DryStar Coating

Figure 3 shows the main components of the Dry‐
Star Coating unit.
1 Slide-in dryer (IR and hot air)
2 Dryer cabinet
3.3 Dryer cabinet

Design of air-cooled dryer cabinet
SC.906.4418-000GRAUND_00
1 1 Exhaust-air hood (option)

2 Dryer cabinet
3 Connection opening (1)
4 Main switch
2 (1): Used for leading through the electrical cables to
4
the electric module, and the hoses for the sheet
guide plate cooling.
Note
Only the air-cooled version of the dryer
cabinet can be equipped with an option‐
al exhaust hood.
Fig. 4 Air-cooled dryer cabinet
B.11.8 00.999.5895/
IR dryer DryStar
3.4 Air supply and air removal during the printing process
The supply air for the slide-in dryer is produced local‐
ly by blowers. The blowers sit on the flange plates
and provide the slide-in dryers with ambient air.

3.5 Cooling circulation of sheet track

1 Feed line
SC.906.4419-000GRAUND_00
2 Return flow
water-cooled sheet track whose cooling circulation is
routed through the dryer cabinet (Fig. 5).
1 2 The dryer cabinet is available in two different versions:
In the upper part of the water-cooled dryer cabinet
version, there are two additional cooling water con‐
nections for the cooling circulation at the customer
side. The external (customer side) cooling circulation
controls the cooling of the sheet track. The resulting
waste heat can be used at the secondary side.
Fig. 5 Open dryer cabinet
3.6 Connection of the external refrigeration cycle

Note
Prior to connecting the water-cooled
DryStar Coating, flush the re-cooling
system at the customer side. To pre‐
vent foreign bodies from penetrating
the heat exchanger, a filter element
with a mesh width of 0.08 mm
(0.003 in) must be installed in the cool‐
ing water pipe at the customer side.
00.999.5895/ B.11.9
IR dryer DryStar
SC.906.4435-000GRAUND_00
1200/47.2
270/10.6 660/26.0
1
700/27.6
130/5.1 1
130/5.1
350/13.8
2 220/8.7
Fig. 6 Connection of external refrigeration cycle (dimensions in mm/in)

1 Feed line
2 Return flow
The locations of the connections (Fig. 6/1 and 2) are
the same for all water-cooled air DryStar Coating units.
(Fig. 6/2) is 40 mm (1.57 in).
Cooling water connections of the DryStar Coating

Feed line 1"
Return flow 1"
Tab. 1
B.11.10 00.999.5895/
IR dryer DryStar
4 IR Dryer DryStar Combination

FS.906.4412-000UTKENU_01
4.1 Description of DryStar Combination

DryStar Combination supports the drying process of
the printed and coated sheets.
The DryStar Combination is available in two versions:
● DryStar Combination air-cooled,
● DryStar Combination water-cooled.
In the air-cooled version of the DryStar Combination,
the waste heat of the sheet track is dissipated via a
water/air heat exchanger to the ambient air.
In the water-cooled version of the DryStar Combina‐
tion the waste heat of the sheet track is dissipated
over a water/water heat exchanger to an external cool‐
ing circuit.
Note
haust hood and an additionally installed
exhaust air duct with supporting blower
to the outside.
Operator control
The DryStar Combination IR dryer is controlled via
the Prinect Press Center of the printing press.
Power supply
The DryStar Combination IR dryer requires a sepa‐
rate three-phase mains connection. Further informa‐
tion about the mains connection of the DryStar Com‐
bination IR dryer can be found in the chapter Mains
connection of the IR dryer to the three-phase mains.
00.999.5895/ B.11.11
IR dryer DryStar
4.2 Main components
SC.906.4417-000GRAUND_00
4
1
2
Fig. 7 Main components of the DryStar Combination (with 3 slide-in dryers)

Figure 7 shows the main components of the Dry‐
Star Combination.
1 Slide-in dryer (suction device and cooling air)
2 Slide-in dryer (hot air)
3 Slide-in dryer (IR and hot air)
4 Dryer cabinet
Note
Figure 7 does not show the maximum
configuration of the DryStar Combina‐
tion. The DryStar Combination is also
available with two or with four slide-in
dryers.
B.11.12 00.999.5895/
IR dryer DryStar
4.3 Dryer cabinet

Design of air-cooled dryer cabinet
SC.906.4418-000GRAUND_00
1 1 Exhaust-air hood (option)
2 Dryer cabinet
3 Connection opening (1)
4 Main switch
2 (1): Used for leading through the electrical cables to
4
the electric module, and the hoses for the sheet
guide plate cooling.
Note
Only the air-cooled version of the dryer
cabinet can be equipped with an option‐
al exhaust hood.
Fig. 8 Air-cooled dryer cabinet
4.4 Air supply and air removal in the printing process

The supply air for the slide-in dryer is produced local‐
ly by blowers. The blowers sit on the flange plates
and provide the slide-in dryers with ambient air.

4.5 Cooling circulation of the sheet track

1 Feed line
SC.906.4419-000GRAUND_00
2 Return flow
water-cooled sheet track whose cooling circulation is
routed through the dryer cabinet (Fig. 9).
1 2 The dryer cabinet is available in two different versions:
In the upper part of the water-cooled dryer cabinet
version, there are two additional cooling water con‐
nections for the cooling circulation at the customer
side. The external (customer side) cooling circulation
controls the cooling of the sheet track. The resulting
waste heat can be used at the secondary side.
Fig. 9 Open dryer cabinet
00.999.5895/ B.11.13
IR dryer DryStar
4.6 Connecting external refrigeration cycle

Note
Prior to connecting the water-cooled
DryStar Combination, flush the re-cool‐
ing system at the customer side. To pre‐
vent foreign bodies from penetrating
the heat exchanger, a filter element
with a mesh width of 0.08 mm
(0.003 in) must be installed in the cool‐
ing water pipe at the customer side.
SC.906.4435-000GRAUND_00
1200/47.2
270/10.6 660/26.0
1
700/27.6
130/5.1 1
130/5.1
350/13.8
2 220/8.7
Fig. 10 Connection of external refrigeration cycle (dimensions in mm/in)

1 Feed line
2 Return flow
The location of the connection (Fig. 10/1 and 2) is
the same for all water-cooled air DryStar Combina‐
tion units.
(Fig. 10/2) is 40 mm (1.57 in).
Cooling water connection of the DryStar Combination

Feed line 1"
Return flow 1"
Tab. 2
B.11.14 00.999.5895/
IR dryer DryStar
5 Installation instructions for the DryStar

SG.906.4406-000UTKENU_00

The location of the DryStar must be selected such
that it is easily accessible at any time for service and
maintenance work.
tracting the cooling exhaust air and the process air.
Free space above:
● in air-cooled version: min. 1700 mm (66.93 in);
● in the water-cooled version: min. 1500 mm
(59.06 in).
The minimum distance between the opened doors
and the nearest obstacle must be 700 mm (27.56 in).
Note
The areas of the air inlet and outlet open‐
ings at the DryStar must remain free.
They must not be obstructed by objects
that impede the free flow of air through
the inlets and outlets.
The suction hoses should be installed in straight
lines in order to keep the flow losses as minimal as
possible. In general, each 90° hose elbow increases
the air resistance.

The standard position of DryStar Coating and Dry‐
Star Combination is in the delivery zone on D.S.
The DryStar Ink has been integrated into the deliv‐
ery. It does not require any additional installation
space.
The standard position of the DryStar is shown in the
floor plans. The floor plans are a part of the main chap‐
ter Specifications.
The position of the DryStar may differ from the posi‐
tion shown in the floor plans. A different installation
depends chiefly on the remaining length of the serial
connection hoses (flexibility).
Basic flexibility
The basic flexibility of the DryStar results from the flex‐
ibility of the standard connection hoses. It usually is:
● with DryStar Coating: 3.0 m (9.8 ft);
● with DryStar Combination: 3.0 m (9.8 ft).
00.999.5895/ B.11.15
IR dryer DryStar
The basic flexibility can change as the configuration

and other circumstances change.
The flexibility of the standard connection hoses is
based on the standard position of the DryStar that is
shown in the floor plans.
The DryStar Ink is integrated into the delivery. The
DryStar Ink does therefore not require any basic flex‐
ibility.
5.2.1 DryStar Coating for Preset Plus delivery
SC.906.5686-001GRAUND_00
A.S.
D.S.
C.E. 1
L.I. 3
Fig. 11 Basic flexibility of the DryStar Coating without extension package

1 DryStar Coating (dryer cabinet)
2 Exhaust air cleaning cabinet (optional)
3 Basic flexibility
B.11.16 00.999.5895/
IR dryer DryStar
5.2.2 DryStar Combination for Preset Plus delivery
SC.906.5621-002GRAUND_00
A.S.
D.S.
C.E. 1
L.I. 3
Fig. 12 Basic flexibility of the DryStar Combination without extension package

1 DryStar Combination (dryer cabinet)
2 Exhaust air cleaning cabinet (optional)
3 Basic flexibility
5.3.1 DryStar Coating for Preset Plus delivery

There is no preassembled extension package availa‐
ble for the DryStar Coating.
An extension of the standard hoses by + 10 m (32.8
ft) is possible as a customized solution. In addition,
please contact the Heidelberg Service department.
Note
The DryStar Coating must be installed
at the same level as the printing press.
5.3.2 DryStar Combination for Preset Plus delivery

There is no preassembled extension package availa‐
ble for the DryStar Combination.
An extension of the standard hoses by + 10 m (32.8
ft) is possible as a customized solution. In addition,
please contact the Heidelberg Service department.
Note
The DryStar Combination must be in‐
stalled at the same level as the printing
press.
00.999.5895/ B.11.17
IR dryer DryStar
6 Exhaust air routing in presses with Preset Plus delivery

SC.906.4013-000UTKENU_03

The exhaust air routing in printing presses of the
CD 102 (with Preset Plus delivery) and the CX 102
product line depends on the press configuration.
The differences in exhaust air routing are given by
the selection of the DryStar dryer and the CleanStar.
There are 2 variants of connecting the exhaust air
cleaning system:
● CleanStar Compact with one or two exhaust air
collecting box(es) as interface to the exhaust air
supply of the print shop ("connection concept 1");
● CleanStar with exhaust air cleaning cabinet
and, depending on the configuration, with an ad‐
ditional exhaust air collecting box ("connection
concept 2").
In the standard version, the filtered exhaust air is
blown out of the exhaust air cleaning cabinet into the
pressroom. An optional exhaust hood may be used
for the exhaust air cleaning cabinet. This requires ad‐
ditional supporting fans to be installed in the exhaust
air duct.
Note
Removing the produced warm exhaust
air via the optionally available exhaust
hoods and an exhaust air piping from
the pressroom to the outside is recom‐
mended.
DryStar Ink
Printing presses that are equipped with a DryStar Ink
can be combined with the CleanStar Compact or the
CleanStar. The electronic system for the dryer is inte‐
grated in the electric module on the printing press.
B.11.18 00.999.5895/
IR dryer DryStar
6.2 Exhaust air routing for DryStar Ink
6.2.1 Exhaust air routing for DryStar Ink without additional exhaust air cleaning
SC.906.4421-001GRAUND_00
1 Star Ink and without CleanStar is removed by a G1G
blower.
1 G1G blower
2 Flange plate
4
2 3 Slide-in dryer
4 Pile in delivery
3
Fig. 13 Exhaust air routing for DryStar Ink without

additional exhaust air cleaning
6.2.2 Exhaust air routing for DryStar Ink with CleanStar Compact
SC.906.4437-000GRAUND_00
Star Ink and CleanStar Compact is removed with a Di‐

1 etz blower.
1 Dietz blowers
3
3 Pile in delivery

CleanStar Compact
00.999.5895/ B.11.19
IR dryer DryStar
6.2.3 Exhaust air routing for DryStar Ink with CleanStar

SC.906.4438-000GRAUND_00
1 Star Ink and CleanStar is filtered and removed
through the exhaust air cleaning cabinet.
3 Pile in delivery

CleanStar
6.3 Exhaust air routing for DryStar Coating with CleanStar Compact
FS.906.5889-000GRAUND_00
1 Star Coating and CleanStar Compact is removed by

a Dietz blower to the exhaust air collecting box.
2 1 Exhaust air collecting box
2 Dietz blowers
5 4 3
5 Pile in delivery

CleanStar Compact
B.11.20 00.999.5895/
IR dryer DryStar
6.4 Exhaust air routing for DryStar Coating with CleanStar

FS.906.5897-000GRAUND_00
1 Star Coating and CleanStar is removed through the
4 3 2 4 Pile in delivery

CleanStar
SC.906.4436-000GRAUND_00

2 CleanStar Compact is routed through two Dietz blow‐
ers to the exhaust air collecting box.
2 Dietz blowers
6 Pile in delivery

pact
00.999.5895/ B.11.21
IR dryer DryStar
FS.906.5901-000GRAUND_00
3
3 Dietz blowers
FS.906.5893-000GRAUND_00

2 CleanStar Compact is routed through three Dietz
blowers to the exhaust air collecting box.
2 Dietz blowers
6 Pile in delivery

pact
B.11.22 00.999.5895/
IR dryer DryStar
FS.906.5901-000GRAUND_00
3
3 Dietz blowers
00.999.5895/ B.11.23
IR dryer DryStar
7 Mains connection of the IR dryers to the three-phase mains

SC.906.4409-000UTKENU_04

be observed!
General information
● The IR dryer is connected to the three-phase
mains via the dryer cabinet.
● The operating voltage of the IR dryer is AC 400 V.
● A direct connection is possible with a mains volt‐
age of AC 380 V, AC 400 V and AC 415 V.
● For mains voltages below AC 380 V and above
AC 415 V, Heidelberg always supplies an addi‐
tional series transformer that is installed by Hei‐
delberg Service.
● The feeder cables to series transformer and dry‐
er cabinet are included in the delivery package.
● The IR dryer must be connected to the printing
press without any additional EMC measures.
● The IR dryer is equipped with a half-wave con‐
trol which is located in the dryer cabinet. When
a printshop contains several printing presses
that are equipped with dryers, the local public
utility company must be contacted to clarify
whether or not the installation of a desynchroni‐
zation system is required.
Nominal voltages and frequen‐ IR dryer version with mains connection version
cies of the three-phase mains
DryStar Coating DryStar Combina‐ DryStar Perfecting DryStar LYL
tion (1 )
AC 200...220 V 50 Hz A1 A1 A1 A1
60 Hz A1 A1 A1 A1
B.11.24 00.999.5895/
IR dryer DryStar
Nominal voltages and frequen‐ IR dryer version with mains connection version
cies of the three-phase mains
tion (1 )
AC 230, 240 V 60 Hz A1 A1 A1 A1
AC 350 V 50 Hz A1 A1 A1 A1
AC 380 V 50 Hz A3 A3 A3 A3
60 Hz A3 A3 A3 A3
AC 400, 415 V 50 Hz A3 A3 A3 A3
AC 440 V 50 Hz A1 A1 A1 A1
60 Hz A1 A1 A1 A1
AC 480, 600 V 60 Hz A1 A1 A1 A1
Tab. 3 Overview of standard power supply connections
(1): Applies only to printing presses of the SM 102
product line with Preset Plus delivery.
Note
Please contact Heidelberg Service to
agree on the correct mains connection
for the IR dryer if the table above does
not permit any allocation to be made.

You ordered the IR dryer version "DryStar Coating"
for a printing press.
The local three-phase AC mains has a voltage of
380 V and a mains frequency of 50 Hz.
The row "AC 380 V/50 Hz" and the column "Dry‐
Star Coating" show:
Mains connection variant A3.
7.3 Standard mains connection, variants A1 and A3
7.3.1 Standard mains connection, version A1

Please connect the mains connection variant A1 via
the series transformer to the mains.
Interconnection diagram for mains connection variant

A1
00.999.5895/ B.11.25
IR dryer DryStar
FS.906.4411-001GRAENU_00
Responsibility of the 2 1
customer
4 5
Responsibility of 6
Heidelberg Service
Fig. 22 Structure of the mains connection for variant A1 (example: XL105)

1 Mains
2 Fuses
3 Feeder cable to the series transformer
4 Series transformer
5 Cable between series transformer and dryer cab‐
inet
6 Dryer cabinet with mains connection area
Valid for all dryer versions with the following electric
connection values:
● AC 200...220 V / 50 and 60 Hz
● AC 230 V / 60 Hz
● AC 240 V / 60 Hz
● AC 350 V/50 Hz
● AC 440 V / 50 and 60 Hz
● AC 480 V / 60 Hz
● AC 600 V / 60 Hz
B.11.26 00.999.5895/
IR dryer DryStar
SG.904.4412-000GRAENU_00
Power supply Mains connection zone
system (series transformer)
PE
3ā āAC 400 Vā/

BackĆup fuses 50/60 Hz
L1
L2
L3
Series transformer
7.3.2 Standard mains connection, version A3

Please connect mains connection variant A3 via the
dryer cabinet to the mains.
Interconnection diagram for mains connection variant

A3
FS.906.4412-001GRAENU_00
Responsibility of 2 1
customer
4
Responsibility of
Heidelberg Service
Fig. 24 Structure of the mains connection for variant A3 (example: XL105)

1 Mains
2 Fuses
3 Feeder cable to the dryer cabinet
00.999.5895/ B.11.27
IR dryer DryStar
4 Dryer cabinet with mains connection area

Valid for all dryer versions with the following electric
connection values:
● AC 380 V / 50 and 60 Hz
● AC 400 V / 50 Hz
● AC 415 V / 50 Hz
SG.904.4406-001GRAENU_00
Power Mains connection area
supply system (dryer cabinet)
PE
Back-up fuses
L1
L2
L3
Responsibility of customer Responsibility of Heidelberg service
7.4 Cross sections of the conductor terminals

● The series transformer may only be used as the
power supply for the dryer cabinet and for the
Heidelberg-approved electrical consumers con‐
nected to it.
● Do not connect any additional consumers (such
as non-Heidelberg units) to the series transform‐
er.
● Only one current conductor may be connected
per terminal. Clamp the cables such that they
cannot work loose during operation.
● The instructions in chapter Basic instructions for
mains connections which apply to the require‐
ments for the power lines and the type and check‐
ing of the mains connection apply.
Connection Cross sections of the conductor terminals [mm2] ([sq in])

tion (1 )
IR dryer cabinet 150 (0.232) 150 (0.232) 150 (0.232) 150 (0.232)
Connection 70 (0.108) 240 (0.372) (2) 95 (0.147) (2) 240 (0.372) (2)
transformer primary
150 (0.232) (4) 70 (0.108) (3) 150 (0.232) (4)
B.11.28 00.999.5895/
IR dryer DryStar
Connection Cross sections of the conductor terminals [mm2] ([sq in])

tion (1 )
70 (0.108) (5) 70 (0.108) (5)
secondary 70 (0.108) 70 (0.108) 70 (0.108) 70 (0.108)
Tab. 4 Cross sections of the conductor terminals
(1): Applies only to printing presses of the SM 102
product line with Preset Plus delivery.
(2): valid for 200...240 V
(3): valid for 350 V and 440...600 V
(4): valid for 350 V
(5): valid for 380...600 V
Conductor terminals and possible cable cross sections
The cross sections of the conductor terminals in the
matching transformer and in the IR dryer cabinet per‐
mit the following conductor cross sections in fine-
strand supply lines:
Cross section of the conductor termi‐ Possible cable cross section in the Possible cable cross section in the
nals [mm2] ([sq in]) IR dryer cabinet [mm2] ([sq in]) matching transformer [mm2] ([sq in])
70 (0.108) 10...95 (0.015...0.147) 10...95 (0.015...0.147)
95 (0.147) - 16...120 (0.025...0.186)
150 (0.232) 35...185 (0.054...0.286) 35...185 (0.054...0.286)
240 (0.372) - 70...240 (0.108...0.372)
Tab. 5 Conductor terminals and possible cable cross sections
Note
Conductor terminal for the protective
earth PE: eyelet terminal, diame‐
ter = 8.5 mm (0.33 in) (M8 thread).
00.999.5895/ B.11.29
IR dryer DryStar
8 Ultraviolet drying
SC.906.4404-000UTKENU_02
8.1 General note

Caution - Danger from improperly per‐
formed installation work!
Planning and any other work regarding
the installation of UV dryers in the print‐
ing press must be initiated by the user
or the management of the printshop
and must be carried out by qualified ex‐
pert staff only.
Therefore Heidelberger Druckmaschi‐
nen AG accepts no warranty or liability
for personal injury, press damage, or
any defects that are caused by attach‐
ing or installing non-HDM devices.
The specifications in the IEC/
EN 60204-1 standard, in particular,
must be observed. Relevant national
provisions must also be observed!
8.2 Technical preinstallation by Heidelberger Druckmaschinen AG

Upon special request, certain Heidelberg presses
can be prepared in the factory for the installation of
UV dryers.
Also a retrofit to prepare the press for the installation
of a UV dryer is possible. This retrofit may only be per‐
formed by Heidelberg Service.
8.3 Interdeck drying

The intermediate floor drying process runs in the
SC.906.4410-000GRAUND_00
area of the transfer cylinder or (with the perfector) in

the area of the storage drum. Its purpose is to accel‐
erate the drying of inks and varnishes.
Intermediate floor drying requires special dryers
which are not part of the Heidelberg range of products.
Depending on the installed electrical power of the dry‐
ers, there is an increased heat emission between the
printing units above the transfer cylinder.
In order to prevent printing press and print sheets
from overheating in the event of an unscheduled in‐
terruption (an emergency stop, for example), the man‐
ufacturer of the ultraviolet dryers must take appropri‐
ate technical measures that exclude press damages
due to overheating.
For example, it is possible to equip the UV radiators
with an automatic water-cooled shutter mechanism.
Fig. 26 Place of installation of the intermediate
floor dryer components
B.11.30 00.999.5895/
IR dryer DryStar
8.4 Requirements placed upon the UV drying system

The following guidance value must be observed
when a UV dryer is installed:
● Maximum temperature in the area of the sensor
of the sheet travel monitor: 70°C (158°F) ;
Furthermore, UV dryers that comply with the follow‐
ing characteristic values have proved successful in
practice:
● Application of CMC radiators (Cold Mirror Con‐
vex; cold-light mirror);
● Maximum aperture of the radiator: 45 mm
( 1.77 in);
● Max. electrical power per radiator based on a
press speed of 5000 impressions per
hour: 120 W;
● Maximum exhaust-air temperature:
60 °C (140 °F).
Note
The supplier of the UV dryer must ini‐
tiate the production of the required radi‐
ation protection plates.
8.5 Clarification of technical issues by the manufacturer of the UV dryers

The following technical matters must be verified by
the supplier prior to the installation of UV dryers:
● Calculation of the air flow rate in the cooling sys‐
tem of the UV dryers.
● Dimensioning and installation of suction con‐
duits, hoses and blowers for exhaust-air removal.
● Verifying the application of heat exchangers for
heat recovery from the exhaust air.
● Catalysis of the ozone content in the exhaust air.
00.999.5895/ B.11.31
IR dryer DryStar
B.11.32 00.999.5895/
Prinect peripheral units
1 Mains connection of the Prinect peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.3

1.2 Power supply for the Prinect peripherals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.3
2 Overview of the standard power supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.4

2.1 Overview of standard power supply connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.4
00.999.5895/ B.12.1
B.12.2 00.999.5895/
1 Mains connection of the Prinect peripheral units

FS.906.4801-000UTKENU_02

be observed!
1.2 Power supply for the Prinect peripherals
Prinect peripheral unit Power supply via Connection made by

Central control Prinect Press Separate mains Heidelberg Qualified per‐
cabinet Center connection (1) Service sonnel
Prinect Press Center x x
with Prinect Axis Control
with Prinect Inpress Con‐
trol
Standard daylight lamp x x
for Prinect Press Center
Prinect Image Control x x
Prinect Autoregister x x
Tab. 1 Power supply for the Prinect peripherals
(1): Mains connection to the AC mains (lighting
mains; one phase).
Note
If Prinect peripherals are powered by a
separate single-phase AC mains con‐
nection, it might be necessary to re‐
place the supplied plug of the mains ca‐
ble by a plug which corresponds to the
local requirements. This plug is not de‐
livered with the press.
00.999.5895/ B.12.3
2 Overview of the standard power supply connections

SC.906.4802-000UTKENU_04
2.1 Overview of standard power supply connections

The Prinect peripheral units mentioned below must
be adapted by the commissioned qualified staff to
the supply voltage available at the location of the
press. The following nominal voltages and frequen‐
cies are possible:
Nominal voltages and frequencies of Prinect Image

the AC system Control
AC 100 V 50/60 Hz *
AC 110 V 50/60 Hz *
AC 115 V 50/60 Hz
AC 120 V 50/60 Hz *
AC 125 V 50/60 Hz
AC 145 V 50/60 Hz
AC 160 V 50/60 Hz
AC 200 V 50/60 Hz *
AC 220 V 50/60 Hz
AC 230 V 50/60 Hz *
AC 240 V 50/60 Hz
AC 250 V 50/60 Hz *
Tab. 2 Overview of standard power supply connec‐
tions
* Mains connection possible
● Please contact Heidelberg Service to agree the
mains connection if Table 2 does not permit any
clear allocation to be made for a Prinect periph‐
eral unit.
● The mains connection must be connected by
the skilled personnel appointed by the print
shop user.
B.12.4 00.999.5895/
Flexible peripherals installation
1 Flexible installation of peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.3

1.2 Extension kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.3
1.3 Distance of the peripheral units +5 m (16.4 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.4
1.4 Distance of the peripherals + 10 m (32.8 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.4
1.5 Distance of the peripheral units + 20 m (65.6 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.4
2 Double row installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
2.2 Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
2.3 Extension package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.6
2.4 Base system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.7
2.5 Center gangway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.8
2.6 Assembling cabinet base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.8
3 Raised and lowered installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.10

3.2 Raised installation on a scaffolding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.10
3.3 Raised installation on an upper floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.14
3.4 Lowered installation on a floor below . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.14
00.999.5895/ B.13.1
B.13.2 00.999.5895/
1 Flexible installation of peripheral units

SC.906.2140-000UTKENU_00
SG.198.0003-002GRAUND_00
Fig. 1 Printing press with peripheral units (example: XL 105, schematic)
The flexible installation of peripheral units permits a
variable installation of one or more peripheral units:
● at a distant location,
● in two rows,
● at an elevated position,
or
● deeper.
This is possible at the time the press is installed or at
a later time as a conversion.
The flexible installation of peripheral units gives the
print shop more flexibility.
1.2 Extension kits

Depending on the peripheral unit in question, there
are the following extension kits for the flexible instal‐
lation of peripheral units:
● + 5 m (16.4 ft),
● +10 m (32.8 ft),
● + 20 m (65.6 ft).
For the exact assignment of the extension kits to the
peripherals please refer to the Tables 1, 2 and 3.
00.999.5895/ B.13.3
1.3 Distance of the peripheral units +5 m (16.4 ft)

Table 1 lists the possible distances as installation dis‐
tance in meters (ft).
Peripheral unit Additional distance to standard equipment [m] Remark

[(ft)]
Extension kit/ Depth below Height above
Installation press level press level
distance
Pneumatic compressor +5 (16.4) -5 (16.4)...+5 (16.4)
ScrollStar
HydroStar central dampening +5 (16.4) -
solution supply Installation only at floor level
CombiStar combination unit +5 (16.4) -
CoatingStar varnish supply +5 (16.4) - Installation only at floor level
unit
Washing fluid disposal Wash‐ Customizing -3 (9.84)...+0.2 (0.66)
Star
CleanStar exhaust air clean‐ +5 (16.4) -5 (16.4)...+5 (16.4)
ing cabinet
Central control cabinet +5 (16.4) - Installation only at floor level
Tab. 1 Distance of the peripheral units +5 m (16.4 ft)
1.4 Distance of the peripherals + 10 m (32.8 ft)


[(ft)]
distance
Air supply cabinet AirStar +10 (32.8) -5 (16.4)...+5 (16.4)
IR dryer DryStar Coating Customizing: -
+10 (32.8) Only installation at ground level
IR dryer DryStar Combination Customizing: - with respect to the printing press
+10 (32.8)
Tab. 2 Distance of the peripherals + 10 m (32.8 ft)
1.5 Distance of the peripheral units + 20 m (65.6 ft)

B.13.4 00.999.5895/

[(ft)]
distance
Air supply cabinet AirStar +20 (65.6) -5 (16.4)...+5 (16.4) ● The installation version +20 m
(65.6 ft) requires a permanent
piping (1).
● Only the electrical connecting
cable +20 m (65.6 ft) is includ‐
ed in the scope of delivery.
Pneumatic compressor +20 (65.6) -5 (16.4)...+5 (16.4)
ScrollStar
HydroStar central dampening +20 (65.6) -5 (16.4)...+5 (16.4) ● The installation version +20 m
solution supply (65.6 ft) requires a permanent
piping (1).
CombiStar combination unit +20 (65.6) -5 (16.4)...+5 (16.4)
● Heidelberg supplies only the fit‐
tings.
Tab. 3 Distance of the peripheral units +20 m (65.6 ft)
(1): Planning and installation of the fixed tubing must
be arranged for by you as the user and/or manage‐
ment of the print shop. Only employ qualified and skil‐
led personnel for carrying out the installation. For fur‐
ther information on permanent piping please refer to
chapter Permanent piping.
00.999.5895/ B.13.5
2 Double row installation

SC.906.6001-000UTKENU_01
2.1 General
One option involving versatile peripheral unit installa‐
tion consists of installing the peripheral units as dou‐
ble row ones. This can be done, e.g. when other pe‐
ripheral units are located at the press.
In the event of peripheral unit rows that are too long,
single or multiple peripheral units can however be in‐
stalled relatively close to the press.
A precondition for a double-row installation is that suf‐
ficient space is made available.
The peripheral units are connected by a base system.
2.2 Space required

For double row installation of the peripheral units you
LS.906.5873-000GRAUND_00
will require an additional space requirement of

1700 mm (66.93 in).
1
1 Previous space required
2 Space required up to wall at least 700 mm
(27.56 in)
2
3 Center gangway between first and second row
1000 mm (39.37 in)
4 Additional space required of 1700 mm
(66.93 in) for the double-row installation
Fig. 2 Space required for single row installation Note
(example: CD 102) For double-row installation observe the
connecting points for the electrics and
LS.906.5874-000GRAUND_00
the easy operation of the cabinet doors.

Note
4
In addition to this, note the cable and
hose jumpers. The intermediate gang‐
way is to be selected such that the ho‐
3 2 ses can be easily routed with a diame‐
ter of up to 200 mm (7.78 in).
Fig. 3 Additional space required for double row in‐

stallation (example: CD 102)
2.3 Extension package

For double row installation you will require the exten‐
sion package +5 m (16.4 ft).
B.13.6 00.999.5895/
2.4 Base system
ÂÂÂÂÂÂÂÂÂÂ Base element requirements
LS.996.1076-000GRAUND_00
ÂÂÂÂÂÂÂÂÂÂ
max. 40 mm
1
The size of the base elements (Fig. 4/1) is made up
385 mm
of the:
ÂÂÂÂÂÂÂÂÂÂ ● Quantity
ÂÂÂÂÂÂÂÂÂÂ ● size and
● location
of the peripheral units.
Note
When creating the base elements the lo‐
cal and country-specific safety rules
and legislation must be observed.
Only non-slip plates should be used for the base ele‐
ment surfaces (e.g. bulb plates).
2 The feet (Fig. 4/2) must be adjustable in height. This
then enables any floor irregularities to be compensat‐
ed for.
Fig. 4 Base element
Fasten T-slot rails (Fig. 5/1) that match the size of
SG.996.0012-001GRAUND_00
the base to the underside. The support legs

(Fig. 5/2) must be adjustable longitudinally in the T-
1 slot rails.
Fig. 5 Support leg with internal thread

Base system assembly
LS.906.5878-001GRAUND_00
We recommend the use of a modular base system.

1000 The base system will provide you with excellent ver‐
satility.
For a modular base system the individual base ele‐
ments have to be screwed to each other to stop
700 them drifting apart.
When assembling the base system, the required
amount of space must be considered (see Section
385 on "Space required“).
Assemble the first row of cabinets onto a base sys‐
tem. This way the hose connections to the printing
press are kept as short as possible.
Fig. 6 Base union joint
00.999.5895/ B.13.7
Route the supply lines and hoses for the second row
under the first row and then connect them by the
most direct route.
2.5 Center gangway

In order to ensure that there is a sufficient degree of
accessibility between the two rows of cabinets, we
recommend a gangway width of approx. 1000 mm
(39.37 in). This ensures that there is sufficient space
for maintenance and service purposes.
Note
Make sure that the center gangway's
footboards are easily accessible and de‐
tachable. This will make any service
work on the electrical connecting ca‐
bles located under the center gangway
easier.
2.6 Assembling cabinet base

Please use rubber as an insulating material between
LS.906.5879-000GRAUND_00
the base and peripheral unit. This serves to prevent

any interruptive resonance characteristics.
The peripheral units do not have to be screwed into
place.
1 1 Peripheral unit
2 Rubber mat
3 Bulb plate
2 4 Base system
5 Adjusting foot, height adjustable
3
6 Variable height (depending on installation and
4 the printing press)
Fig. 7 Design
B.13.8 00.999.5895/
2.7 Minimum distances

For safety-related reasons the minimum distances of
LS.906.5880-000GRAUND_00
the peripheral units to permanent obstacles (wall
etc.) have to be adhered to. Observe the standard re‐
quirements.
500 mm (16.69 in)
Dimensions are available in the "Specifications" doc‐
umentation or the operating manual for each device.
Make sure that access to the air inlets and outlets is
free.
1 Minimum distance to the wall (for AirStar min.
ZSG 700 mm (27.56 in))
2 Peripheral units (width 700 mm (27.56 in), dis‐
Fig. 8 Minimum distances tance of row 1 to 2 approx. 1000 mm (39.37 in))
LS.906.5881-000GRAUND_00
3 Base system
4 Printing press
1
2
4
Fig. 9 Minimum distances (example: CD 102)
00.999.5895/ B.13.9
3 Raised and lowered installation

SC.906.6002-000UTKENU_01

In pressrooms, available space on the hall floors is
frequently filled up to the last inch. The height, how‐
ever, is a dimension that is quite often only rarely con‐
sidered - if at all.
An additional versatile installation option for peripher‐
al units is that of the:
● raised installation on a scaffolding system with
working platform;
● raised installation on a floor above;
● lowered installation on a floor below (cellar in‐
stallation).
The raised or lowered installation enables available
space volume to be better utilized and thus the versa‐
tility in the printing press area is significantly en‐
hanced (driveways, areas for printing press etc.).
However, with excessively loing peripheral unit rows
and restricted space, single or multiple peripheral
units can be installed relatively close to the press.
3.2 Raised installation on a scaffolding system

Here, single or multiple peripheral units are installed
on a scaffolding system with a working platform.
Space requirement
A double-floored installation requires sufficient
amount of height (approx. 6.5 m (21.33 ft)). For pe‐
ripheral units without exhaust hoods the required min‐
imum height level is reduced accordingly.
Design of the scaffolding system

The length of the scaffolding system depends on the
number of peripheral units to be installed and may
vary at a later stage.
The distance from the floor to the lower edge of the
working platform for air-cooled and water-cooled pe‐
ripheral units should be 3500 mm (137.80 in) (Fig. 10).
Note
When creating the scaffolding system,
the local and country-specific safety
rules and legislation must be observed.
Have the design and production of the
scaffolding system carried out by a pro‐
ficient fitter's shop.
B.13.10 00.999.5895/
Note
When calculating the statics the weight
of the peripheral units must be taken in‐
to account! The maximum number of
people, who may be on the platform at
any given time must also be taken into
consideration. The weight specifica‐
tions of the peripheral units are availa‐
ble in the Specifications documentation.
There are no outwardly acting dynamic
forces or loads from the peripheral
units. Dynamic forces induced by peo‐
ple moving have to be borne.
Note
A suitable set of stairs must be provid‐
ed for free access to the working plat‐
form. From a maximum height of
3000 mm (118.11 ft) onwards, a podi‐
um (Fig. 10/4) has to be installed in the
stairs leading up to the working platform.
Note
The railing on the working platform
must be secured against falling down.
Only non-slip plates should be used for the surfaces

of the working platform and stairs (e.g. bulb plates).
00.999.5895/ B.13.11
SM.891.0000-000GRAUND_00
1 3
ÕÕ Õ Õ Õ
ÕÕ Õ Õ Õ
ÕÕ
ÕÕ ÕÕ ÕÕ ÕÕ
ÕÕ
ÕÕ ÕÕ ÕÕ ÕÕ
ÕÕ Õ Õ ÕÕ Õ Õ Õ
ÕÕ ÕÕ ÕÕ ÕÕ ÕÕ ÕÕ ÕÕ
mm
ÕÕ ÕÕ
ÕÕ
ÕÕ ÕÕ ÕÕ ÕÕ
ÕÕ ÕÕ ÕÕ ÕÕ
ÕÕ Õ Õ ÕÕ Õ Õ Õ
ÕÕ 5
Õ Õ ÕÕ 4
Õ Õ Õ
Fig. 10 Raised installation on a scaffolding system with a working platform (front and side views)
1 Peripheral unit on working platform, front view
2 Roller gate edge
3 Peripheral unit on working platform, side view
4 Podium (small landing)
5 Peripheral unit with exhaust hood
B.13.12 00.999.5895/
ÀÀÀÀÀÀÀÀÀÀÀÀÀÀÀÀÀÀÀ
SG.996.0017-001GRAUND_00
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3500 mm
3
Fig. 11 Raised installation on a scaffolding system with a working platform

1 Peripheral unit on working platform, front view
2 Roller gate edge
3 Peripheral unit
Installation of peripheral units

You can install single or multiple peripheral units on
a scaffolding system with working platform. Peripher‐
al units with exhaust hood (Fig. 10/5) or water cool‐
ing are not suitable for installation on a scaffolding
system.
Sufficient space must be available for installed periph‐
erals for maintenance and service work.
00.999.5895/ B.13.13
3.3 Raised installation on an upper floor

For this variant the peripheral units are installed on
LS.906.5856-000GRAUND_00
an upper floor over the pressroom. The maximum dif‐
2 ference in height may not exceed 5 m (16.40 ft).
If not already given, wall or ceiling breakthroughs
must be provided at suitable points for the routing of
hoses.
Fasten the vertical hose installation at short distan‐
ces using band-type clamps and tightening straps.
Note
max. 5 m
Please observe the requirements in the
(16.40 ft)
chapter Exhaust air piping.
1 Printing press
1 2 Peripheral unit
Fig. 12 Raised installation (example: CD 102)
3.4 Lowered installation on a floor below

For this variant the peripheral units are installed on a
LS.906.5885-000GRAUND_00
floor below the pressroom. The maximum difference

in height may not exceed 5 m (16.40 ft).
If not already given, wall or ceiling breakthroughs
must be provided at suitable points for the routing of
hoses.
1 Fasten the vertical hose installation at short distan‐
ces using band-type clamps and tightening straps.
Note
Please observe the requirements in the
chapter Exhaust air piping.
max. 5 m
(16.40 ft) 2
1 Printing press
2 Peripheral unit
Fig. 13 Lowered installation (example: CD 102)
B.13.14 00.999.5895/
3.5 Minimum distances

For safety-related reasons the minimum distances of
LS.906.5880-000GRAUND_00
the peripheral units to permanent obstacles (wall
etc.) have to be adhered to. Observe the standard re‐
quirements.
500 mm (16.69 in)
Dimensions are specified in the documents Techni‐
cal information and Specifications of the printing
press, or in the operating manual of the related unit.
Make sure that access to the air inlets and outlets is
free.
ZSG
Fig. 14 Minimum distances
00.999.5895/ B.13.15
B.13.16 00.999.5895/
Permanent piping and exhaust air piping
1 Permanent piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.3

1.2 Permanent piping construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.3
2 Exhaust air piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.6

2.1 Flow-related and design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.6
2.2 Channel types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.7
2.3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.8
2.4 Pressure conditions in exhaust hoods and exhaust air pipes . . . . . . . . . . . . . . . . . . . . B.14.9
2.5 Protection against environmental influences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.10
2.6 Explosion prevention measures and zone structures . . . . . . . . . . . . . . . . . . . . . . . . . B.14.11
2.7 Fire protection measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.12
00.999.5895/ B.14.1
B.14.2 00.999.5895/
1 Permanent piping
SC.906.6010-000UTKENU_02

For a remote installation (>10 m (>32.81 ft)), we rec‐
LS.996.0028-000GRAUND_00
ommend fixed tubing (Fig. 1/1).
This avoids safety-relevant aspects, such as:
● risk of tripping, and/or
● an excessive number of cable bridges.
Flexibility in the pressroom is retained.
Planning and realization

1 The planning and installation of permanent piping
must be authorized by the operator or the manage‐
ment of the print shop and may only be performed by
qualified skilled personnel.
Fig. 1 Permanent piping on the ceiling

Note
Some air exits on the AirStar supply
compressed hot air (up to approx. 80°C
(176°F)). This in turn means that there
is a risk of burns if contact made with
pipelines in the entry area.
1.2 Permanent piping construction

The pipeline cross section must always be adapted
LS.906.5829-000GRAUND_00
to match the distance in question.
Materials
10°...20° Selection of the materials is geared towards the re‐
quirement profile to be fulfilled:
● non-crush capability,
Fig. 2 Most favorable angle for transitions ● deburred edges,
LS.906.5830-000GRAUND_00
● temperature resistant up to 110°C (230°F),

● chemical resistance etc.
The materials best suited for permanent piping are:
● steel (e.g. St35BK, Ck45K),
● plastics, polybutyle terephtalate (PBT).
Additional notes on diameter enlargement or reduc‐
Fig. 3 Hose extension for hoses tion:
● Transition pieces with an angle between
15...20° feature the best flow conditions.
● Conical transition parts may not be used.
00.999.5895/ B.14.3
● Dull or step-shaped transition pieces may not
LS.906.5831-000GRAUND_00
be used.
● An enlargement or reduction must take place im‐
mediately after the start or before the end of the
permanent piping. Changing diameter over a cer‐
tain distance only is not permitted (Fig. 7)!
Fig. 4 Hose extension for permanent piping
LS.906.5832-000GRAUND_00
Fig. 5 Step-shaped transition LS.906.5833-000GRAUND_00
Fig. 6 Butt transition

LS.906.5834-000GRAUND_00
A.S.
D.S.
C.E.
L.I.
Fig. 7 Diameter enlargement or reduction (exam‐

ple: CD 102)
B.14.4 00.999.5895/
Bends in permanent piping
LS.906.5835-001GRAUND_00
A 90° bend must have a radius of at least 5 times the
inside pipe diameter.
(R (min) ≥5 x d)
Fig. 8 Bend with inside diameter for pipeline

cross sections
Determining pipeline cross sections
For physical or flow technology reasons, it is neces‐
sary that the cross sections of the connecting pipe‐
lines between the printing press and peripheral unit
be enlarged - depending on the distance and line rout‐
ing.
Air distribution to the printing press must always take
place using the hoses provided by the factory.
The reasons for any increase in air resistance and
any resulting increase in pipeline cross sections are:
● the number of required bends or the angle in
the pipeline route;
● the pipeline length.
Note
Enlargement of the pipeline cross sec‐
tion increases with distance and the
greater the number of air deflectors.
00.999.5895/ B.14.5
2 Exhaust air piping

SC.906.6005-000UTKENU_02
2.1 Flow-related and design requirements

Exhaust air lines and ducts
This chapter contains information on exhaust air ex‐
traction from Heidelberg peripheral units.
Exhaust process air

Process exhaust air is the air that is removed from
the printing process (dry extraction, powder extrac‐
tion from delivery).
Irrespective of the cabinet's type of cooling process
exhaust air is always present. The exhaust air tem‐
perature can be as high as 80°C (176°F).
Flow-related requirements
This includes, e.g.:
● internal flush longitudinal and cross connections
(no steps),
● air deflection without any sharp corners (no
dead corners),
● internal radius for deflectors min. 100 mm
(3.94 in),
● no sudden changes to cross sections (angle of
inclination less than 45°),
● low resistance for reinforcements.
The cross sections specified by Heidelberg must be
adhered to!
These measures not only reduce the losses in pres‐
sure and thus the current consumption of the fan, gut
also serve to avoid any flow noise.
Design requirements
The manufacture and assembly of air pipes is essen‐
tially determined by:
● design (round, square, oval),
● material,
● operating pressure (excess pressure or vac‐
uum),
● wall thickness,
● tightness,
● type of connection,
● reinforcement (strength),
● heat insulation,
● soundproofing,
● maintenance.
Materials
Use aluminum or galvanized steel plate with a
smooth inside (such as folded spiral-seam tube) for
the exhaust air pipe at the building side.
B.14.6 00.999.5895/
The employed material must be resistant to:

● Corrosion,
● Ozone (UV applications),
● Small quantities of ammonia,
● Heat.
Please remember that the exhaust air temperature
can be higher than the maximum permissible contact
temperature. The exhaust air pipes should therefore
be insulated - at last in the working area.
Tightness
The joints of the pipes must carefully be sealed in or‐
der to prevent air from escaping.
Area reinforcements
Surface reinforcement at the duct wall for providing a
sufficient degree of strength and for prevention of
"wobble noise" can be achieved through:
● beading, ribbing,
● cantings and vertical folds,
● reinforcements etc.
Execution of longitudinal seams and, in particular,
the types of connection for air pipes (fold, welded
seam, socket, flange etc.) are dependent on:
● tightness,
● size and shape of cross-section,
● corrosion-resistance and
● fire protection.
2.2 Channel types

One differentiates essentially between two types of
duct:
● Round ducts (sheet metal pipes, folded spiral-
seam tubes, shaped parts) that are most fre‐
quently used because of their rather easy han‐
dling.
● Rectangular ducts (sheet metal ducts and shap‐
ed duct parts) that are second in use due to
their space-saving installation.
Advantages of round ducts:
● less material per cross-section area and im‐
proved heat insulation,
● cheaper manufacture,
● simply assembly,
● low pressure losses,
● high degree of tightness.
Advantages of rectangular ducts:
● excellent adaptation capability in terms of
shape and cross section,
00.999.5895/ B.14.7
● little height required (even with high volumetric

flows),
● laying of larger ducts in suspended roofs also
possible,
● simple cutting and installation of large and long
grids.
Transition from round to square
All Heidelberg exhaust hoods are fitted with a round
connecting cross section as standard.
Note
At the transition from a round duct to a
rectangular duct you must ensure that
the cross section of the rectangular
duct is larger than the cross section of
the round duct.
2.3 Assembly
Planning and realization
LS.906.5812-000GRAUND_00
The planning and installation of exhaust air piping

must be authorized by the operator or the manage‐
1
ment of the print shop and may only be performed by
qualified skilled personnel.
Assembly
2 A major role is played by careful installation of the ex‐
haust-air lines. In particular you should observe re‐
quirements pertaining to hangers, fastenings, tight‐
ness and fire and noise protection.
The exact duct routing can be traced on a thorough
assembly drawing.
3 The hangers (threaded rod, steel bridge, corner brack‐
et, clamp, semi clamp with threaded rod etc.) are gen‐
erally fastened in place using dowels (Fig. 9/1). The
spacing of the (Fig. 9/2) hangers is dependent on the
Fig. 9 Assembly drawing duct cross section and the type of duct. The distance
is approximately 2.5...3.0 m (8.20...9.84 in) (if possi‐
ble in the vicinity of a flange (Fig. 9/3)), with stiff
ducts at approximately 4.0 m (13.12 in), with flexible
ducts at approximately 1.0...1.5 m (3.28...4.92 in).
Ceilings and wall passages must be provided with
ducts and ventilation pipes with a noise-insulating cas‐
ing (e.g. mineral fibers).
The ducting system must be configured such that
cleaning and inspection work can be performed with‐
out any problem. An important factor here is ensur‐
ing that the cover maintains the above-mentioned
tightness even when repeatedly actuated.
Note
There can be restrictions in the printing
process if the system has not properly
been installed.
B.14.8 00.999.5895/
2.4 Pressure conditions in exhaust hoods and exhaust air pipes

Pressure conditions in exhaust hoods and exhaust
XG.906.0311-000GRAUND_00
air piping
One should bear in mind that the blowers may be
very different in terms of volume and pressure.
Note
The exhaust air should be extracted by
way of a separate duct for each cabi‐
net. Collective ducts should be avoided
where possible.
Fig. 10 Exhaust air piping, single exhaust air duct

with exhaust hood
Pressure measurement in exhaust hood
LS.906.5882-000GRAUND_00
For the purpose of measuring pressure or flow condi‐

1 tions, the exhaust hood can be provided with a small
borehole approx. 20...30 mm (0.79...1.18 in)) on both
sides.
The boreholes must be sealed with a covering cap.
You may remove the covering cap to perform the
measurements in the exhaust hood. Perform the
measurements using suitable measuring equipment.
Seal the boreholes with the covering cap once the
measurements have been taken.
1 Boreholes for measurement of pressure or flow
conditions in the exhaust hood
Note
The pressure conditions in an exhaust
hood must lie between +20...-20 Pa
(+0.0029 psi...-0.0029 psi).
Fig. 11 Boreholes for measurement of pressure or
flow conditions in the exhaust hood
00.999.5895/ B.14.9
Backup ventilator
XG.906.0313-000GRAUND_00
Note
A supporting blower (Fig. 12), which is
adjusted to the pressure conditions,
that removes the exhaust air must al‐
ways be provided.
Note
Pressure losses result from pipe
lengths, additional installations such as,
e.g. flap traps, weather-protection gra‐
ting and wind load.
Caution - Explosion hazard materials!
Observe the protection classes for the
backup ventilator: risk of powder-dust
Fig. 12 Backup ventilator explosion.
Signals for controlling the supporting blower must be
tapped from the peripheral units concerned.
2.5 Protection against environmental influences

Protection against environmental influences
The peripheral units may be restricted in terms of
their function or even be damaged as a conse‐
quence of environmental influences.
In the worst case, condensation water is formed in
the peripheral unit and this may lead to technological
damage.
Note
Cold air may be taken in during the win‐
ter (wind load, chimney effect). In re‐
gions where temperatures drop to less
than 0°C (32°F) heat exchangers may
freeze up!
Note
At 10...15°C (50...59°F) outside temper‐
ature the formation of condensation wa‐
ter is also possible (moist pressroom
air).
B.14.10 00.999.5895/
A supporting blower and a flap trap should be instal‐
XG.906.0316-001GRAUND_00
3 led in the exhaust pipe to protect against environmen‐
tal influence.
1 Wind direction, inflowing cold air (wind load), rain
2 Flap trap open
3 Booster ventilator on
1
2
Fig. 13 Protection against environmental influen‐

ces (condition when running)
1 Wind direction, inflowing cold air (wind load), rain
XG.906.0315-001GRAUND_00
3 2 Flap trap closed

3 Backup ventilator off
Note
The flap trap must mechanically or elec‐
trically be closed when the peripheral
unit is switched off or the fan is stopped.
1
2
Fig. 14 Protection against environmental influen‐

ces (condition when not running)
2.6 Explosion prevention measures and zone structures

Powder and paper dust can be combustible and ex‐
plosive. Observe the following instructions when han‐
dling these substances:
● The interior space of suction tubes and suction
systems can be allocated to Zone 22 to ATEX
Directive or to EN 1127-1.
● IP54 is required as minimum protection rating
for electrical equipment.
00.999.5895/ B.14.11
● Company-specific explosion prevention meas‐

ures must be defined in the company, and be ob‐
served.
● Heidelberg is unable to make any statements
with respect to the currently used type and quan‐
tity of powder and the arising paper dust in print
shops. The user must therefore determine the
zone to ATEX Directive or to EN 1127-1 within
the scope of the national legal requirements for
a hazard analysis (e.g. in the Operational Safe‐
ty Ordinance). The data sheets of the employed
products could also be helpful here.
● If you are in doubt, we recommend using com‐
ponents that are allowed to be used with re‐
spect to Zone 22.
● Observe the applicable accident prevention reg‐
ulations and safety data sheets from the manu‐
facturers.
Zone structures
Amongst other topics, the following zones must be
dealt with within the scope of the operator-related haz‐
ard analysis:
Place Zone
Uncleaned delivery Zone 22
Interior space of suction tubes and suction systems Zone 22
Exhaust air cleaning cabinet, interior space when shaking Zone 21
Exhaust air cleaning cabinet, external environment (when undamaged and no zone
tight)
Additionally possible zones must be determined via the operator-related hazard analysis that is to be done.
Tab. 1 Zone structures (selection)
2.7 Fire protection measures

There is a risk of fire spreading through ventilation
systems by means of the conflagration gases. Legis‐
lation therefore requires that RLT systems (ventila‐
tion and air conditioning) are set up such that fire
and smoke cannot spread to other areas.
Note
Observe the local and country-specific
safety regulations and rules.
Note
Make sure that if necessary sufficient
space is available to enable rescue op‐
erations and extinguishing work to be
performed.
B.14.12 00.999.5895/
Interface adapter
Interface adapter
1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3

1.1 Correct use of the interface adapter signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3
1.2 EMC regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.3
2 Interface adapter, overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4

2.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4
2.2 Place of installation of the components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.4
3 SEM3 Interface input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5

3.1 Design and task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5
3.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.5
3.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.7
4 SEM3 input signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.8

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.8
4.3 Interdeck dryer in operation (E2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.9
4.4 UV dryer not ready to run (input E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.9
4.5 Malfunction: exhaust air (E4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.9
4.6 Dryer malfunction (E5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.10
4.7 Dryer blocking after washing (input E6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.10
4.8 Final UV dryer without shutter in operation (E7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.10
5 SAM17 Interface output module 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.12

5.1 SAM17, design and task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.12
5.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.13
5.3 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.13
6 SAM17 output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16

6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16
6.2 Run (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.16
6.3 Enable standby of final dryer (A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.17
6.4 Enable production of final dryer (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.17
6.5 Sheets in printing unit 1 (A4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.18
6.6 Emergency stop (A5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.18
6.7 Sheet counter ON (A6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.19
6.8 Feeder ON (A7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.19
6.9 Enable powder spray device (A8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.19
6.10 Washup active (A9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.20
00.999.5895/ B.15.1
Interface adapter
6.11 Emergency stop (A10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.20

6.12 Enable interdeck dryer (A11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.20
6.13 Enable final dryer (A12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.21
6.14 Enable standby of interdeck dryer (A13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.21
6.15 Air supply ON (A14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.22
6.16 CleanStar ON (A15) (SM 102, CD102 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.22
6.17 Main switch ON (A16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.22
6.18 Press cycle (A17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.23
B.15.2 00.999.5895/
Interface adapter
1 Safety instructions
00.110.9465-000UTKENU_01
1.1 Correct use of the interface adapter signals

The signals from the interface adapter are intended
for HEIDELBERG devices or for devices checked
and approved by HEIDELBERG. If devices are con‐
nected which are not checked and approved by HEI‐
DELBERG, it is the responsibility of the operator and
of the external device manufacturer to use the sig‐
nals provided in such a way that
● the products and units connected,
● the interfaces (mechanical, electrical) con‐
cerned and
● the press thereby altered and/or enhanced as a
whole
comply with the relevant and valid safety require‐
ments.
This may mean that reapproval by a national inspec‐
tion agency is necessary!
If external equipment is connected to the interface
adapter, the signal levels, signal currents and maxi‐
mum connected load must comply with HEIDEL‐
BERG specifications.
Plausibility check
Safety-relevant signals are transmitted redundantly.
In the case of the CAN devices, you must therefore
check whether both the hard-wired signal and the sig‐
nal routed via the CAN interface are transmitted. If
one of the two signals is missing, the operator must
be informed accordingly!
Warning - Physical injuries

Before putting the equipment into op‐
eration, check whether the emergen‐
cy stop signal from each connected
external device causes an emergen‐
cy stop of the printing press.
Caution - Press damage

If the connection of external devices
leads to press damages, the manufac‐
turer of the external device or the oper‐
ator of the equipment will be held re‐
sponsible!
1.2 EMC regulations

The applicable EMC directives and standards must
be adhered to when external devices are connected.
00.999.5895/ B.15.3
Interface adapter
2 Interface adapter, overview

00.110.9458-000UTKENU_03
2.1 Block diagram
00.110.4445-000GRAENU_03
External equipment
Operating Safety path signals

path signals
SEM SAM Interface adapter
Operating path Safety path
MDPS/MDIS
DIPM VDCB2
VDSC
Sheetfed Con-
CAN-BW
CAN-S trol control sys-
tem
SCU2
Control station Messages from

external equip-
MID feeder ment
Delivery touch panel
Fig. 1 Block diagram of interface adapter
2.2 Place of installation of the components

The electronic boards of the interface adapter (SEM,
SAM) are at the left side panel of the central control
cabinet.
B.15.4 00.999.5895/
Interface adapter
3 SEM3 Interface input module

00.110.9459-000UTKENU_02
3.1 Design and task

1 X2, terminal strip for external equipment
LS.110.0818-001GRAUND_00
1 2
2 X1, terminal strip for the inputs to the DIPM
3 X3, ground connection

The SEM isolates the output signals of the external

equipment electrically from the CPTronic control sys‐
tem by means of optocouplers.

Fig. 2 Design of SEM3
3.2 Block diagram
00.110.4642-001GRAENU_01
DC 24V
P+
DC 15 V P-
E+ / E+8
(DC 24V)
X2
E1...E8
X1
External device SEM3 DIPM
Fig. 3 Principle: output signals of external equipment
00.999.5895/ B.15.5
Interface adapter
On the SEM3, 15 V DC are generated from 24 V DC.
LS.110.0811-001GRAUND_00
DC
24 V P+ This voltage is made available to external devices as
DC
P- signal voltage. Depending on the desired signal, the
10
15 V external devices feed the voltage back to the SEM3.
11 E+ An optocoupler then transmits a voltage of DC 24 V
to the DIPM. The signals E1...E7 are transmitted to
10 E1 the SCU over the operating path.
12 The input voltage "E+8" for input 8 is not connected
10 by wire link to the voltage "E+" of the other inputs.
E2
13 The signal E8 is transmitted to the SCU over the safe‐
ty path.
10 E3
14
10 E4
15
10 E5
16
10 E6
17
10 E7
18 E+8
E8
X2 X1
Fig. 4 Block diagram of SEM3
B.15.6 00.999.5895/
Interface adapter
3.3 Connections
LS.110.0813-002GRAUND_00
1 2 3
- 18
E8
10
17
E7
10
+
16
E6
10
15
E3 / E4 / E5
E5 / E7 10
14
E4
10
. 13
. E3 10
. 12
E2 10
11
E1 10
E1 / E2 /
E6 / E8
Fig. 5 Connections at the SEM3

1 External device
2 X2, terminal strip for the output signals of the ex‐
ternal equipment
3 X1, terminal strip for the inputs of the DIPM
Note
If optocoupler outputs are used for the
external device, make sure the polarity
is correct ("+" to terminals 10; "-" to ter‐
minals 11...18). If NC contacts (E1, E2,
E6, E8) or NO contacts (E3, E4, E5,
E7) are used, the polarity is irrelevant.
The lines of the external devices are connected to ter‐
minal strip SEM3-X2.
00.999.5895/ B.15.7
Interface adapter
4 SEM3 input signals

00.110.9460-000UTKENU_02
4.1 Overview
Input Terminal Signal

E1 10 and 11* External emergency stop (signal redundant to E8)
E2 10 and 12* Interdeck dryer in operation
E3 10 and 13 UV dryer not ready to run
E4 10 and 14 Malfunction: exhaust air
E5 10 and 15 Dryer malfunction
E6 10 and 16* Dryer blocking after washing
E7 10 and 17* Final UV dryer without shutter in operation
E8 10 and 18* External emergency stop (signal redundant to E1)
Tab. 1 SEM3 signals
* When connecting an external device to the termi‐
nals 10 and 11, 10 and 12, 10 and 16, 10 and 17, 10
and 18, remove the corresponding jumper.
Note
The connected signals must be poten‐
tial-free!
4.2 External emergency stop (E1)

Signal redundant to "External emergency stop" (E8).
Signal from an external device.
Terminals Signal Effect on the printing press
10 11 The contacts must be closed if: ● No effect.

● there is no emergency stop.
10 11 The contacts must be open if: ● The press stops as quickly as possible and the
● there is an emergency stop. malfunction is indicated.
● Together with the "External emergency stop" sig‐
nal (E1), the "External emergency stop" signal
(E8) must be set. If this is not the case, a plausi‐
bility error will be signaled (see operating manual).
Tab. 2
B.15.8 00.999.5895/
Interface adapter
Connection of several emergency stop signals
SG.110.4702-000GRAENU_00
SEM3 If the printing press has more than one external de‐
10 11 vice, it may be necessary to connect several "Exter‐
nal emergency stop" signals to the contacts 10 and
11. The individual signals must be connected in ser‐
ies in this case. The figure opposite illustrates the con‐
nection.
Emergency Emergency Emergency

stop stop stop
Device 1 Device 2 Device n
Fig. 6 Connection of several emergency stop sig‐

nals
4.3 Interdeck dryer in operation (E2)

Signal from an interdeck dryer.
10 12 The contacts must be closed if: ● After the signal change from open to closed con‐
● there is no interdeck dryer. tact (corresponds to the shutdown of the inter‐
deck dryer), there is a waiting time until an auto‐
● the interdeck dryer is not in opera‐
matic washup procedure may be started.
tion.
10 12 The contacts must be open if: ● Washup is not possible.

● the interdeck dryer is in operation.
Tab. 3
4.4 UV dryer not ready to run (input E3)

Signal from a UV dryer.
10 13 The contacts must be closed if: ● The feeder of the press is disabled. A yellow er‐
● the UV dryer is not ready to run ror message is displayed.
(e.g. while heating up).
● a malfunction has occurred in the
UV dryer.
10 13 The contacts must be open if: ● The feeder of the press is not disabled.
● the UV dryer is ready to run.
Tab. 4
4.5 Malfunction: exhaust air (E4)

Signal from an air-conditioning system.
00.999.5895/ B.15.9
Interface adapter

● the fans and blowers are switched
on.
10 14 The contacts must be open if: ● A yellow error message is displayed.

● the fans and blowers are switched
off.
Tab. 5
4.6 Dryer malfunction (E5)

Signal from a dryer which demands no direct reac‐
tion from the press upon failure (feeder not disabled).
10 15 The contacts must be closed if: ● A yellow error message is displayed, printing can
● a malfunction has occurred in the continue.
dryer.
10 15 The contacts must be open if: ● No effect.

● no malfunction has occurred in the
dryer.
Tab. 6
4.7 Dryer blocking after washing (input E6)

Signal from an interdeck dryer.
10 16 The contacts must be closed if: ● No effect. No waiting time after an automatic
● there is no interdeck dryer. washup procedure.
10 16 The contacts must be open if: ● After an automatic washup procedure, the inter‐
● there is an interdeck dryer and volt‐ deck dryer is only started after a waiting time.
age is applied.
Tab. 7
4.8 Final UV dryer without shutter in operation (E7)

Signal from a final UV dryer without shutter.
10 17 The contacts must be closed if: ● No effect. The grippers can be positioned in the
● the final UV dryer without shutter is radiation area of the UV lamps.
not in operation.
10 17 The contacts must be open if: ● Positioning of the grippers in the radiation area
● the final UV dryer without shutter is of the UV lamps is problematic.
in operation. If the grippers are in the radiator area while the
press is at a standstill and the radiators are
turned on, a buzzer will sound. The press opera‐
B.15.10 00.999.5895/
Interface adapter

tor must remove the gripper bar from the radiator
area in inching mode. Otherwise the dryer will be
turned off after one minute (SAM3 signals, "ena‐
ble standby of final dryer" (A1) and "enable final
dryer" (A2)).
Tab. 8
4.9 External emergency stop (E8)

Signal redundant to "External emergency stop" (E1).
Signal from an external device.

● there is no emergency stop.
10 18 The contacts must be open if: ● The press stops as quickly as possible and the
● there is an emergency stop. malfunction is indicated.
● Together with the "External emergency stop" sig‐
nal (E8), the "External emergency stop" signal
(E1) must be set. If this is not the case, a plausi‐
bility error will be signaled (see operating manual).
Tab. 9
Connection of several emergency stop signals
Please refer to the corresponding section under "Ex‐
ternal emergency stop (E1)".
00.999.5895/ B.15.11
Interface adapter
5 SAM17 Interface output module 17

00.110.9462-000UTKENU_02
5.1 SAM17, design and task
00.110.4595-000GRAUND_00
X3 X1 Connection of DIPM outputs
X2 Connections of external equipment
87 86 X3 Connections of external equipment
85 84
83 82 The function of the SAM17 is to isolate the outputs of
81 80 the CPTronic control system electrically from the ex‐
79 78 ternal equipment.
77 76
75 74
73 72
71 70 X1
69 68
67 66
65 64 A17
63 62 A16
61 60 A15
59a 58a A14
57a 56a A13
59 58 C12
57 56 A12
55 54 C11
53 52 A11
51 50 C10
49 48 A10
47 46 A9
45 44 A8
43 42 A7
41 40 A6
39a 38a A5
37a 36a A4
39 38 A3
37 36 A2
35 34 A1
33 32 COM
31a 30a
29a 28a
31 30
29 28
27 26
25 24
23a 22a
21a 20a
23 22
21 20
X2
Fig. 7 Design of SAM17
B.15.12 00.999.5895/
Interface adapter
5.2 Block diagram
00.110.9032-001GRAENU_01
A1...A9,
X2/X3 A13...A17
X1
Ground
COM
X2/X3 A10...A12
X1
Ground
C10...C12
External de-
vice SAM17 DIPM
Fig. 8 Block diagram of SAM17
5.3 Connections
Caution - Risk of damage to the opto‐
couplers on the SAM17
Max. 24 V, 300 mA may be applied to
the output terminals of the SAM17. If
the connected load is higher, the opto‐
couplers on the SAM17 can be dam‐
aged!
If inductive loads are connected to the
output terminals, external protective
components must be installed addition‐
ally!
00.999.5895/ B.15.13
Interface adapter
00.110.4476-002GRAUND_00
20 22 20a 22a A1
A1
21 23 21a 23a
24 26 A2
A2
25 27
28 30 28a 30a A3
A3
29 31 29a 31a
32 34 A4
A4
33 35
36 38 36a 38a A5
A5
37 39 37a 39a
40 42 A6
A6
41 43
44 46 A7
A7
45 47
48 50 A8
A8
49 51
52 54 A9
A9
53 55 COM
Fig. 9 SAM17, part 1
B.15.14 00.999.5895/
Interface adapter
00.110.7139-001GRAUND_00
56 58 56a 58a A10
A10
57 59 57a 59a C10
60 62 A11
A11
61 63 C11
64 66 A12
A12
65 67 C12
68 70 A13
A13
69 71
72 74 A14
A14
73 75
76 78 A15
A15
77 79
80 82 A16
A16
81 83
84 86 A17
A17
85 87 COM
Fig. 10 SAM17, part 2
00.999.5895/ B.15.15
Interface adapter
6 SAM17 output signals

00.110.9461-000UTKENU_02
6.1 Overview
Output Terminals Signal

A1 20, 21 / 20a, 21a / 22, 23 / 22a, 23a Run
A2 24, 25 / 26, 27 Enable standby of final dryer
A3 28, 29 / 28a, 29a / 30, 31 / 30a, 31a Enable production of final dryer
A4 32, 33 / 34, 35 Sheets in printing unit 1
A5 36, 37 / 36a, 37a / 38, 39 / 38a, 39a Emergency stop (safety-relevant signal, carry out
plausibility check - see "Safety instructions")
A6 40, 41 / 42, 43 Sheet counter ON
A7 44, 45 / 46, 47 Feeder ON
A8 48, 49 / 50, 51 Enable powder spray device
A9 52, 53 / 54, 55 Washup active
A10 56, 57 / 56a, 57a / 58, 59 / 58a, 59a Emergency stop (safety-relevant signal, carry out
A11 60, 61 / 62, 63 Enable interdeck dryer (safety-relevant signal, carry
out plausibility check - see "Safety instructions")
A12 64, 65 / 66, 67 Enable final dryer (safety-relevant signal, carry out
A13 68, 69 / 70, 71 Enable standby of interdeck dryer
A14 72, 73 / 74, 75 Air supply ON
A15 76, 77 / 78, 79 CleanStar ON (SM 102, CD 102 only)
A16 80, 81 / 82, 83 Main switch ON
A17 84, 85 / 86, 87 Press cycle
Tab. 10 SAM17 signals
6.2 Run (A1)
Terminals Signal Meaning

The contacts are connected with each Signal for external equipment.
20 21
other when:
20a 21a
● Printing press rotates.
22 23
22a 23a
20 21 The contacts are not connected with

each other when:
20a 21a
22 23
22a 23a
B.15.16 00.999.5895/
Interface adapter

● Printing press is at standstill.
Tab. 11
6.3 Enable standby of final dryer (A2)

The contacts are connected with each ● IR or hot-air dryers: the dryers are preheated.
24 25
other when all the following conditions ● UV dryers: the UV radiators are preheated at
26 27 are fulfilled: 100 % power. This takes several minutes. After‐
● The dryers have been preselected. wards the radiator power is reduced. The shutter
● The press is at a standstill and remains closed.
there are no sheets in the press
(no rapid stop) or the press is in op‐
eration.
● There is no washup request.
● The delivery guards relevant to the
dryer are closed (see tables below).
● No emergency stop on the press.
The contacts are not connected with Shutdown of the final dryers.
24 25
each other when one of the following
26 27 conditions is fulfilled:
● One of the guards relevant to the
dryer was opened (see tables be‐
low).
● Emergency stop on the press.
● After a rapid stop or during inching,
sheets are under a UV dryer with‐
out shutter.
● The preselection was canceled and
there are no sheets in the press.
● The press is at a standstill. The fi‐
nal UV dryers have no shutters and
the gripper bars are in the unpermit‐
ted zone for more than one minute.
Tab. 12
6.4 Enable production of final dryer (A3)

The contacts are connected with each ● IR or hot-air dryer: the radiators operate at the
28 29
other when: preset power level and the dryer goes into opera‐
28a 29a
● the signal "Enable standby of final tion.
30 31 dryer" is applied. ● UV dryer: the shutters are opened and the radia‐
30a 31a ● the press rotates at min. 3000 rpm. tors operate at the preset power level.
● the first sheet is 4 seconds in front
of the delivery.
00.999.5895/ B.15.17
Interface adapter

The contacts are not connected with The final dryers go into "standby" mode (see signal
28 29
each other when: "Enable standby of final dryer" (A2))
28a 29a
● the last sheet is placed on the deliv‐
30 31 ery pile.
30a 31a ● the dryers are deselected (preselec‐
tion of dryers is canceled).
● the press rotates at less than
3000 rpm (e.g. after a rapid stop)
● the signal "Enable standby of final
dryer" is absent.
Tab. 13
6.5 Sheets in printing unit 1 (A4)

The contacts are connected with each Signal for the turning on of the radiators in the inter‐
32 33
other when: deck zone and for static eliminators.
34 35
● the press is in production and
sheets are in printing unit 1.
The contacts are not connected with Signal for static eliminators. The radiators in the in‐
32 33 each other when: terdeck zone are turned off via the signal "Enable
34 35 ● the last sheet leaves printing unit 1. production of final dryer" since the signal "Sheets in
printing unit 1" (A4) is reset too early.
Tab. 14
6.6 Emergency stop (A5)

The contacts are connected with each Normal operation of the external equipment.
36 37
other when: Signal redundant to the "Emergency stop" signal
36a 37a
● No emergency stop on the press. (A10).
38 39
38a 39a
The contacts are not connected with The external equipment must be turned off.
36 37 each other when: Signal redundant to the "Emergency stop" signal
36a 37a ● Emergency stop on the press. (A10).
38 39
38a 39a
Tab. 15
Connection of more than 4 external devices
If more than 4 external devices are to be connected,
increase the number of outputs by means of an addi‐
B.15.18 00.999.5895/
Interface adapter
tional relay with several contacts. The relay must be

suitable for the desired application and comply with
the relevant specifications.
6.7 Sheet counter ON (A6)

The contacts are connected with each Signal for tape inserter.
40 41
other when:
42 43
● printed sheets reach the delivery.
The contacts are not connected with

40 41
each other when:
42 43
● no printed sheets reach the delivery.
Tab. 16
6.8 Feeder ON (A7)

The contacts are connected with each
44 45 other when:
46 47 ● The feeder is engaged.

44 45
each other when:
46 47
● The feeder is disengaged.
Tab. 17
6.9 Enable powder spray device (A8)

The contacts are connected with each Spraying of powder enabled for powder spray device.
48 49
other when:
50 51
● printed sheets leave the last print‐
ing unit and powdering has been
preselected.
The contacts are not connected with Spraying of powder not enabled for powder spray de‐
48 49
each other when: vice.
50 51
● no printed sheets leave the last print‐
ing unit or powdering has not been
preselected.
Tab. 18
00.999.5895/ B.15.19
Interface adapter
6.10 Washup active (A9)

The contacts are connected with each Signal for dryer.
52 53
other when:
54 55
● a washup procedure is in progress
in the press: blanket washup, im‐
pression cylinder washup or wash‐
up of printing plate via the blanket.
Washup of the printing plate via the
blanket only exists on SM 102/
CD 102 with Autoplate.
52 53
each other when:
54 55
● no washup procedure is in prog‐
ress in the press.
Tab. 19
6.11 Emergency stop (A10)

The contacts are connected with each Normal operation of the external equipment.
56 57 other when: Signal redundant to the "Emergency stop" signal (A5).
56a 57a ● No emergency stop on the press.
58 59
58a 59a
The contacts are not connected with The external equipment must be turned off.
56 57
each other when: Signal redundant to the "Emergency stop" signal (A5).
56a 57a
58 59
58a 59a
Tab. 20
Connection of more than 4 external devices
Please refer to the corresponding section under
"Emergency stop (A5)".
6.12 Enable interdeck dryer (A11)

The contacts are connected with each Redundant signal for the turning on of the interdeck
60 61
other when: dryer in conjunction with the signal "Enable standby
62 63
● all guards in the interdeck zone of interdeck dryer" (A13).
which are relevant to the dryer are
closed.
B.15.20 00.999.5895/
Interface adapter

The contacts are not connected with Redundant signal for the turning off of the interdeck
60 61 each other when: dryer when the signal "Enable standby of interdeck
62 63 ● at least one guard in the interdeck dryer" (A13) is not applied anymore.
zone which is relevant to the dryer
is open.
6.13 Enable final dryer (A12)

The contacts are connected with each Redundant signal for the turning on of the final dryer
64 65
other when: in conjunction with the signal "Enable standby of fi‐
66 67
● all guards in the delivery area nal dryer" (A2) or "Enable production of final dryer"
which are relevant to the dryer are (A3).
closed.
The contacts are not connected with Redundant signal for the turning off of the final dryer
64 65
each other when: when the signal "Enable standby of final dryer" (A2)
66 67
● at least one guard in the delivery or "Enable production of final dryer" (A3) is not ap‐
area which is relevant to the dryer plied anymore.
is open.
Tab. 22
6.14 Enable standby of interdeck dryer (A13)

The contacts are connected with each The interdeck dryer is switched to standby mode.
68 69 other when:
70 71 ● the dryers have been preselected.
● the guards in the interdeck zone
which are relevant to the dryer are
closed.
● There is no washup request.
● possible waiting times have expired.
● the press is at a standstill and there
are no sheets in the press (conse‐
quently no rapid stop) or the press
rotates at min. 3000 rpm.
● No emergency stop on the press.
The contacts are not connected with Interdeck dryer off.
68 69 each other when:
70 71 ● one of the guards in the interdeck
zone which is relevant to the dryer
was opened.
● the preselection of the dryers was
canceled and there are no sheets
in the press.
00.999.5895/ B.15.21
Interface adapter

● a washup request was output.
Tab. 23
6.15 Air supply ON (A14)

The contacts are connected with each Signal for building installations for the turning on or
72 73
other when: off of additional blowers.
74 75
● the air supply of the press is turned
on.

72 73
each other when:
74 75
● the air supply of the press is turned
off.
Tab. 24
6.16 CleanStar ON (A15) (SM 102, CD102 only)

The contacts are connected with each CleanStar is turned on.
76 77
other when:
78 79
● the powder spray device is turned
on or the dryer is in production
mode.
The contacts are not connected with CleanStar is turned off.
76 77
each other when:
78 79
● the powder spray device and dryer
are turned off for more than 30 sec‐
onds.
Tab. 25
6.17 Main switch ON (A16)

The contacts are connected with each Signal for building installations for the turning on or
80 81
other when: off of an air-conditioning system.
82 83
● the main switch of the press is
turned on.

80 81 each other when:
82 83 ● the main switch of the press is
turned off.
Tab. 26
B.15.22 00.999.5895/
Interface adapter
6.18 Press cycle (A17)

The signal is a square-wave signal. The signal provides the press cycle for external equip‐
84 85 The signal edges vary for the different ment.
86 87 press model lines.
Tab. 27
00.999.5895/ B.15.23
Interface adapter
B.15.24 00.999.5895/
Annex
Annex
1 Physical measures and their units in the SI system and the ANSI system . . . . . . . . . . . . . . B.16.3
1.1 Physical measures and their units in the SI system and the ANSI system . . . . . . . . . . B.16.3
2 Special conversions and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.4

2.1 Special conversions and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.4
3 Water hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.5

3.1 Water hardness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.16.5
00.999.5895/ B.16.1
Annex
B.16.2 00.999.5895/
Annex
1 Physical measures and their units in the SI system and the ANSI system
SC.906.5400-000UTKENU_01
1.1 Physical measures and their units in the SI system and the ANSI system
Measure Unit and conversion

SI system ANSI system ANSI system SI system
Length 1 mm 0.03937 in 1 in 25.4001 mm
1 cm 0.3937 in 1 in 2.54001 cm
1m 3.28084 ft 1 ft 0.30480 m
Area 1 mm2 0.00155 sq in 1 sq in 645.16129 mm2
1 cm2 0.15500 sq in 1 sq in 6.45162 cm2
1 m2 10.7639 sq ft 1 sq ft 0.09290 m2
Volume 1 cm3 0.06102 cu in 1 cu in 16.38706 cm3
1 dm3 61.02376 cu in 1 cu in 0.01639 dm3
1 m3 35.31466 cu ft 1 cu ft 0.02832 m3
Velocity 1 m/s 3.28084 ft ps 1 ft ps 0.3048 m/s
1 m/min 3.28084 ft pm 1 ft pm 0.3048 m/min
Volume flow 1 dm3/min 61.0238 cu in/min 1 cu in/min 0.01639 dm3/min
1 dm3/h 61.0238 cu in/h 1 cu in/h 0.01639 dm3/h
1 m3/h 35.31466 cu ft/h 1 cu ft/h 0.02832 m3/h
Mass 1 kg 2.20462 lbs 1 lbs 0.45359 kg
Density 1 kg/dm3 0.03613 lbs/cu in 1 lbs/cu in 27.6796 kg/dm3
1 kg/m3 0.06243 lbs/cu ft 1 lbs/cu ft 16.01846 kg/m3
Force 1N 0.22481 lbf 1 lbf 4.44822 N
Pressure 1 bar 14.5038 psi 1 psi 0.06895 bar
1 N/mm2 145.038 lbf/sq in 1 lbf/sq in 0.00689 N/mm2
1 N/cm2 1.45038 lbf/sq in 1 lbf/sq in 0.68948 N/cm2
1 N/m2 0.02089 lbf/sq ft 1 lbf/sq ft 47.879 N/m2
1 kg/m2 0.20482 lbf/sq ft 1 lbf/sq ft 4.88233 kg/m2
Power 1 kW 1.34102 hp 1 hp 0.74570 kW
1W 0.73756 lbf ft/ s 1 lbf ft/ s 1.35582 W
Illuminance 1 lx 10.7640 fc 1 fc 0.09290 lx
Tab. 1 Physical measures and their units in the SI system and the ANSI system
00.999.5895/ B.16.3
Annex
2 Special conversions and multiples

SC.906.5401-000UTKENU_01
2.1 Special conversions and multiples

Conversion of linear measurement units
1 ft = 12 in
1 yard = 3 ft = 36 in
Conversion of volume units

1 liter = 1 dm3
1 liter = 0.26417 US gal
1 liter = 0.21997 UK gal
1 US gal = 231.0 cu in = 3,785 dm3
1 UK gal = 277.4 cu in = 4,546 dm3
1 cu ft = 1728 cu in
Conversion of mass units

1 lb = 16 oz (avoirdupois) = 453.6 g
1 oz (avoirdupois) = 28.35 g
Conversion of pressure units

1 bar = 10 N/cm2
1 Pa = 1 N/m2
Conversion of temperature units

Conversion degrees Celsius into degrees Fahrenheit:
1.8 x n °C + 32
Conversion degrees Fahrenheit into degrees Celsius:
(n °F - 32) / 1.8
Conversion of energy units
1 W = 3.413 Btu/h
(British thermal units per hour)
1 kW = 3413 Btu/h
1 kW = 0.94806 Btu/s
(British thermal units per second)
1 Btu/h = 0.29307 W
1 Btu/s = 1.05506 kW
B.16.4 00.999.5895/
Annex
3 Water hardness
SC.906.5402-000UTKENU_01
3.1 Water hardness

A criterion for describing water quality is the water
hardness. It is defined by the contents of calcium
ions and magnesium ions in the water.
In Germany, the water hardness is usually specified
as "°dH" (German degrees of hardness). The interna‐
tional specification of the water hardness is the con‐
centration of the amount of substance in "mmol/l" (mil‐
limol per liter).
1 °dH corresponds to a calcium oxide contents
(CaO) of 10 mg/l (corresponds to 0.178 mmol/l).
The following table gives an overview of the different
hardness ranges :
Water type Hardness Hardness CaO con‐

range [°dH] tents [mg/l]
soft I 0...7.9 0...79
medium II 8...14.9 80...149
hard
hard III 15...21.9 150...219
22...27.9 220...279
very hard IV 28...34.9 280...349
35...40 350...400
Tab. 2 Water hardness
Conversion of water hardness units
German water hardness:
1 °dH corresponds to 10 mg CaO per liter water
American water hardness:
1 °aH corresponds to 1 grain per US gal
(1 grain = 0.0648 g CaO)
English water hardness:
1 °eH corresponds to 1 grain per UK gal
(1 grain = 0.0648 g CaO)
French water hardness:
1 °fH corresponds to 10 mg CaCO3 per liter of water
Equivalents
Unit °dH °aH °eH °fH
Factor 1 1.04 1.25 1.79
Tab. 3 Equivalents
00.999.5895/ B.16.5
Annex
B.16.6 00.999.5895/
Index
Index
A Blanket A.1.5
Blanket cylinder A.1.5
Air conditioning B.2.4
Building openings A.1.101, B.2.3
Air pipes
– Determining the diameter for a length >10 m (>33 ft)
B.5.16 C
– Requirements B.5.18
Ceilings in buildings B.2.3
AirStar B.5.3
Central air supply B.6.8
– Air-cooled AirStar B.5.3, B.5.6
Central compressed air supply B.6.8
– Air cooling of the air-cooled AirStar B.5.7
– Checking the compressed air connection B.6.10
– Air throughput of the air-cooled AirStar B.5.6
– Configuration of the compressed air connection
– Air throughput of the water-cooled AirStar B.5.8
B.6.8
– Allocation A.1.94
– Safety and protective measures B.6.10
– Assignments of the connecting sockets of the
Central compressed-air supply
AirStar B.5.4
– Repair work B.6.10
– Calculation of the air pipe diameter B.5.18
Central control cabinet
– Calculation of the pressure drop, ANSI units
– Dimensions and weights A.1.10
B.5.15
– Shipping data A.1.99
– Calculation of the pressure drop, metric units
Central dampening solution supply systems B.7.9
B.5.15
Channel types B.14.7
– Determining the air pipe diameter B.5.16
CleanStar B.9.3
– Air throughput B.9.3
– Exhaust air removal with the air-cooled AirStar
B.5.7
– External refrigeration cycle B.5.9
– Extracting the process air from the printing
– Specifications A.1.87
process with the water-cooled AirStar B.5.9
CleanStar Compact
– Flexible installation of peripheral units B.5.13
– Installation B.5.14
– Installation instructions B.5.11
Coating blanket A.1.5
– Installation site requirements B.5.14
Coating blanket cylinder A.1.5
– Minimum distances at the installation site B.5.11
Coating plate A.1.5
– Pressure drop when using exhaust hoods on the
CoatingStar B.10.3
air-cooled AirStar B.5.14
– Specifications of the process air supply B.5.4
– Standard installation B.5.12
– Technical specifications A.1.80
– Minimum distances at the place of installation
– Water-cooled AirStar B.5.3, B.5.8
B.10.6
Air supply
– Requirements for the place of installation B.10.5
– See central air supply B.6.8
Air supply cabinet B.5.3
Air throughput
CoatingStar Compact
– Of the air-cooled AirStar B.5.6
– Of the CleanStar B.9.3
– of the ScrollStar B.6.3
– Of the water-cooled AirStar B.5.8
CombiStar B.7.3
Allocation
– Of the peripheral equipment A.1.94
Annex B.16.3
– External refrigeration cycle B.7.3
Average static floor load A.1.22, A.1.24, B.2.6,
B.2.8
B – Specifications A.1.83
Backup ventilator B.14.10
00.999.5895/ Ind.1
Index
Compressed air – Base system B.13.7

– Required from central air supply systems B.6.8 – Center gangway B.13.8
Compressed air supply – Extension package B.13.6
– See also central compressed air supply B.6.8 – Minimum distances B.13.9
Conductor terminals – Space required B.13.6
– Cross sections of the terminals at the series Double-row installation B.13.6
transformer B.4.23 Dryer cabinet
Configuration – Cross sections of the conductor terminals
– Printing press A.1.93 B.11.28
Connecting sockets – Mains connection variant A1 B.11.25
– Assignments of the AirStar B.5.4 – Mains connection variant A3 B.11.27
Connection to power supply – Mains connection variants A1 and A3 B.11.25
– of the Prinect peripheral units B.12.4 DryStar
– Tolerances B.4.10 – Assigning A.1.97
Constructional requirements – Dimensions and weights A.1.13
– In the pressroom B.2.3 – Electrical connection specifications A.1.78
Conversion – Flexible installation of peripheral units B.11.17
– Of energy units B.16.4 – Shipping information A.1.100
– Of linear measurement units B.16.4 – specifications A.1.88
– Of mass units B.16.4 DryStar
– Of pressure units B.16.4 – Installation instructions B.11.15
– Of temperature units B.16.4 – Standard installation B.11.15
– Of volume units B.16.4 DryStar Coating
– Of water hardness units B.16.5 – Air supply and air removal B.11.9
– Physical B.16.4 – Description B.11.7
Conversion table – Dryer cabinet B.11.8
– Units B.16.3 – External refrigeration cycle B.11.9
– Main components B.11.8
– Refrigeration cycle B.11.9
D
DryStar Combination
Dampening solution connection – Air supply and air removal B.11.13
– Layout of the dampening solution connection – Cooling circulation B.11.13
B.7.10 – Description B.11.11
– Testing the dampening solution connection – Dryer cabinet B.11.13
B.7.10 – External refrigeration cycle B.11.14
Dampening solution supply – Main components B.11.12
– Design of a supply network B.7.9 DryStar cooling and electric module
– Installation of the dampening solution supply – Allocation A.1.98
B.7.9 – Dimensions and weights A.1.13
– Via central dampening solution supply systems DryStar dryer cabinet
B.7.9 – Allocation A.1.98
Dampening solution supply pipes – Dimensions and weights A.1.13
– Requirements B.7.9 DryStar Ink
Dampening system A.1.5 – Air supply and air removal B.11.5
Dimensions – Cooling circulation B.11.6
– Exhaust hoods A.1.15 – Description B.11.4
– Foundation for elevated installations A.1.29, – Main components B.11.5
B.2.13
– Foundation for standard installations A.1.28,
E
B.2.12
– Peripheral units A.1.10 Electrical connection specifications
– Printing press A.1.7 – General information A.1.31
– Printing press for elevated installation A.1.8 – Mains connection of the DryStar infrared dryer
– Printing press for standard installation A.1.7 A.1.32
Disposal lines B.2.3 – Mains connection of the printing press A.1.31
Double row installation – Maximum short-circuit current Icu A.1.32
– Assembling cabinet base B.13.8 – of the DryStar IR dryers A.1.78
Ind.2 00.999.5895/
Index
– Printing press with 4 printing units A.1.33 Exhaust air removal

– Printing press with 5 printing units A.1.42 – With the air-cooled AirStar B.5.7
– Printing press with 6 printing units A.1.51 Exhaust air routing
– Printing press with 7 printing units A.1.60 – DryStar B.9.6, B.11.18
– Printing press with 8 printing units A.1.69 – DryStar Coating with CleanStar B.9.9, B.11.21
– Using LVHBC fuses A.1.32 – DryStar Coating with CleanStar Compact B.9.8,
Electrical installation B.11.20
– General information B.4.3 – DryStar Combination (2 slide-in units) B.9.9,
Electrical power supply B.2.15 B.9.10, B.11.21, B.11.22
Elevated press – DryStar Combination (3 slide-in units) B.9.10,
– Oil drip pans B.3.11 B.9.11, B.11.22, B.11.23
Elevated printing press – DryStar Ink B.9.7, B.11.19
– Calculating the weight of the strip foundations – DryStar Ink with CleanStar B.9.8, B.11.20
B.3.6 – DryStar Ink with CleanStar Compact B.9.7,
– General information B.3.3 B.11.19
– Installation B.3.3 Exhaust hood
– Installation of strip foundations B.3.7 – Pressure measurement B.14.9
– Installation of strip foundation segments B.3.7 Exhaust hoods
– Installation of the motor mounting base B.3.10 – Dimensions A.1.15
– Material requirements for strip foundations B.3.6 Explosion prevention measures B.9.3, B.14.11
– Material requirements for the motor mounting base Extension kits B.13.3
B.3.8 – +20 m (65.6 ft) B.13.4
– Motor mounting base B.3.8, B.3.9 – +5 m (16.4 ft) B.13.4
– Production of strip foundations B.3.7 Extension packages
– Production of strip foundation segments B.3.7 – +10 m (32.8 ft) B.13.4
– Required accessories B.3.4
– Requirements B.3.3
F
– Strip foundations B.3.6
– Strip foundation versions B.3.6 FilterStar
– Weight calculation of the motor mounting base – Allocation A.1.96
B.3.8 – Dimensions and weights A.1.12
EMC requirements B.4.8 – Specifications A.1.86
Exhaust air cleaning cabinet B.9.3 FilterStar Compact
– Allocation A.1.97 – Allocation A.1.96
– Dimensions and weights A.1.12 – Dimensions and weights A.1.12
– Flexible installation of peripheral units B.9.5 – Specifications A.1.86
– Installation instructions B.9.4 Fire protection measures B.14.12
– Specifications A.1.87 Flexible installation of peripheral units B.13.3
– Standard installation B.9.4 – CoatingStar B.10.7
Exhaust air collecting box – Extension kits B.13.3
– Allocation A.1.97 – Of the AirStar B.5.13
– Dimensions and weights A.1.12 – Of the CombiStar B.7.7
Exhaust air piping B.14.6 – Of the DryStar B.11.17
– Area reinforcements B.14.7 – Of the exhaust air cleaning cabinet B.9.5
– Assembly B.14.8 – Of the ScrollStar B.6.6
– Backup ventilator B.14.10 Flexible peripherals installation
– Channel types B.14.7 – Of the WashStar B.8.5
– Design requirements B.14.6 Floor compression A.1.26, B.2.10
– Exhaust process air B.14.6 Floor coverings B.2.3
– Explosion prevention measures B.14.11 Floor plans A.2.3
– Fire protection measures B.14.12 – CX 102, elevated A.2.18
– Flow-related requirements B.14.6 – CX 102 + L, elevated A.2.19
– Materials B.14.6 – CX 102 + L (X2), elevated A.2.20
– Pressure conditions B.14.9 – CX 102 + L (X3), elevated A.2.21
– Protection against environmental influences – CX 102-4 A.2.3
B.14.10 – CX 102-4 + L A.2.4
– Zone structures B.14.11 – CX 102-4 + L (X2) A.2.5
00.999.5895/ Ind.3
Index
– CX 102-4 + L (X3) A.2.5 I

– CX 102-5 A.2.6
Indicator plate
– CX 102-5 + L A.2.7
– For the connection of the printing press B.4.5
– CX 102-5 + L (X2) A.2.8
– Location in the ZSG B.4.5
– CX 102-5 + L (X3) A.2.8
Inking unit A.1.5
– CX 102-6 A.2.9
InkStar
– CX 102-6 + L A.2.10
– CX 102-6 + L (X2) A.2.11
– CX 102-6 + L (X3) A.2.11
– CX 102-7 A.2.12
– CX 102-7 + L A.2.13
Input signals (SEM)
– CX 102-7 + L (X2) A.2.14
– Dryer blocking after washing B.15.10
– CX 102-7 + L (X3) A.2.14
– Dryer malfunction B.15.10
– CX 102-8 A.2.15
– External emergency stop B.15.8
– CX 102-8 + L A.2.16
– External emergency stop (safety input) B.15.11
– CX 102-8 + L (X2) A.2.17
– Final UV dryer without shutter in operation
– CX 102-8 + L (X3) A.2.17
B.15.10
– General notes A.2.23
– Interdeck dryer in operation B.15.9
– Legend A.2.24
– Malfunction: exhaust air B.15.9
– Notes on the peripheral units A.2.23
– UV dryer not ready to run B.15.9
– Variable dimensions A.2.25
Installation instructions
Floors B.2.3
– CombiStar B.7.5
Floor space required
– For the AirStar B.5.11
– For standard installation A.1.16
– For the CoatingStar B.10.6
Floor space requirements
– For the DryStar B.11.15
– Elevated installation A.1.17
– For the exhaust air cleaning cabinet B.9.4
Flow-related requirements B.14.6
– For the ScrollStar B.6.5
Foundation A.1.22, B.2.6
– For the WashStar B.8.3
– Dimensions A.1.28, B.2.12
Instructions
– Dynamic foundation loads A.1.25, B.2.9
– Second-level B.1.3
– Elevated installation A.1.29, B.2.13
– Third-level B.1.3
– Flatness tolerance limit A.1.25, B.2.9
Interdeck drying B.11.30
– Floor compression A.1.26, B.2.10
Interface adapter B.15.4
– Foundation settling A.1.25, B.2.9
IR dryer
– Material requirements A.1.24, B.2.8
– DryStar Coating B.11.7
– Rigidity A.1.26, B.2.10
– General information B.11.3
– Standard installation A.1.28, B.2.12
– Interconnection diagram variant A1 B.11.25
– Uncoupled foundation A.1.26, B.2.10
– Interconnection diagram variant A3 B.11.27
Foundation length
– Mains connection B.11.24
– Elevated installation A.1.29, B.2.13
– Overview of the standard mains connections
– In standard installation A.1.28, B.2.12
B.11.24
Foundation settling A.1.25, B.2.9
IR Dryer
– DryStar Combination B.11.11
G – DryStar Ink B.11.4
Gravity centers A.2.27
L
H Leveling blocks A.2.27
– Coating unit A.2.28, A.2.29
Heat emission A.1.6
– First printing unit A.2.27
Heidelberg Service
– Last printing unit A.2.28
– Printing Office planning B.2.17
– Middle printing unit A.2.27
HydroStar
– Preset Plus delivery A.2.28
– Preset Plus delivery without extension module
A.2.28
– Shipping information A.1.100
– Preset Plus delivery with three extension modules
– Technical specifications A.1.81
A.2.29
Ind.4 00.999.5895/
Index
– Preset Plus delivery with two extension modules – Explanation of the general notes B.1.3
A.2.29
– Preset Plus feeder A.2.27
P
Line terminals
– Cross section area at the main switch B.4.23 Packing sheets A.1.5
Lowered installation B.13.14 Partitions B.2.3
Peripheral equipment
M
Mains connection B.2.15 Peripheral units
– Cable entry into the central control cabinet – Dimensions A.1.10
B.4.12 – Shipping data A.1.99
– Cable laying B.4.11 – Weights A.1.10
– EMC requirements B.4.8 Permanent piping B.14.3
– Flickers B.4.14 – Bends in permanent piping B.14.5
– Fuses and protective measures B.4.7, B.4.14 – Construction B.14.3
– Harmonics B.4.14 – Materials B.14.3
– Layout B.4.7, B.4.14 – Pipeline cross sections B.14.5
– Load characteristics B.4.14 Pile heights A.1.6
– Mains impedance values B.4.10 – For printing presses elevated by 500 mm B.3.5
– Material for power cables and PE conductors Plate cylinder A.1.5
B.4.14 Plate punch
– Notes B.4.17 – Dimensions and weights A.1.14
– Of the IR dryer B.11.24 – Shipping data A.1.100
– Of the Prinect peripheral units B.12.3 Pneumatic compressor B.6.3
– Of the printing press B.4.16 Powder spray devices
– Overview B.4.18 – Allocation A.1.96
– Power cable requirements B.4.11 – Specifications A.1.87
– Recommendations and notes B.4.14 Power supply B.2.15
– Test B.4.12 Power supply system
– Variants A1 and A2 B.4.19 – Requirements B.4.7
– Variants B1 and B2 B.4.20 Preloading device
Main switch – Dimensions A.2.30
– Cross sections of the line terminals B.4.23 Press weights A.1.22, B.2.6
Maximum pile weight A.1.6 Prinect peripheral equipment
Maximum static surface pressure A.1.24, B.2.8 – Allocation A.1.94
Minimum distances B.13.15 – Dimensions and weights A.1.10
Minimum working space required – Shipping data A.1.99
– In elevated installation A.1.20 – Specifications A.1.79
– In standard installation A.1.19 Prinect Press Center
Motor mounting base – Floor space required A.1.16
– Material requirements B.3.8 – Minimum working space required A.1.19, A.1.20
– Weight calculation B.3.8 Printing materials A.1.5
Multiples Printing Office Planning B.2.17
– Physical B.16.4 Printing performance A.1.5
Printing plate A.1.5
Printing press
N
– Basic regulations for the mains connection
Nameplate B.4.7
– For the electrical equipment of the printing press – Configuration A.1.93
B.4.4 – Connection to the three-phase mains B.4.16
– Location on the ZSG B.4.5 – Dimensions A.1.7
Noise emission A.1.6 – Dimensions for elevated installation A.1.8
Nonstop Preset Plus feeder B.3.5 – Dimensions for standard installation A.1.7
– General information B.3.5 – Floor space required for standard installation
– Pile heights B.3.5 A.1.16
Notes
00.999.5895/ Ind.5
Index
– Floor space requirements for elevated installation – Of the printing press A.1.99
A.1.17 Slide-in dryers
– Minimum working space required in elevated – Allocation A.1.98
installation A.1.20 – Dimensions and weights A.1.13
– Minimum working space required in standard Socket system B.13.7
installation A.1.19 Space requirements
– Motor mounting base for elevated printing press – In the pressroom B.2.3
B.3.8 Specifications
– Shipping data A.1.99 – Peripheral equipment A.1.79
– Specifications A.1.5 – Printing press A.1.5
– Specifications of the electrical equipment B.4.4 Strip foundations
Print-related specifications A.1.5 – Elevated printing press B.3.6
Process air supply Suction air and blast air B.5.3
– Of the AirStar B.5.4 Supply lines B.2.3, B.2.15
– Water-cooled AirStar B.5.8 Supply systems B.2.15
– With the air-cooled AirStar B.5.7 Supply systems and supply lines
Process exhaust air volumes – Compressed-air supply and compressed-air
– DryStar Coating and CleanStar A.1.90 treatment B.2.16
– DryStar Combination and CleanStar A.1.90 – Suction air and blast air supply B.2.16
– DryStar Ink and CleanStar A.1.89
– Of the CleanStar A.1.89
U
– Of the DryStar A.1.89
Ultraviolet drying B.11.30
– Clarification of technical issues B.11.31
R
– Note B.11.30
Raised installation – Requirements B.11.31
– On an upper floor B.13.14 – Technical preinstallation B.11.30
– On a scaffolding system B.13.10 Units
Raised printing press – Conversion table B.16.3
– Possible heights B.3.3
Remote installation
V
– Permanent piping B.14.3
Room height B.2.3 Varnish supply unit B.10.3
S
SAM17 Interface output module 17 B.15.12 Ventilation
Scaffolding system B.13.10 – of the pressroom B.2.4
ScrollStar B.6.3 Versatile peripheral unit installation
– Allocation A.1.95 – Double-row installation B.13.6
– Dimensions and weights A.1.11 – Lowered installation B.13.10
– Flexible installation of peripheral units B.6.6 – Raised installation B.13.10
– Minimum distances at the place of installation
B.6.5
W
– Overall air throughput B.6.3
– Requirements on the place of installation B.6.3 Walls B.2.3
– shipping data A.1.100 WashStar
– Technical specifications A.1.81 – Allocation A.1.96
ScrollStar – Dimensions and weights A.1.12
– Installation instructions B.6.5 – Flexible peripherals installation B.8.5
– Standard installation B.6.5 – Installation instructions B.8.3
SEM3 Interface input module B.15.5 – Shipping data A.1.100
Series transformer – Specifications A.1.85
– Cross sections of the conductor terminals B.4.23 – Standard installation B.8.3
Shipping data Water hardness B.16.5
– Miscellaneous A.1.101 – Conversion of the units B.16.5
– Of the peripheral units A.1.99 – Harness ranges B.16.5
Ind.6 00.999.5895/
Index
Water supply B.2.15 – Of the machine components A.1.23, B.2.7

Water treatment B.2.15 – Peripheral units A.1.10
Weights
00.999.5895/ Ind.7
Index
Ind.8 00.999.5895/

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Speedmaster CX 102

1.1 Notes for the reader

Copyright, address of the manufacturer

Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1

B Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1

Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.1.1

Preparation of the location of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2.1

Elevated printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.3.1

Electrical installation of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4.1

Air supply cabinet AirStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.5.1

Pneumatic compressor ScrollStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6.1

Dampening solution supply CombiStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.7.1

Washing fluid disposal WashStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8.1

Exhaust air cleaning cabinet CleanStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.9.1

Varnish supply unit CoatingStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10.1

IR dryer DryStar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.11.1

Prinect peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.12.1

Flexible peripherals installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.13.1

Permanent piping and exhaust air piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.14.1

Interface adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.15.1

1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5

2 Dimensions of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.7

3 Dimensions and weights of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10

4 Floor space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16

5 Minimum working space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.19

6 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22

6.6 Material requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.24

7 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.28

8 Electrical connection specifications, general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.31

9 Electrical connection specifications, printing press with 4 printing units . . . . . . . . . . . . . . . . A.1.33

10 Electrical connection specifications, printing press with 5 printing units . . . . . . . . . . . . . . . . A.1.42

11 Electrical connection specifications, printing press with 6 printing units . . . . . . . . . . . . . . . . A.1.51

12 Electrical connection specifications, printing press with 7 printing units . . . . . . . . . . . . . . . . A.1.60

13 Electrical connection specifications, printing press with 8 printing units . . . . . . . . . . . . . . . . A.1.69

14 Electrical connection specifications of the DryStar IR dryers . . . . . . . . . . . . . . . . . . . . . . . . . A.1.78

15 Specifications of the peripheral equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.79

16 Printing press configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.93

17 Allocation of the peripheral equipment to the printing press . . . . . . . . . . . . . . . . . . . . . . . . . A.1.94

18 Shipping data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99

18.2 Shipping data of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.99

Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.1

1 Floor plans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.3

2 Floor plan legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.23

3 Positions of the leveling blocks and gravity centers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.27

4 Dimensions of the preloading device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.2.30

1 Print-related specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.5

2 Dimensions of the printing press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.7

3 Dimensions and weights of the peripheral units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.10

4 Floor space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.16

5 Minimum working space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.19

6 Machine foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.22

6.7 Foundation settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.25

7 Foundation dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.28

8 Electrical connection specifications, general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.31

9 Electrical connection specifications, printing press with 4 printing units . . . . . . . . . . . . . . . . A.1.33

10 Electrical connection specifications, printing press with 5 printing units . . . . . . . . . . . . . . . . A.1.42

11 Electrical connection specifications, printing press with 6 printing units . . . . . . . . . . . . . . . . A.1.51

12 Electrical connection specifications, printing press with 7 printing units . . . . . . . . . . . . . . . . A.1.60

13 Electrical connection specifications, printing press with 8 printing units . . . . . . . . . . . . . . . . A.1.69