852 GB

Operating Manual
Combined Refrigerated Circulating

Water Level
CRCWL 852- 300- 160 HS/ AD ..WAD ..WWAD
CRCWL 852- 600- 160 HS/ WAD ..WWAD
Geräte - Typ
Model type
Serien- Serial-
Nr.:
Elektro - Schaltplan
Wiring diagram
Nr.:
BALDWIN - Ident.-Nr. DOC.0.090151.02 GB

01.98/CRCWL852/GB Seite / Page 1
Seite / Page 2 01.98/CRCWL852/GB
BALDWIN services Manufacturer
BALDWIN EUROPA BALDWIN-GRAFOTEC GMBH
Baldwin (UK) Ltd. DERCHINGER STR.137

Unit 13, Apex Business Centre D-86165 AUGSBURG
Boscombe Road, Dunstable
Bedfordshire LU5 4SB POSTFACH 41 01 25 (POB)
Great Britain D-86068 AUGSBURG
Tel. +44-1582-477 449
Fax +44-1582-478 510 TELEFON: (08 21 ) 79 42-0
Baldwin France Sarl TELEFAX: (08 21) 7942-222

30, avenue de Bergoďde
F-60550 Verneuil en Halatte
Frankreich
Tel. +33-3-44 25 06 81
Fax +33-3-44 25 16 40
BALDWIN AMERIKA
Baldwin Graphic Products

12 Commerce Drive
Shelton, CT 06484-0941
USA
Tel. +1 203-925-1100
Fax +1 203-929-7856
BALDWIN ASIEN
Baldwin Graphic Equip. Pty. Ltd.

P.O.Box 1234
Rozelle NSW 2039
6/323A Darling Street
Balmain NSW 2041
Australien
Tel. 612-9555-9975
Fax 612-9555-8246
Baldwin Japan Ltd.

4- 34 Toyo 2- chome
Kohtoh- ku
J- Tokyo 135 Japan
Tel. +81 3- 5606- 2771
Fax +81 3- 5606- 2779
Baldwin Printing Controls Ltd.

Unit A, 26th Floor, Seaview Plaza
283 Shaukeiwan Road
Hong Kong
Tel. 852-811-2987
Fax 852-811-0641 Ó All rights reserved. No part of this operating manual
may be reproduced or duplicated in any form (printing,
photocopying or any other process) without the
permission in writing from BALDWIN GmbH.

Combined Refrigerated Circulating Water Levels by
BALDWIN are sophisticated designs based on our
years of experience in the development and manu-
facture of ancillary equipment for the graphic arts, that
will always be ready for service and reach a long life,
provided they are operated properly and are given
careful maintenance in due time.

Contents
Page Page
1. Introduction ................................................ 7 9.3 Density measuring with commercial

hydrometers ............................................... 60
2. Basic notes on safety ................................. 8 9.4 Additive and temperature setting at
2.1 Warning notes and symbols ......................... 8 Alcohol Control Unit .................................... 61
2.2 Usage to the intended purpose .................... 8 9.5 Setting the thermostat ................................ 62
2.3 Organisational measures .............................. 8 9.6 Checking the sight glass ............................. 62
2.4 Selection and qualification of personnel........ 8 9.7 Checking the water pressure in the IRHC... 63
2.5 Operating modes .......................................... 9
2.6 Special dangers ............................................ 9
2.7 Operator/customer ....................................... 9 10. Maintenance ............................................. 65
10.1 General ...................................................... 65
10.2 Maintenance intervals ................................. 65
3. Description ............................................... 11 10.3 Replacing the fountain solution filters ......... 68
3.1 Usage to the intended purpose ................... 11 10.4 Cleaning the fountain solution storage
3.2 Description of the unit ................................. 11 tank ............................................................ 68
10.5 Cleaning the entire fountain solution
system ........................................................ 68
4. Technical data ........................................... 15 10.6 Cleaning the Alcohol Control Unit ............... 69
10.7 Cleaning the fresh water filter ..................... 69
10.8 Checking the maintenance unit .................. 70
5. Mode of operation .................................... 27 10.9 Cleaning the filter in alcohol and/or
5.1 Fountain solution premixing ........................ 32 additive storage tanks ................................. 70
5.2 Alcohol Control Unit .................................... 34 10.10 Cleaning the ribs of the condenser ............. 70
5.3 Return flow filter unit ................................... 36
11. Repairs ...................................................... 72

6. Installation ................................................ 38 11.1 General ...................................................... 72
6.1 Unpacking .................................................. 38 11.2 Replacing the supply line pump or
6.2 Location ...................................................... 39 heat exchanger pump ................................. 72
6.3 Hose connections ....................................... 40 11.3 Replacing the circulating pump IRHC ......... 73
6.4 Connection to cooling centres .................... 42 11.4 Replacing the thermostats .......................... 73
6.5 Alcohol and additive supply ........................ 42
6.6 Filling with alcohol and additives ................. 43
6.7 Refrigerant ................................................. 43 12. Trouble shooting ...................................... 74
6.8 Electrical connection .................................. 43 12.1 Error messages at the display .................... 75
12.2 Failures not indicated at the display ............ 81
7. Start-up and Shut-down ........................... 44

7.1 Controls ...................................................... 44 13. Dismounting ............................................. 84
7.2 Initial operation of the 13.1 Electric connection ..................................... 84
fountain solution cooling RCWL .................. 45 13.2 Hose connections ....................................... 84
7.3 Initial operation of the 13.3 Fountain solution, alcohol (alcohol substi-
ink roll heating/cooling IRHC ...................... 48 tutes) and additives .................................... 84
7.4 Setting the bypass valve (wet and/or 13.4 Antifreezer and anticorrosive ...................... 84
dry offset) ................................................... 51 13.5 Refrigerant ................................................. 84
7.5 Shut-down RCWL and/or IRHC .................. 52 13.6 Scrapping ................................................... 84
8. Operation of display ................................. 53 14. Parts list .................................................... 85

8.1 Description of function ................................ 53 14.1 General ...................................................... 85
8.2 Setup .......................................................... 55 14.2 Notes for using ........................................... 85
8.3 Service mode ............................................. 58 14.3 Illustrated parts list ..................................... 85
9. Adjusting and checking ........................... 59

9.1 General ...................................................... 59
9.2 Basic settings of the maintenance unit ...... 59

Foreword
1.0 Foreword to the operating instructions

Attention:
The markings for transport and stocking
These operating instructions are designed to familiarize indicated on the packaging have to be observed
the user with the machine/plant and its designated use. under all circumstances.
This manual contains important notes which are to be

observed during the installation, operation and
maintenance of the device, in order to guarantee a
safety, proper and economical use of the system. Note:
Please check the type of manual against the
The obeyance of the instructions helps to avoid dangers. label on your BALDWIN device.
The operating instructions must always be available This manual is only valid for:
wherever the machine/plant is in use.
(see title-page)
These operating instructions must be read and applied
by any person in charge of carrying out work with and
on the machine/plant, such as
- operation including setting up, troubleshooting in

the course of work, evacuation of production waste,
care and disposal of fuels and consumables.
- Installation, set-up, wiring
- maintenance (servicing, inspection, repair)
- transport
In addition to the operating instructions and to the

mandatory rules and regulations for accident prevention
and environmental protection in the country and place
of use of the machine/plant, the generally recognized
technical rules for safe and proper working must also be
observed.

Fundamental safety instructions
2.0 Fundamental safety instructions 2.3 Organizational measures
2.1 Warning notes and symbols 2.3.1 This manual has to be accomplished by the user/
The headings „Warning, Attention and Note“ marked in customer with instructions (national regulations of
this manual have the following meaning: security, regulations for dangerous goods, environ-
mental protection and possible internal working or
security rules) including legal responsibility and
compulsory registration in order to take internal company
peculiarities, regarding working organization or
personnel involved in these working processes into
consideration.
Warning:
This heading is used whenever the ignorance or 2.3.2 Check - at least from time to time - whether the
inaccurate obeying of factory rules, working personnel is carrying out the work in compliance with
rules, laid down work routines, etc.can lead to the operating instructions and paying attention to risks
the death, injuring or an accident of a person. and safety factors.
2.3.3 For reasons of security, long hair must be tied

back or otherwise secured, garments must be close-
fitting and no jewellery - such as rings - may be worn.
Attention: Injury may result from being caught up in the machinery
This heading is used whenever the ignorance or or from rings catching on moving parts.
inaccurate obeying of factory rules, working
rules, laid down work routines, etc. can lead to 2.3.4 Use protective equipment wherever required by
damages on the system. the circumstances or by law.
2.3.5 Observe all safety instructions and warnings

attached to the machine/plant.
Note: 2.3.6 In the event of safety-relevant modifications or

This heading is used when an exceptional feature changes in the behaviour of the machine/plant during
should be taken noticeof. operation, stop the machine/plant immediately and
report the malfunction to the competent authority/
person.
2.3.7 Never make any modifications, additions or

conversions which might affect safety without the
supplier’s approval. This also applies to the installation
2.2 Basic operation and designated use of the and adjustment of safety devices and valves as well as
machine/plant to welding work on load-bearing elements.
2.3.8 Never modify the software of programmable
2.2.1 The machine/plant has been built in accordance control systems.
with state-of-the-art standards and the recognized safety
rules. Nevertheless, its use may constitute a risk to life
and limb of the user or of third parties, or cause damage
to the machine and to other material property. 2.4 Selection and qualification ofpersonnel -
Basic responsibilities
2.2.2 The machine/plant must only be used in technically
perfect condition in accordance with its designated use 2.4.1 Employ only trained or instructed staff and set out
and the instructions set out in the operating manual, clearly the individual responsibilities of the personnel
and only by safety-conscious persons who are fully for operation, set-up, maintenance and repair.
aware of the risks involved in operating the machine/
plant. Any functional disorders, especially those affecting 2.4.2 Work on the electrical system and equipment of
the safety of the machine/plant, should therefore be the machine/plant must be carried out only by a skilled
rectified immediately. electrician or by instructed persons under the supervision
and guidance of a skilled electrician and in accordance
with electrical engineering rules and regulations.

Fundamental safety instructions
2.5 Safety instructions governingspecific opera- 2.6.2 Hydraulic and pneumatic equipment
tional phases
2.6.2.1 Check all lines, hoses and screwed connections
2.5.1 Take the necessary precautions to ensure that regularly for leaks and obvious damage. Repair damage
the machine is used only when in a safe and reliable immediately. Splashed medium may cause injury and
state. fire.
Operate the machine only if all protective and safety-
oriented devices, such as removable safety devices, 2.6.2.2 Depressurize all system sections and pressure
emergency shut-off equipment, sound-proofing pipes (hydraulic system, compressed-air system) to be
elements and exhausters, are in place and fully removed in accordance with the specific instructions for
functional. the unit concerned before carrying out any repair work.
2.5.2 Check the machine/plant at least once per working 2.6.2.3 Hydraulic and compressed-air lines must be
shift for obvious damage and defects. Report any laid and fitted properly. Ensure that no connections are
changes (incl. changes in the machine’s working interchanged. The fittings, lengths and quality of the
behaviour) to the competent organization/person hoses must comply with the technical requirements.
immediately. If necessary, stop the machine immediately
and lock it. 2.6.3 Alcohol, Water additives and other chemical
substances
2.5.3 In the event of malfunctions, stop the machine/
plant immediately and lock it. Have any defects rectified 2.6.3.1 Whenever using one of the a.m. substances the
immediately. security regulations valid for the product must be strictly
observed! (Safety data sheet of the manufacturer and
2.5.4 If the machine/plant is completely shut down for generally valid regulations)
maintenance and repair work, it must be secured
against inadvertent starting by: 2.6.3.2 Only approved containers may be used to store
about one day´s supply
- locking the principal control elements and removing
the ignition key and/or
- attaching a warning sign to the main switch.
2.7 User/Customer
2.5.5 Ensure that all consumables and replaced parts
are disposed of safely and with minimum environmen- The safety guard for mobile parts may not be removed
tal impact. while the system is running.
Work at the cooling unit may only be drained by a

specialised firm for refrigeration and air-condition
2.6 Warning of special dangers engineering.
2.6.1 Electric energy Leaks (e.g. tube connections) of dangerous liquids

(e.g. explosive, toxic, hot) have to be drawn off in such
1.6.1.1 Work on the electrical system or equipment a way that neither persons nor the environment will be
may only be carried out by a skilled electrician himself endangered.
or by specially instructed personnel under the control The legal requirements must be fulfilled.
and supervision of such electrician and in accordance
with the applicable electrical engineering rules.
2.6.1.2 If provided for in the regulations, the power

supply to parts of machines and plants, on which
inspection, maintenance and repair work is to be carried Warning:
out must be cut off. Before starting any work, check the Ignoring the safety regulations can have a
de-energized parts for presence of power and ground harmful effect on persons or cause damages to
or short-circuit them in addition to insulating adjacent the system or environment. Ignoring the safety
live parts and elements. regulations may cause a loss of claim for
damages.
2.6.1.3 The electrical equipment of machines/plants is
to be inspected and checked at regular intervals. Defects
such as loose connections or scorched cables must be
rectified immediately.

Description
3. Description alcohol substitutes are metered proportional to volume,

alcohol (isopropanol) via density measuring as required.
3.1 Usage to the intended purpose The evaporated alcohol portion is automatically added
by this system and the adjusted alcohol percentage is
maintained.
The ink roll heating/cooling is controlled by a special

Warning: control unit. The inking unit is cooled by cooled-down
The unit is to be used only for cooling, premixing fountain solution via a water-water-heat exchanger.
and cleaning the fountain solution required for Heating the inking unit is by an integrated heating
offset printing as well as ink roll heating/cooling. element.
- Fountain solution temperature

- Alcohol and/or alcohol substitute
- Additives
Warning: - Consumption of alcohol / additives / water
- Unauthorized modifications of and changes - Alarm functions
to the unit, - Inking unit temperature
- use for any other purpose, and - Conductivity value (option) 0 - 2000 µS/cm
- the use of any other than the above additives - pH-value (option) pH 2 - pH 9
are forbidden for safety reasons.

In emergency mode, the fountain solution temperature
All safety devices such as personnel protecting is controlled by a thermostat should the control unit fail.
switches and emergency stop buttons must be In order to maintain the fountain solution circulation
available. during emergency mode, the outputs of the supply line
and heat exchanger pump are short-circuited.
A conductivity and pH measuring device may be fitted

as an option. The value concerned is determined by the
conductivity and/or pH measuring device by means of
3.2 Description of the unit electrodes and is displayed at the digital control unit.
Depending on the configuration concerned, the fountain

solution is pumped to one or several fountain pan(s) of
the press by the installed submerged pump.
Cooling of the fountain solution is by an integrated

refrigerating unit with heat exchanger and air-cooled
and/or water-cooled condenser or without refrigerating
unit by a central refrigeration and a water-water heat
exchanger.
Control of the refrigerating unit is by the electronics of

the control unit to obtain a constant fountain solution
temperature during printing. The amount of heat dis-
sipated is given to the room air (air-cooled design) or via
a cooling tower (water-cooled design).
Cleaning of the fountain solution is by integrated filters

of the Combined Refrigerated Circulating Water Level.
The CRCWL is provided with an integrated premixing

unit - BALDWIN Automix (AMX) - for adding additive
and alcohol and/or alcohol substitutes. Additives and

Description
The main components of the BALDWIN CRCWL are:

e) Electric supply
a) Cooling unit The electrical components and safety features as
with compressor (unit type "AD /WAD") well as additional electrical connections are mounted
The compressors are driven by internally protected on a mounting plate in the switchbox.
motors.
- Condensator with fans f) Digital control unit

(with air-cooled design "AD") The digital control unit comprises all possibilities for
and operation for fountain solution and ink roll heating/
- condenser with condensation pressure cooling (IRHC) as well as failure indications and
regulator error messages.
(with water-cooled design "WAD") Connection to the central control console upon prior
The heat exchangers and condensator assemblies consultation of BALDWIN.
are made of corrosion-resistant material.
with central refrigeration (type "WWAD") g) Temperature control

Cooling of the fountain solution is only by central The temperatures are registered for the fountain
refrigeration that is made available by a cooling solution circuit and the ink distributor circuit by one
centre. The heat transfer is in a water-water heat temperature sensor each (Pt 100 = ohmic principle
exchanger. of measurement) and are evaluated in the control
unit.
Emergency operation via thermostat control is
b) Fountain solution cooling tank with filter unit possible.
and pump cover
The fountain solution cooling tank serves as storage
tank for premixed fountain solution. The fountain
solution in the cooling tank is also used as
temperature buffer in wet and dry offset as well as
for cooling in the ink roll heating/cooling system.
The filter unit cleans the fountain solution recirculated

from the water pans.
An integrated alarm sensor signals any conta-

mination of the fountain solution to the control unit
(display and electronic).
c) Alcohol control
The actual value of the alcohol percentage is
constantly measured by the alcohol control to the
density measuring principle (hydrometer) and is
reported to the control unit. When the value drops
below the setpoint, alcohol is added by the automatic
mixing unit.
d) Fountain solution premixing

The fountain solution is mixed proportional to volume
via piston metering pumps. Input is at the digital
control unit.

Description
Fig. 3-1
Key to Fig. 3-1
1 Digital control unit 10 Bypass valve

2 Fountain solution storage tank 11 Heating
3 Heat exchanger pump (HEP) 12 Expansion vessel with safety valve and
4 Temperature sensor (fountain solution) automatic ventilating valve
5 Evaporator 13 IRHC-pump
6 Cooling unit 14 Temperature sensor (IRHC)
7 Fountain solution supply pump 15 Flow monitoring switch
8 Water pan 16 Printing unit with inking unit
9 Water-water-plate heat exchanger 17 Mixing valve

Technical data
4. Technical data
Water-cooled design Air-cooled design
Key to model designation
Example: CRCWL 85 2 - 600 - 160 HS / WW A D
Combined Refrigerated
Circulating Water Level (CRCWL)
Product group
Number of circuits
Basic performance number of

cooling unit or heat exchanger
Tank contents in litres (in this case: 160 l)
Upright cabinet
Omitted = heat dissipation via refrigerant and air-cooled condenser

W = heat dissipation via refrigerant and water-cooled condenser
WW= heat dissipation only via cooling water (cooling centres)
Integrated mixing unit

Automix (AMX)
Digital control unit

Technical data
Technical data (applies to all units)
General
Temperature setting range

for fountain solution .......................................................... 8...19°C
for ink roll heating/cooling ................................................. 14...40°C
Dimensions (length x width x height) ................................. 1450/750/2000 mm
Space requirements (length x width x height) .................... approx. 2450/1900/2500 mm
Noise emission
(A-weighted equivalent continuous mean
sound pressure level) ....................................................... £ 70 dB(A)
Degree of protection for electrical connection .................... IP 54
EMC .................................................................................. as per EN 55011 B and EN 50082-2
Processor .......................................................................... 80-C-188
Connection to central control console ................................ upon consultation of BALDWIN
Remote indication with operator panel ............................... option
Connections, supplies, volumes
Fresh water connection (500 kPa; 5 bar max.) .................. dia. 12 mm
Fountain solution supply to press ...................................... dia. 19/25/32 mm
Fountain solution return from press ................................... dia. 19/25/32 mm
IRHC-supply to press ........................................................ dia. 25/32/40 mm
IRHC-return from press ..................................................... dia. 25/32/40 mm
Alcohol connection ............................................................ dia. 3/8''
Additive connection ........................................................... dia. 12 mm
Compressed air connection (tube type: Mecanyl) .............. dia. 8/12 mm
Compressed air consumption ............................................ 12.5 Nl/min
Recommended additives ................................................... commercial

(pH 4.8...5.2 at a dosage of 0...6 %)
Alcohol ............................................................................... technically pure isopropyl 99 %
Alcohol substitute .............................................................. commercial products
Fountain solution storage tank ........................................... 160 l

Technical data
Fountain solution metering
Fountain solution additives ................................................ 1 additiv (option: 2 additives)

Metering method........................................................... volumetric via metering pumps
Setting range ................................................................ 0 - 6 % ±0.5 % (in steps of 0.5 %)
Alcohol (isopropanol)
Measuring method ........................................................ aerometric (density measuring)
Alcohol substitute
Measuring method ........................................................ --
Max. fountain solution mixing capacity

with addition of 10 % of Al ............................................ 700 l/h
Max. mixing period with initial filling (100 l)

with addition of 10 % of Al ............................................ 6 - 10 min
Conductivity measurement (option)

Measuring method ........................................................ electrode
Measuring range .......................................................... 0 - 2000 µS/cm ±1 µS/cm
pH measurement (option)
Measuring method ........................................................ electrode
Measuring range .......................................................... pH 2 - pH 9 ±0.1
Ambient conditions
Temperature,
Operation .......................................................................... +5...+40°C
Storage/transport .............................................................. -20...+60°C
Relative air humidity, no moisture condensation ................ 30...95% (max. permissible)

Operation/storage/transport
Perm. site altitude (above mean sea level)

for air-cooled design ......................................................... up to 1500 m 1)
for water-cooled design .................................................... unlimited
1) over 1500 m perm. site altitude the refrigerating capacity decrease

Technical data
Model ........................................................... 852-300-160-HS/AD ..................... 852-300-160-HS/WAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50

(voltage adjustment 440±10% /3/60 ............................. 440±10% /3/60
see wiring diagram)
Total current input Imax (A) ............................. 24.5 .............................................. 24.5
Total power input (kW) ................................. 14.75 ............................................ 14.75
Refrigerating capacity in dry offset 2) (kW) .... 12.0 (50 Hz) / 13.0 (60 Hz) .......... 12.0 (50 Hz) / 13.0 (60 Hz)
(at 22°C inking unit cooling water
temperature)
Refrigerating capacity in wet offset 2) (kW) ... 8.0 (50 Hz) / 9.0 (60 Hz) .............. 8.0 (50 Hz) / 9.0 (60 Hz)
(at 10°C fountain solution temperature
and 22°C ink uniting cooling water
temperature)
Liquefaction temperature2) ............................ approx. 55°C ................................. approx. 55°C
Kind / quantity of refrigerant .......................... R 134a / see type plate ................. R 134a / see type plate
Total heat dissipation max. (kW) .................. 18.6 .............................................. 18.6
max. air quantity given off (m3/h) ................. * .................................................... --
max. required cooling

water flow rate at Dt 6°C (m3/h) .................... -- ................................................... 3.0 (60 Hz)
Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz) .............. 5.0 (50 Hz) / 6.0 (60 Hz)
Supply pump KTE 141

(A/ kW) ........................................................ 1.0/ 0.38 ........................................ 1.0/ 0.38
Heat exchanger pump KTE 141

(A/ kW) ........................................................ 1.0/ 0.38 ........................................ 1.0/ 0.38
IRHC 4) pump CHI 4-20

(A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8
Weight (kg) ................................................... approx. 620 ................................... approx. 600
*) not known when this documentation went to print

2) at approx. 40°C ambient- and/or 32°C cooling water temperatur
4) IRHC = Ink Roll Heating/Cooling

Technical data
Model ........................................................... 852-300-160-HS/WWAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50

(voltage adjustment 440±10% /3/60
see wiring diagram)
Total current input Imax (A) ............................. *
Total power input (kW) ................................. *
Refrigerating capacity in dry offset 2) (kW) .... *

temperature)
Refrigerating capacity in wet offset 2) (kW) ... *

and 22°C inking unit cooling water
temperature)
Total heat dissipation max. (kW) .................. *

water flow rate at Dt 6°C (m3/h) .................... *
Heating capacity (kW) .................................. 5.0 (50 Hz) / 6.0 (60 Hz)
Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85
Heat exchanger pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.4/ 0.8
Weight (kg) ................................................... *


Technical data
Model ........................................................... 852-400-160-HS/AD ..................... 852-400-160-HS/WAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50

see wiring diagram)
Total current input Imax (A) ............................. 30 (60 Hz) ..................................... 28 (60 Hz)
Total power input (kW) ................................. 17 (60 Hz) ..................................... 15 (60 Hz)
Refrigerating capacity in dry offset 2) (kW) .... 18 (50 Hz) / 21.5 (60 Hz) ............. 18 (50 Hz) / 21.5 (60 Hz)
temperature)
Refrigerating capacity in wet offset 2) (kW) ... 12 (50 Hz) / 14.4 (60 Hz) ............. 12 (50 Hz) / 14.4 (60 Hz)
temperature)
Total heat dissipation max. (kW) .................. 37 (60 Hz) ..................................... 37 (60 Hz)
max. air quantity given off (m3/h) ................. 6000 (60 Hz) ................................. --

Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8


Technical data
Model ........................................................... 852-400-160-HS/WWAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50

see wiring diagram)

temperature)

temperature)

Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.4/ 0.8
Weight (kg) ................................................... *


Technical data
Model ........................................................... 852-500-160-HS/AD ..................... 852-500-160-HS/WAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50

see wiring diagram)
Total current input Imax (A) ............................. 31 (60 Hz) ..................................... 31 (60 Hz)
Total power input (kW) ................................. 16.5 (60 Hz) .................................. 16.5 (60 Hz)
Refrigerating capacity in dry offset 2) (kW) .... 14.5 (50 Hz) / 17.4 (60 Hz) .......... 14.5 (50 Hz) / 17.4 (60 Hz)
temperature)
Refrigerating capacity in wet offset 2) (kW) ... 12 (50 Hz) / 14.4 (60 Hz) ............. 12 (50 Hz) / 14.4 (60 Hz)
temperature)
Total heat dissipation max. (kW) .................. 24.3 (60 Hz) .................................. 24.3 (60 Hz)
max. air quantity given off (m3/h) ................. 6000 (60 Hz) ................................. --

Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8


Technical data
Model ........................................................... 852-400-160-HS/WWAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50

see wiring diagram)

temperature)

temperature)

Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.4/ 0.8
Weight (kg) ................................................... *


Technical data
Model ........................................................... 852-600-160-HS/WAD .................. 852-600-160-HS/WWAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50

see wiring diagram)
Total current input Imax (A) ............................. 30 (60 Hz) ..................................... *
Total power input (kW) ................................. 18 (60 Hz) ..................................... *
Refrigerating capacity in dry offset 2) (kW) .... 27 (50 Hz) / 33 (60 Hz) ................ *
temperature)
Refrigerating capacity in wet offset 2) (kW) ... 14.5 (50 Hz) / 16 (60 Hz) ............. *
temperature)
Liquefaction temperature2) ............................ approx. 55°C ................................. --
Kind / quantity of refrigerant .......................... R 134a / see type plate ................. --
Total heat dissipation max. (kW) .................. 45 (60 Hz) ..................................... *

water flow rate at Dt 6°C (m3/h) .................... 6.8 (60 Hz) .................................... *
Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.4/ 0.8 ......................................... 2.4/ 0.8


Technical data
Model ........................................................... 852-1000-160-HS/WAD ................ 852-1000-160-HS/WWAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50

see wiring diagram)
Total current input Imax (A) ............................. 34 (60 Hz) ..................................... *
temperature)
Refrigerating capacity in wet offset 2) (kW) ... 20 (50 Hz) / 23 (60 Hz) ................ *
temperature)

water flow rate at Dt 6°C (m3/h) .................... 8.1 (60 Hz) .................................... *
Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85
IRHC 4) pump CH 12-20

(A/ kW) ........................................................ 2.8/ 1.6 ........................................ 2.8/ 1.6

4) IRHC = Ink Roll Heating/Coolingv

Technical data
Model ........................................................... 852-1200-160-HS/WAD ................ 852-1200-160-HS/WWAD
Voltage (V/ph/Hz) ......................................... 400±10% /3/50 ............................. 400±10% /3/50

see wiring diagram)
Total current input Imax (A) ............................. 45.2 (60 Hz) .................................. *
temperature)
Refrigerating capacity in wet offset 2) (kW) ... 45 (50 Hz) / 50 (60 Hz) ................ *
temperature)

water flow rate at Dt 6°C (m3/h) .................... 11.7 (60 Hz) .................................. *
Supply pump KTB 200

(A/ kW) ........................................................ 2.0/ 0.85 ........................................ 2.0/ 0.85
Heat exchanger pump KTE 142

(A/ kW) ........................................................ 4,1/ 1,7 ......................................... 4,1/ 1,7
IRHC 4) pump CH 12-20

(A/ kW) ........................................................ 2.8/ 1.6 ........................................ 2.8/ 1.6


Mode of operation
5. Mode of operation (Fig. 5-1 /5-2 / pressure (loss of refrigerant), the low-pressure manostat
(4.11), in the case of an excess system pressure, the
5-3) high-pressure manostat (4.13) will automatically cut
out the compressor (4.2).
Fountain solution premixing
Fresh water flows via supply line (1.1) and the filter (1.2) Cooling (type “WWAD”)
into the fountain solution storage tank (2.1) of the Cooling of the fountain solution is only by central
CRCWL. Alcohol (1.10) and fountain solution additives refrigeration that is made available by a cooling centre
(1.5) are added as required by the pumps (1.8/1.12). (4.18).The heat transfer is in a water-water heat
The fountain solution premixing unit, that works in exchanger (4.19). The fountain solution temperature
cycles and is controlled electronically, is cut in by the entered is controlled by a pneumatically operated 3/2
solenoid float switch (2.4) and the alcohol control (3.1). way valve (4.20). The fountain solution either flows
The fountain solution level, the fountain solution additi- through the water-water heat exchanger or bypasses
ves and alcohol percentage in the fountain solution the heat exchanger by a bypass line.
storage tank (2.1) are maintained.
Emergency mode
The alcohol control (3.1), that is flushed via connection Should the control unit fail, fountain solution cooling and
(3.2), measures the actual alcohol percentage in the circulation are maintained by emergency mode.
fountain solution. When this value drops below the Emergency mode is called in by switch S4 (see wiring
setpoint entered at the display (6.4) (caused by diagram and/or Fig. 7-1/2), and is indicated by the fault
consumption and evaporation), alcohol is added to the signal lamp (6.5).
fountain solution by the metering pump (1.12) in addition Control of the fountain solution temperature is taken
to the normal filling cycle in percent by volume. over by the thermostat (4.16). Measurement is by the
capillary measuring line and temperature sensor. The
Fountain solution circulation thermostat also supplies an electric signal for cutting
The fountain solution is supplied to the fountain pans of the compressor (4.2) in and out.
the press (2.7) by the supply line pump (2.2) via the The supply line pump and the heat exchanger pump are
supply line valve (2.3). When the fountain solution cut in in emergency mode to maintain the circulation of
returns to the CRCWL, it is cleaned by a filter (2.11). the fountain solution.
The filter condition in the return flow is monitored by a The Ink Roll Heating/Cooling Unit is off during this
level sensor (2.12). Contamination and/or required function.
replacement of filter will be indicated by an alarm signal.
A return flow filter station (2.9) may additonally be Ink Roll Heating/Cooling System
integrated in the fountain solution return flow line. The Ink Roll Heating/Cooling System is a closed-loop
system and is completely isolated from the fountain
Cooling (type "AD/WAD") solution circuit. The "setpoint" of the inking unit
Cooling of the fountain solution is by the heat exchanger temperature is entered at the control unit (display). A
(4.1). The pump (2.13) in the fountain solution temperature sensor (5.7) transmits the temperature
refrigerating circuit recirculates the fountain solution data to the electronic unit. Based on this information, a
through the heat exchanger to the fountain solution mixing valve (5.18) is controlled that directs the cooling
storage tank (2.1). water via the water-water heat exchanger (5.1) or via a
heating element (5.3). The IRHC pump (5.8) supplies
Entering the "setpoint" for the fountain solution the cooling water to the inking units of the press (5.13)
temperature is at the control unit (display) (6.4) of the and back. The air in the system escapes automatically
CRCWL, from where it is transmitted to the electronic via the air relief valve (5.6). The expansion vessel (5.4)
unit. with the safety valve (5.5) maintains the water pressure
in the system.
The temperature control proper is by the electronic unit
of the operator panel (6.3). The heat exchanger circuit Power supply
and the refrigeration circuit are controlled according to Power supply is by the feeder (6.1), the master switch
the value entered and the data by the temperature (6.2), and the control box (6.3).
sensor (4.16).
The manostats measure the pressure in the high

pressure and the low pressure section. These control
signals are supplied by the suction check valve (4.12)
and/or the pressure check valve (4.14) via capillary
measuring lines. In the case of a drop in the system

Mode of operation
1.9
1.7 1.8 1.7 1.6
2.7 1.5
2.8
2.9 2.6
F 60 P 1.7 1.8 1.7 1.6
1.5
M
1.1
1.4 1.3 1.2
1.6
2.8
1.11 1.7 1.12 1.7 1.11
1.10
3.2 3.3 3.1 3.4 1.13
2.10 2.4 2.5 2.3 1.14
2.11 2.12
M AL M 5.14 5.13 5.12
2.15 2.1 2.2 2.16 2.13

T 5.15 5.11
4.16
5.16 5.10
1 6.3
0
2.14 5.17
0
5.9
6.2 T 5.18
M
4.1
6.4 5.6
6.5 5.5
4.8
4.9 T M
6.1
4.10 4.7
5.1 5.2 5.3 5.19 5.4 5.7 5.8
4.6
LP HP
4.12 4.11 4.2 4.13 4.14 4.3 4.4 4.5
Fig. 5-1 Diagram CRCWL 852-.. AD with air-cooled condenser

Mode of operation
1.9
1.7 1.8 1.7 1.6
2.7 1.5
2.8
2.9 2.6
F 60 P 1.7 1.8 1.7 1.6
1.5
M
1.1
1.4 1.3 1.2
1.6
2.8
1.11 1.7 1.12 1.7 1.11
1.10
3.2 3.3 3.1 3.4 1.13
2.10 2.4 2.5 2.3 1.14
2.11 2.12
M AL M 5.14 5.13 5.12
2.15 2.1 2.2 2.16 2.13

T 5.15 5.11
4.16
5.16 5.10
1 6.3
0
2.14 5.17
0
5.9
6.2 T 5.18
M
4.1
6.4 5.6
6.5 5.5
4.8
4.9 T M
6.1
4.10 4.7
5.1 5.2 5.3 5.19 5.4 5.7 5.8
4.3 4.5 4.6
LP HP
T 4.17 4.18
4.12 4.11 4.2 4.14 4.13 4.15
Fig. 5-2 Diagram CRCWL 852-.. WAD with water-cooled condenser

Mode of operation
1.9
1.7 1.8 1.7 1.6
2.7 1.5
2.8
2.9 2.6
F 60 P 1.7 1.8 1.7 1.6
1.5
M
1.1
1.4 1.3 1.2
1.6
2.8
1.11 1.7 1.12 1.7 1.11
1.10
3.2 3.3 3.1 3.4 1.13
2.10 2.4 2.5 2.3 1.14
2.11 2.12
M AL M 5.14 5.13 5.12
2.15 2.1 2.2 2.16 2.13

T 5.15 5.11
4.16
5.16 5.10
1 6.3
0
2.14 5.17
0
5.9
6.2 4.20 T 5.18
M
6.4 5.6
6.5 5.5
4.19
T M
6.1
5.1 5.2 5.3 5.19 5.4 5.7 5.8
T 4.17 4.18
Fig. 5-3 Diagram CRCWL 852-.. WWAD with water-water-plate heat exchanger and central refrigeration

Mode of operation
Key to Figs. 5-1 /5-2 /5-3
1. Fountain solution premixing 4.15 Cooling water control valve

1.1 Fresh water supply (water-cooled design)
1.2 Filter 4.16 Temperature sensor (PT100)
1.3 Solenoid valve for water supply 4.17 Cooling water thermometer
1.4 Flow meter (water-cooled design)
1.5 Storage tank for additive 4.18 Cooling centre (cooling tower)
1.6 Filter with nonreturn valve 4.19 Water-water-plate heat exchanger
1.7 Nonreturn valve 4.20 3/2-way valve
1.8 Metering pump for additive (pneumatic)
1.9 Additive 2 (option) 5. Ink roll cooling/heating
1.10 Storage tank for alcohol 5.1 Water-water-plate heat exchanger
1.11 Solenoid valves for alcohol supply 5.2 Bypass valve
1.12 Metering pump for alcohol (pneumatic) 5.3 Heating
1.13 Fountain solution supply (water + additive) 5.4 Expansion vessel
1.14 Alcohol supply 5.5 Safety valve
5.6 Automatic ventilating valve
2. Fountain solution circulating 5.7 Temperature sensor (PT100)
2.1 Fountain solution storage tank 5.8 IRHC-pump
2.2 Supply pump 5.9 Flow monitoring switch
2.3 Supply line valve 5.10 Manometer for supply line
2.4 Float switch 5.11 Check valve supply line
2.5 Ventilation 5.12 Cooling water supply line
2.6 Fountain solution supply line 5.13 Printing unit with inking unit
2.7 Fountain pan in fountain unit 5.14 Cooling water return line
2.8 Fountain solution return line 5.15 Check valve return line
2.9 Return flow filter unit (f.ex.: F 40 P) 5.16 Manometer for return line
2.10 Connection (return line) 5.17 Dirt trap
2.11 Filter foam 5.18 Mixing valve
2.12 Sensor for monitoring the filter condition
2.13 Heat exchanger pump 6. Miscellaneous
2.14 Thermostat for emergency mode 6.1 Mains feeder (see wiring diagram)
2.15 Drain for heat exchanger circiut 6.2 Main switch (option)
2.16 Overflow and discharge for fountain solution 6.3 Switchbox
storage tank 6.4 Digital control unit (display and electronic)
6.5 Fault indicator
3. Measurement of alcohol concentration
3.1 Alcohol Control
3.2 Connection for fountain solution measurement
3.3 Restrictor
3.4 Measurement of the alcohol content
4. Refrigerating system
4.1 Heat exchanger with evaporator
4.2 Compressor (refrigerating set)
4.3 Condenser (air and/or water-cooled)
4.4 Fan motor (air-cooled design)
4.5 Collector
4.6 Dry-type filter
4.7 Sight glass
4.8 Expansion valve
4.9 Temperature sensor
4.10 Pressure compensation line
4.11 Low-pressure manostat
4.12 Suction check valve
4.13 High-pressure manostat
4.14 Pressure check valve

Mode of operation
5.1 Fountain solution premixing (Fig. 5-4)
Description
The fountain solution premixing unit comprises in the
4 5 6 7 main
- a flowmeter (4) for measuring and controlling the

amount of water for the damping solution prepar-
ation,
- a metering piston pump (7) for adding alcohol as a

function of the adjusted alcohol setpoint and the
measured actual alcohol value of the alcohol control,
- and a metering piston pump (6) for the fountain

solution additive as a function of the adjusted ad-
ditive percentage and the amount of water supplied.
The quantities of alcohol and additive are calculated

and controlled by the control system. When the key
is pressed, the consumption data for water,

additive and alcohol will be displayed.
Mode of operation (Fig. 5-4)

When the unit is put into operation, switching point 1
triggers the initial filling as per the basic adjustment
When the fountain solution level in the storage tank
drops - caused by the consumption of fountain solution
during printing - a float switch triggers a contact
(switching point 2 is left) for another filling cycle with
some 6 litres of premixed damping solution (H2O +
additive + alcohol = 6 l).
A filling cycle comprises the following steps:
a) Simultaneously
- water is metered via an opened solenoid valve (5)

Switching point 3 and flowmeter (4),
- fountain solution additive is metered proportional to

volume via pumps (6) by several pump lifts,
Switching point 2 - alcohol is metered proportional to percentage via

pumps (7) by several pump lifts.
Switching point 1
Fig. 5-4

Mode of operation
Attention:
Only "technically pure isopropanol" may be
used with this fountain solution premixing unit.
"Alcohol substitutes", that can be added pro-
portional to volume only, may only be used after
the parameters of the control have been altered.
A density measuring of the alcohol will not be
working in this case.
b) The filling cycle will be completed when the adjusted

metering quantity has been added and will be
repeated until the adjusted level in the damping
solution storage tank (float ball at switching point 2)
is reached.
Note:
With the intial service, the tank will first be filled
to the upper switching point 3 by the integrated
fountain solution premixing unit. The fountain
solution circulating pump will only then be cut
in by the elelctronic control.
During printing, the level will adjust itself at the
middle float switching point 2.
c) In the case of a low alcohol percentage during the

production run (e.g. caused by evaporation) as
measured by the alcohol control, additional alcohol
will be metered by several pump lifts until the adjusted
value has been reached (also see 5.2).
Attention:
The pressure reducer must be set to 400 kPa
(4.0 bar) to ensure a perfect metering function
and error detection.

Mode of operation
5.2 Alcohol Control Unit (Fig. 5-5)

3
Attention:
Only "technically pure isopropanol" may be
used with this fountain solution premixing unit.
"Alcohol substitutes", that can be added pro-
portional to volume only, may only be used after
A density measuring of the alcohol will not be
working in this case.
4
The BALDWIN Alcohol Control continuously measures
the actual value of the alcohol percentage in the damping
solution by the density measuring principle.
The desired alcohol percentage (0 to 20%) can be

entered at the display (digital control) of the unit. 2
1
The Alcohol Control is calibrated with 0% of alcohol first
by means of a metering pipe. This is required since the
addition of fountain solution additives will additionally
change the fountain solution density.
The Alcohol Control comprises the following compo-

nents: Fig. 5-5
1) Analysis box with:

Fountain solution supply, standpipe
2) Aerometer:
comprises a special steel float with screwed-on
plastic cap and calibrating discs
3) Housing top with:
optoelectronic reticle scanning
4) Metering pipe for the correction of the fountain
solution density required by the addition of fountain
solution density
Note for repair and/or spare parts orders:

Since the Alcohol Control is accurately calibrated
as an entity with all components, it must be sent
as complete unit to BALDWIN in the case of a
defect.

Mode of operation
Mode of operation of the Alcohol Control (Fig. 5-6)

The alcohol portion in the damping solution is measured
by the density measuring principle (areometer). Higher
alcohol percentages cause the density to decrease, 5
which in turn results in a lower buoyancy of the aerometer
float (4), whereas lower percentages cause the density
to increase, which results in a higher buoyance of the 6
aerometer float (4). 1
Fountain solution is recirculated in a continuous circuit

from the fountain solution refrigerating unit via the
connection (1), analysis box (2) and standpipe (3) to the 2 3 4
refrigerating unit.
When the density in the analysis box is changed, the

aerometer (4) moves a position pickup (5) integrated in
the housing top upwards and/or downwards. Values
are converted by an optoelectronic scanning of this
code measure, and the alcohol percentage (actual Fig. 5-6
value) is digitally displayed at the control panel.
When the value drops below the adjusted alcohol

setpoint, alcohol will be metered by several pump lifts
in addition to the normal filling cycle proportional to
volume by the electronically controlled fountain solution
premixing unit (see Section 5.1).
The Alcohol Control is calibrated to the different densities

of fountain solution additives by means of an adjusting
knob (6) at the analysis box (see section "Adjusting and
checking").
Note:
Alcohol measurement is e.g. upon initial service
only 5 minutes after the supply pump has started
to run.
This On delay ensures a perfect measurement
by the analysis box that will then be sufficiently
flushed with fountain solution.
In the case of an alcohol deviation

- to 0.5 % below setpoint,
1 pump lift will be effected per 15 seconds
- to 1.0 % below setpoint,
1 pump lift will be effected per 6 seconds

Mode of operation
5.3 Return flow filter unit (option)

(Fig. 5-7)
Mode of operation of the return flow filter
The return flow filter is used for pre-cleaning and
recirculating the fountain solution returning from the The fountain solution returning from the fountain pans
water pans of the press into the RCWL. of the press is cleaned by the filter mat (2). A float switch
It is also used as a collecting tank for the fountain (6) monitors the filter condition and signals any clogging
solution when the overall system is switched off. of the filter to the electronic control unit.
The main components of the return flow filter are: An integrated submerged pump (8) recirculates the
fountain solution to the RCWL.
a) filter mat (2) The fountain solution return flow is set by the control
b) filter cage (3) valve (10).
c) float switch (6) A control and/or float valve (9) restricts the pump flow
d) float (7) rate when the fountain solution level in the tank drops,
e) control and/or float valve (9) thus preventing the formation of foam to a large extent.
f) submerged pump (8)
g) tank (5)
h) control valve (10)
Fig. 5-7

Installation
6. Installation
6.1 Remove the packing
General
Check the individual units and components for packing
material (protection for transport, protective covers
etc.) and remove.
Alcohol Control (Fig. 6-1)

Take the packing material (serves as protection during
transport) out of the analysis box of the Alcohol
Control.To do so, loosen the 2 knurled screws (1) at the
front and the rear and remove the electronics section
(2). Remove the float (4) and take the protection for
transport (3) (packing material) out. Align the housing
(5) of the Alcohol Control with the aid of a water level (8)
at 2 sides (A and B) and adjust by means of the
setscrews (7). Now put the float (4) back into the
container.
Warning:
Prior to mounting the black electronics housing,
remove the cap (6) at the bottom

without fail,
to enable the plunger to move freely and to

ensure that the alcohol strength is determined
accurately.
Failing to remove the cap, alcohol Fig. 6-1

will be overdosed.
Attention:
The analysis box must be vertically aligned
during mounting by placing a water level at 2
sides (A and B). To do so, adjust setscrews (7)
correspondingly. Take the packing material out
of the analysis box before putting the unit into
operation ! When mounting, make sure that the
adjusting knob at the housing top (2) points to
the front (operator side).

Installation
6.2 Location
Select the location for the unit in such a way that it will 1480
always be easily accessible for the operating personnel 730
min. 600
and that it is not subjected to extreme heat, e.g. near a
heating etc. The distance between the rear side and the
wall must be at least 40 cm (also see Fig. 6-2).
Warning:
The user must provide adequate ventilation for min. 400
(1450)
the dissipation of heat and the removal of harmful CRCWL
vapours, if any (min. 0.5 m to the top). 852-...
Consult BALDWIN before you install an extraction

system that works in upwards direction.
Place the unit on a firm base.
min. 400
Attention:
The ventilation grids at the unit must not be
blocked and/or covered, since perfect cooling
of the partly very hot components will then no
longer be ensured.
Fig. 6-2
For troublefree funktion the unit must be align to two

faces (see Fig. 6-3).
Attention:
Place the CRCWL at the same level as the printing
press
- cooling unit placed at a lower level in the

basement will require a pump with a higher
capacity,
- cooling unit placed at a higher level will
require an additional return-flow filter,
since there will be no free return flow in this

case.
Secure the unit against sliding.
Fig. 6-3

Installation
6.3 Hose connections
Warning:
Run all hoses in such a way that nobody stumbles
over them (protect by means of suitable cover-
ings).
Note:
Supply and return flow lines will have to be run up to unit type 852-600...
along the press by the customer, depending on
the configuration concerned.
Coordinate this with Messrs. BALDWIN and/or
the press manufacturer.
Note:
The hoses for the ink tempering unit must be run
without any bends and as vertically as possible
to ensure perfect venting of the system. Provide
vent valves at the priting units.
Return flow hoses made of PVC should have a fabric 1 2 3 4 5 6 7

insert due to the hazard of buckling.
Hose connections as per Fig. 6-4. Hose and dimensions

from unit type 852-1000...
of connection see section "Technical data".
1 7 4 2 5 3 6
Fig. 6-4
Key to Fig. 6-4
1 Drain
2 Air connection
3 RCWL supply line
4 Fresh water
5 IRHC supply line
6 RCWL return flow line
(other point of connection feasible)
7 IRHC return line

Installation
l Drain (Fig. 6-4, item 1) l Fresh water supply (Fig. 6-4, item 4)
This connection serves as overflow and drain for the When the fresh water supply is from the in-house water
fountain solution storage tank. main to the cooling unit, a pressure reducer is to be
connected on the line side.
The customer must provide a connection with stop
valve and pipe disconnector.
Warning:
Dispose of the fountain solution in accordance Attention:
with the relevant rules in force. The fresh water supply pressure to the cooling
unit must be between 150 kPa (1.5 bar) and 500
kPa (5 bar).
l Air connection (Fig. 6-4, item 2)
The customer must provide a compressed air connection

of at least 350 kPa, max. 1000 kPa for the drive of the l IRHC supply and return flow line (Fig. 6-4,
alcohol and/or additive pumps. item 5/7)
Note:
Attention:
The hoses for the ink roll heating/cooling (IRHC)
Set the air pressure governor of the unit to 400
must be run without any bends and as vertically
kPa (4 bar).
as possible to ensure perfect venting of the
system. Provide vent valves at the printing units.
l RCWL supply and return flow line (Fig. 6-4,

item 3/6)
only applicable to water-cooled design:
Make sure that these are run without any bends and as
vertically as possible so that the fountain solution flows l Cooling centre supply and return flow line
back into the storage tanks of the cooling unit when the
pump is at standstill. The unit is provided with a cooling circuit with water-
cooled condenser and/or heat exchanger. The heat
exchanger is found at the bottom left in the unit and is
Note:
connected to a cooling centre via the supply/return line
These hoses should be insulated to avoid line
connection.
losses.
Note:
The hoses for supply and return line must be
connected to the heat exchanger directly.

Installation
6.4 Connection to cooling centres

Cooling units are suited for a connection to both cooling out by the high-pressure safety switch, there is
centres (e.g. cooling tower for chill rollers) and municipal no cooling water supply from the cooling centre
water supply. (check the interlocking contacts to the cooling
centre).
Attention:
A continuously working cooling circuit must be When the manometer hunts by more than 5°C
ensured even when the press is at standstill. with the cooling centre running, there is air in
Ensure that the water from the cooling centres the cooling water circuit. Remove this air by
is clean without fail. Any internal contamination venting the circuit, since the chiller will fail very
will prevent the condenser from working soon with this hunting operation, power
perfectly (filter the cooling water, if required). consumption will heavily increase, and the
refrigerating capacity will drop.
Note:
In the case of operation on municipal water,
contact Messrs. BALDWIN prior to initial
operation. A high pH value may damage the
CRCWL.
Cooling water pressure: 6.5 Alcohol and additive supply

min. 200 kPa (2 bar), max. 600 kPa (6 bar)
Alcohol and additive are mixed to the fountain solution
Cooling water temperature: by self-priming pumps from integrated storage tanks
min. +10°C, max. +40°C (from unit type 852-1200..., the storage tanks are
external) .
Cooling water flow rate:
see "Technical data"
When the condenser is supplied with very cold water Warning:

(approx. 10- 15°C), e.g. city water, directly from the line, Improper handling of additives is a danger to life
a pressure reducer (200 kPa / 2 bar) should be connected and limb. Observe the relevant regulations (e.g.
on the line side. Failing this, cutting in and out of the safety regulations, regulation governing the
refrigerating set in the low pressure range might occur. handling of hazardous materials etc.) without
Filters with a mesh width of 80 µm are to be installed fail.
upstream of the cooling unit.
Required nominal widths for supply and return line Attention:

hoses see “Technical data”. Only "technically pure isopropyl" may be used
with this fountain solution premixing unit.
Install stop valves in the cooling lines to allow "Alcohol substitutes", that can be added pro-
maintenance or repair work at the refrigerating set. portional to volume only, may only be used after
Note: A density measuring of the alcohol will not be
Pressure reducer, filters, air ventilation valves working in this case.
and stop valves are not included in "BALDWIN´s
scope of supply".
Attention:
The unit may only be used for adding commer-
Note only for refrigeration engineering expert: cial fountain solution additives. When 0...6% of
Set the cooling water regulating valve so that additives are added, a pH-value suitable for
the high-pressure manometer will constantly printing (4.8...5.2) must be obtained.
indicate 40°C + 2°C (liquefaction temperature)
with the refrigerating set and the cooling water
supply from the cooling centre running!
When the high-pressure manometer hunts to

some 60°C or when the refrigerating set is cut

Installation
6.6 Topping-up alcohol and/or additive (Fig. 6-5) 6.7 Refrigerant
Loosen screw caps (1), remove suction pipe (4) with As a rule, BALDWIN deliver the refrigerating set in filled
filter (5), top up additive (2) and alcohol storage tank (3). condition.
Put suction pipe with filter back in place and mount
screw caps.
Warning:
Topping-up of the units may only be carried out
by a specialised firm for refrigeration and air-
condition engineering upon prior consultation
1 2 of BALDWIN.
The refrigerating set may only be filled with and operated

on the refrigerants stated in the technical data.
Note:
Prior to commissioning, leave the unpacked
unit in its service position for some 24 hours to
allow the refrigerant to gather after transport.
6.8 Electrical connections
- Combined Refrigerated Circulating Water Level

- additional return flow devices
as per the wiring diagram.

3 5 4
Fig. 6-5
Warning:
Work at the electric section must be carried out
by an electrician on principle. The appropriate
wiring diagram is to be observed.
A wiring diagram is supplied with each unit.
Attention:
Compare the mains voltage at site with the
nameplate of the unit.
Regarding a connection to the central control console

consult BALDWIN.

Start-up and Shut-down
7. Start-up and Shut-down
7.1 Controls
4 1 2 3
Legend to Figs. 7-1 and 7-2
1 Display
with the functions:
- Temperature settings
- Request of the current consumption data
- Inquiry about errors
- Service mode
2 Master switch (option)

with:
Pos. “0” voltage off
Pos. “1” voltage on
3 Fault lamp (group alarm)

will light with faults:
- Temperature deviation
- Motor protection
- Tank level
- Filter soiled
Fig. 7-1 Water-cooled design
- Additive tank empty
4 Switch for emergency mode S4:

Should the control unit fail, fountain solution cooling
and circulation are maintained by emergency mode. 2
Fig. 7-2 Air-cooled design

7.2 Initial operation of the fountain solution

cooling RCWL
Warning:
Study the operating manual, especially the
section covering the safety notes first!
Prior to commissioning, leave the unpacked unit in its

service position for some 24 hours to allow the refrigerant
to gather after transport.
Warning:
Improper handling of the additives is a danger to
life and limb. Pay attention to the relevant rules
and regulations (as e.g. safety regulations,
regulation governing the handling of hazardous
materials etc.) without fail.
Check whether
- connection to the mains is available

- supply and return hoses have been run properly
- compressed air is available (max. compressed air
connection 1000 kPa / 10 bar).
- air pressure governor is set to 400 kPa (4,0 bar)
- fresh water is available from the in-house supply line
at the correct admission pressure (min. 150 kPa,
max. 500 kPa)
- containers for additives and alcohol are full
Warning:
!! Danger of freezing !!
Never start the unit without the tank being filled.
a) Turn on master switch (see Fig. 7-1/2).
b) Enter desired fountain solution parameters (alcohol

BALDWIN RCWL LOCAL
TEMP
SET
°C 10.0
ACT
10.5
F1: AMX
ON - OFF
strength, concentration of additives, and temper-
AL % 8.0 8.0 F2: COMP/HEP
ADD. 1 % 3.0 ON - OFF
F3: PUMP
atures in values of % and °C) at the digital control
ON - OFF
F4: IRHC (see section “Operation of display”).
c) Turn on maintenance switches F1, F2 and F3; to do

so, press the F1, F2 and F3 keys.
“ON” will light.
F1 switches on the entire Automix. F2 releases the
cooling unit. F3 switches the supply and return line
pumps on.

d) Open fresh water supply.
The electronic section will be working, and due to
switching point 1 (Fig. 7-3) initial filling is initiated as
per the basic setting.
The fountain solution storage tank will be filled with
mixed fountain solution.
e) Float reaches switching point 2:

The heat exchanger pump and the cooling unit are Switching point 3
cut in.
f) The unit will be filled to switching point 3.

Float reaches switching point 3 (see Fig. 7-3): The
filling cycle is completed, the fountain solution Switching point 2
circulating pump (supply line pump) is switched on
and the circulation system is filled, i.e. the tank
contents will be diminished by the volume of hoses, Switching point 1
water pans etc.
Attention:
Check sense of rotation of heat exchanger pump
(see direction of arrow on the pump housing). Fig. 7-3
Attention:
g) Observe positions of ball valves at the water pans of The setting rings serve as stops, not for adjusting
the press, set, if required. With external recirculation the switching points.
systems the corresponding operating manual must
be observed.
h) The continued consumption of fountain solution

during printing will cause the float to drop below
switching point 2 and to release a contact for another
filling cycle to the electronic section (= normal
operation).
i) One or several filling cycles will be carried out.
k) With normal operating conditions during printing,

steps h) i) will be repeated.
Attention:
When the float switch drops down to switching
point 1 during normal operation, the refrigerating
set and the circulation pump to the press will be
cut out. At the same time, filling to f), g), h) and
i) will be initiated.
Attention:
The cooling unit may only be operated with the
filter foam put in place.

Note:
The NOT READY period is 5 minutes from the
time when the heat exchanger pump (HEP-pump)
is cut in by the control system. Failures, excess
alcohol and temperature, plug X4, and alcohol
measurement will not be displayed during this
period.
Note:
Should the cooling unit start running and then
switch off for approx. 1 minute or longer, check
whether the low pressure manostat is the cause.
When this is the case, refrigerant has escaped
during transport.
Warning:
Sealing the leaks and topping-up of the units
may be carried out by an expert firm for air
conditioning and refrigeration engineering upon
prior consultation of Messrs. BALDWIN only.

7.3 Initial operation of the ink roll heating/cooling
(IRHC)
Warning:
Study the operating manual, especially the
section covering the safety notes first!
Prior to commissioning, leave the unpacked unit in its

service position for some 24 hours to allow the refrigerant
to gather after transport.
Attention:
Pay attention to the local safety regulations and/
or the EC safety data sheets for the antifreezer
and/or anticorrosive used.
Check whether
- connection to the mains is available

- supply and return hoses have been run properly
- compressed air is available (max. compressed air
connection 1000 kPa / 10 bar).
- air pressure governor is set to 400 kPa (4,0 bar)
- fresh water is available from the in-house supply line
at the correct admission pressure (min. 150 kPa,
max. 500 kPa)
- whether antifreezer and/or anticorrosive are available
for initial filling (amount and type as per the press
manufacturer´s instructions).
a) Turn on master switch (see Fig. 7-1/2).
b) Enter setpoints for ink roll temperature (heating and

printing temperature for ink distributor) at the display
(see section 8.2 “Setup”). Key to Fig. 7-4
The difference between heating and printing
temperature should not exceed 2°C. 1 Drain
2 Air connection
BALDWIN recommend the following values: 3 RCWL supply line
- Printing temperature: 25°C 4 Fresh water
- Heating temperature: Printing temperature + 1°C 5 IRHC supply line
6 RCWL return flow line
c) Open automatic vent valve (12) and air relief cock (other point of connection feasible)
(15) (see Fig. 7-4). 7 IRHC return line
8 Feed cock IRHC
d) Open all stop valves. 9 Dirt trap IRHC
10 Mixing valve IRHC
e) For fill circuit (ink roll heating/cooling) by opening the 11 Supply and return line manometer
feed cock (8) (see Fig. 7-4). Only close air relief cock 12 Automatic vent valve
(15) when cooling water emerges of the air relief 13 Pressure relief valve
cock. 14 Equalizing reservoir
15 Air relief cock
Note:
Carefully vent the piping system during filling.

up to unit type 852-600... from unit type 852-1000...
Y Y
12
13
12 14
15
13 11
14 15
Z Z
10 10
11
8
9
8
1 2 3 4 5 6 7 1 7 4 2 5 3 6
Fig. 7-4

f) Fill the unit to 200 kPa (2 bar) with the pump at

standstill; the indication (static pressure) at the
supply and return line manometer (11) must be
identical.
BALDWIN IRHC
SET ACT F4:
F4: IRHC
FWT
TEMP °C 25.8 ON - OFF
HEATING °C 28.0
Attention: PRINTING °C 26.0
SWITCH POS. 0.0
The water pressure in the ink roll heating/cooling
system must not exceed 200 kPa (2 bar) with the
pump at standstill.
g) Check the unit for leaks.
h) Shortly start the circulating pump IRHC via the F4

key for several times, vent the water circuit by
opening the air relief cock (15), if required.
Attention:
Check sense of rotation of circulating pump
IRHC (see direction of arrow on the pump hous-
ing).
i) Should the pressure at the supply line manometer

(11) drop below 200 kPa (2 bar) with the pump at
standstill, top up with water and vent subsequently.
k) F4 key on. IRHC unit is working. IRHC = Ink Roll Heating/Cooling
l) Check the service pressure at the manometers. The

unit should be filled until the return line manometer
indicates a water pressure of min. 50 kPa (0.5 bar).
The supply pressure must not exceed 300 kPa (3
bar).
Attention:
Only switch on the circulating pump IRHC with
an adequate water filling. Danger of running dry!
Attention:
Fill in antifreezer and anticorrosive during initial
filling. Pay attention to the press manufacturer´s
instructions!
Note:
When there are still large air bubbles in the
system, the circulating pump IRHC is cut out by
a protective device against running dry. Subse-
quently, the unit must be vented and topped up
with water, if required. Then start the circulating
pump IRHC by the F4 key for several times
(switch on/off).

7.4 Setting the bypass valve (wet and/or dry

offset)
Wet -> dry offset (Fig. 7-5)
a) Press the maintenance switch F1 (Automix) and F3

(supply line and return flow pumps) to turn them off.
BALDWIN RCWL LOCAL
TEMP
SET
°C 10.0
ACT
10.5
F1: AMX
ON - OFF
„OFF“ will light.
AL
ADD. 1
%
%
8.0
3.0
8.0 F2: COMP/HEP
ON - OFF Set the setpoint for the fountain solution temperature
F3: PUMP
ON - OFF
F4: IRHC
to 17°C (= temperature in the tank) (see paragraph
8.2 „Adjustments“).
b) Fully close the bypass valve (4) at the water-water

heat exchanger (3) (also see Fig. 10-1).
c) Enter the setpoints for the IRHC (heating and printing

temperature for ink rolls) at the display (see
paragraph 8.2 „Adjustments“).
5
Dry -> wet offset (Fig. 7-5)
a) Press the maintenance switch F1 (Automix) and F3

(supply line and return flow pumps) to turn them off.
M
„OFF“ will light.
Set the setpoint for the fountain solution temperature
to 17°C (= temperature in the tank) (see paragraph
8.2 „Adjustments“).
M
b) Half open the bypass valve (4) at the water-water
heat exchanger (3) (also see Fig. 10-1).
c) Enter the setpoints for the IRHC (heating and printing

temperature for ink rolls) at the display (see
paragraph 8.2 „Adjustments“).
1 Fountain solution circuit

2 IRHC circuit
3 Water-water-heat exchanger
4 Bypass valve
5 Maintenance switch (control unit)
Fig. 7-5

7.5 Shut-down RCWL and/or IRHC
a) Turn off master switch
b) Shut supply and return valves
c) Shut and turn off fresh water supply
d) Shut compressed air supply
Note:
All settings carried out during last startup will
be maintained.

Operation of display
8. Operation of display
8.1 Description of function
BALDWIN RCWL LOCAL

SET ACT F1: AMX
TEMP °C 10.0 10.5 ON - OFF
ADD. 1 % 3.0 ON - OFF
F3: PUMP
ON - OFF
F4: IRHC
l Entering setpoints l Scanning/acknowledging errors

With the "Alcohol %", "Additive", "Temperature" keys The error menu is called in by means of the "Error" key.
the value concerned is indicated with its full number of The LED, integrated in the error key, will start flashing
digits and/or entering setpoints is initiated. as soon as there is an error. Errors are acknowledged
The required digit is selected by subsequently pressing in the error menu by means of the F1 key. Now only
the cursor keys ç and è. The value is increased or those errors will be displayed that are continuously
decreased at the digit concerned (within defined limits) scanned by the program (e.g. errors in the supply by the
by means of the é and ê keys. pump monitoring system will no longer be displayed).
When a second additive has been provided (option), a The error menu may be called in from anywhere, but not
selection must first be made and acknowledged by the from the service mode.
ENTER key.
For error messages see the section "Trouble shooting".
l Scanning/clearing consumption data

The current consumption data of the available media l Interrupting the "NOT READY" stage
may be scanned and cleared, if required, by means of The starting stage, that will be active for five minutes
the S key. after switching the unit on, is interrupted by pressing
To do so, press the control key in the display associated the RESET key in the RCWL image. A version
to the medium concerned (see Section 8.2 /8.3). A message will be displayed for 3 seconds, and the
warning will be displayed, and you may now clear the flashing display "NOT READY" in the upper right
consumption value by pressing the ENTER key or you corner of the RCWL image will go out.
can terminate by pressing any other key.
l Stop key
Exit of the menu is by means of the STOP key, unless
you are in a menu with direct entering of parameters
(e.g. complete entering of setpoints by means of
ENTER).

tly
of
be
at Operation of display
l Maintenance switch (F1/F2/F3 keys)

by The entire Automix is switched on and/or off by means
tly of F1, any active filling cycle will be completed. The
refrigerating set is locked or released by means of F2.
The supply and return flow pumps are cut in or out by
means of F3.
ed
ns
be l Ink roll heating/cooling (IRHC)
et If integrated (via the parameter menu), the ink roll
he heating/cooling can be called by means of key F4.The
operating state concerned will be shown in the right
upper corner of the display provided the ink roll heating/
cooling has been switched on via key F4. Entering of
ds setpoints for the heating and printing temperature as
to per item 1 is started by means of the "Temperature"
key.
l Options
- additive 2
- conductivity measurement of
the fountain solution
- pH measurement of the fountain solution
C) - connection to central control console
mp For further information please contact BALDWIN.
ow
ng
l Service mode (only instructed personnel)
only when in the "LOCAL" mode

ely
Attention:
The service mode may be used by BALDWIN
technicians or personnel instructed by BALDWIN
only. When this menu is used by personnel that
he is not trained in it and should parameters be
d. altered, the unit may no longer operate perfectly.
ed Messrs. BALDWIN cannot be held responsible
in such a case.
er Note:
on The unit will automatically switch off in the
is service mode.
Settings and changes in the service mode are described

in a separate Service Instructions for "Digital Control
Unit" (German, English, French).
ity
a-
H
a-
ral Seite / Page 54 01.98/CRCWL852/GB

de
8.2 Setup
AMX (Automix) ON / OFF

BALDWIN RCWL LOCAL
SET ACT F1: AMX Fresh water supply and
TEMP °C 10.0 10.5 ON - OFF
AL
ADD. 1
%
%
8.0
3.0
8.0 F2: COMP/HEP
ON - OFF
fountain solution premixing
F3: PUMP
ON - OFF
F4: IRHC
COMP / HEP ON / OFF

Compressor (refrigerating set) and
heat exchanger pump, if any
Pump ON / OFF
Pump of supply line to press
Note for actuating the 16 keys:
The key function will only be initiated when a Menu: Ink roll heating/cooling (IRHC)
"click" becomes audible and sensible.
BALDWIN RCWL LOCAL RCWL setpoints

SET ACT F1: AMX
TEMP °C 10.0 10.5 ON - OFF
ADD. 1 % 3.0 ON - OFF
F3: PUMP
ON - OFF
F4: IRHC
RCWL display
Temperature setpoint
enter temperature setpoint acknowledge
Alcohol setpoint
enter alcohol setpoint acknowledge
Additive 1
enter additive setpoint acknowledge

Ink roll heating/cooling
BALDWIN IRHC
SET ACT F4:
F4: IRHC
FWT
HEATING °C 28.0
PRINTING °C 26.0
SWITCH POS. 0.0
BALDWIN IRHC
SET ACT F4: IRHC
HEATING °C 28.0
PRINTING °C 26.0
SWITCH POS. 0.0
IRHC display
Entering setpoints for IRHC
Select heating or enter temperature setpoint acknowledge

printing temperature
return to the IRHC menu
return to the RCWL menu

Display of consumption data
The current alcohol, additive and fresh water consumption data will be indicated at the display.
BALDWIN RCWL
(F1) CONSUMPTION ALCOHOL: 0.0 LITER

(F2) CONSUMPTION ALC.SUB : 0.1 LITER
(F3) CONSUMPTION ADD. : 0.0 LITER
(F4) CONSUMPTION WATER : 323 LITER
CLEAR CONSUMPTION -> FX
The consumption data are cleared by means of the control keys.Function F4

is only assigned when additive 2 (option) has been provided/parameterized.
Return to the RCWL menu.
Error table
The current error table will be indicated at the (error).

For error messages and elimination of faults see section "Trouble shooting".
Return to the RCWL menu.
Changeover REMOTE <-> LOCAL mode
REMOTE: central control operation (according to protocol specification)

- complete data exchange at interface
(from the central control it is not possible to enter setpoints, delete
consumption data and operate in the service mode)
LOCAL: display keyboard operation

- with service functions
The currently set mode is displayed in the first line in the RCWL menu.
Changeover by +
Select the desired mode by and acknowledge with .

Service mode
Attention:
The service mode may be used by BALDWIN
technicians or personnel instructed by BALDWIN
only. When this menu is used by personnel that
is not trained in it and when parameters are
altered, the unit may no longer operate perfectly.
Messrs. BALDWIN cannot be held responsible
in such a case.
Settings and changes in the service mode are described

in a separate Service Instructions for "Digital Control
Unit" (German, English, French).

Adjusting and checking
9. Adjusting and checking

9.1 General
The adjustments concerned may be made by Messrs.

BALDWIN and/or authorized personnel only.
Attention:
All adjustments sealed with safety lacquer must
not be changed.
The unit has been adjusted by Messrs. BALDWIN. For

the settings see the enclosed certificate.
9.2 Basic setting of the pneumatic maintenance

unit (Fig. 9-1)
1 a) Optimum pressure with the metering pumps not

running:
400 kPa (4.0 bar)
2
Slightly raise the handwheel (1) and release the
pressure reducer by turning counter-clockwise. Turn
clockwise until the desired service pressure is
indicated on the manometer. Lock the handwheel
by pressing it down.
b) Setting the amount of oil (2):

1 drop / 40 strokes (metering pump)
Turning clockwise “less oil”

Turning counter-clockwise ”more oil”.
Fig. 9-1

9.3 Density measurement by commercial hydro-

meters
The hydrometer used for measuring the IPA content in

the fountain solution is calibrated for mixtures IPA/pure
water.
There will always be an error of measurement when
fountain solution additives are added. The portion of
IPA contained in the fountain solution is actually higher
than the value indicated at the measuring scale of the
hollow body.
However, the correct value may be determined on the
basis of the measured value by means of a correction
table.
Density of the
fountain
solution additive Portion of
in g/cm3 additive Indicated IPA concentration in %
1.05 1% 3.5 5.4 7.2 9.1 11.0 12.9 14.7 16.6 18.5 20.4
2% 3.1 5.0 6.8 8.7 10.5 12.4 14.2 16.1 17.9 19.7
3% 2.8 4.6 6.4 8.2 10.1 11.9 13.7 15.5 17.3 19.1
4% 2.5 4.3 6.0 7.8 9.6 11.4 13.1 14.9 16.7 18.5
1.10 1% 3.2 5.0 6.9 8.7 10.6 12.4 14.3 16.1 17.9 19.8
2% 2.5 4.3 6.1 7.9 9.7 11.4 13.2 15.0 16.8 18.6
3% 1.9 3.6 5.3 7.0 8.8 10.5 12.2 13.9 15.6 17.4
4% 1.2 2.9 4.5 6.2 7.9 9.5 11.2 12.8 14.5 16.1
1.15 * 1% 2.9 4.7 6.5 8.3 10.1 11.9 13.8 15.6 17.4 19.2
2% 1.9 3.6 5.3 7.1 8.8 10.5 12.2 14.0 15.7 17.4
3%* 0.9 2.6 4.2 5.8 7.5 9.1 10.7 * 12.3 14.0 15.6
4% 0.0 1.5 3.0 4.6 6.1 7.6 9.2 10.7 12.3 13.8
1.2 1% 2.5 4.3 6.1 7.9 9.7 11.5 13.3 15.0 16.8 18.6
2% 1.3 2.9 4.6 6.3 7.9 9.6 11.2 12.9 14.6 16.2
3% 0.0 1.5 3.1 4.6 6.1 7.7 9.2 10.8 12.3 13.8
4% -1.3 0.1 1.6 3.0 4.4 5.8 7.2 8.61 10.0 11.4
4 6 8 10 12 14 16 * 18 20 22
actual IPA concentration in %
Fig. 9-2
Example for using the table (fig. 9-2):
A fountain solution contains 3 % of an additive of a Note:

density of 1.15 g/cmł. The value determined by the The hydrometer is calibrated to 20°C as a rule.
hydrometer test is 11.5 %. Measuring in the cooled fountain solution (10°C)
results in a further deviation by some 2 %.
Search the line in the table that belongs to a density of
1.15 g/cmł and the additive of 3 %. The indicated value In the example, the actual alcohol concentration is
of 11.5 is between the stated values of 10.7 and 12.3; approx. 19 % at a fountain solution temperature of
the actual concentration is approx. 17 % (see *). some 10°C.

9.4 Additive and temperature calibration at the
Alcohol Control Unit (Fig. 9-3)
The Alcohol Control may be calibrated to the different

densities of fountain solution additives by a setting knob
BALDWIN RCWL LOCAL
(1) with scale (2) at the analysis box.
SET ACT F1: AMX
TEMP °C 10.0 10.5 ON - OFF
ADD. 1 % 3.0 ON - OFF
F3: PUMP
ON - OFF
Attention:
Complete drain the fountain solution storage
tank and the circulation system when you change
from one fountain solution additive to the other.
Repeat the setting when you change the fountain
solution additive and/or when you alter the
metering amount.
Setting:
BALDWIN RCWL LOCAL
SET ACT F1: AMX a) Completely drain the fountain solution system.
TEMP °C 10.0 10.5 ON - OFF
ADD. 1 % 3.0 ON - OFF b) Enter the desired additive and temperature setpoint
F3: PUMP at the display and/or the central control console of
ON - OFF
the press (see 8.2 "Setup").
c) Set alcohol setpoint to 00.0 %.
d) Switch the Automix on (F1).

The refrigerating unit will start to premix the fountain
solution.
- Only fountain solution additive (no alcohol) will be

added.
e) Wait until fountain solution premixing is completed

and the temperature setpoint has been reached.
2
1 f) Correcting the specific gravity:
- Loosen setting knob (1) and lower the metering

pipe to the bottom stop.
- Watch the actual alcohol value and slowly lift the

metering pipe until the actual alcohol value
reaches 00.0 %.
- Secure the metering pipe by means of the setting

Fig. 9-3 knob (1).
g) Enter the desired alcohol setpoint at the display

(and/or central control console).
The desired alcohol percentage will automatically
be maintained by a piston metering pump.

9.5 Adjusting the thermostat (Fig. 9-4)
Attention:
Adjustment only in emergency operation.
1 a) The thermostat for the cooling system allows the

fountain solution temperature to be set from -5°C to
max. +25°C.
Attention:
2 The thermostat must not be set below 8°C.
The thermostat has been factory-set to 10°C.
b) Set desired damping solution temperature at the

knurled knob (1).
c) The value set at the differential scale (2) indicates

the max. difference between the max. and min.
temperature of the fountain solution at the fountain
solution outlet of the cooling unit.
Fig. 9-4
Attention:
This value, set to 2°C, must not be changed,
since due to the higher operating frequency the
refrigerating set might be damaged.
9.6 Checking the sight glass (Fig. 9-5)
Note:
Check the sight glass with the unit running!
CAUTION
(Call BALDWIN after-sales service)
DRY
(Refrigerant circuit ok)
WET
(Refrigerant circuit not ok, call BALDWIN after-sales
service or technician for air conditioning /
refrigeration engineering)
Fig. 9-5

9.7 Checking the water pressure in the IRHC
Read off the service pressure at the manometers:
a) with the pump at standstill:

Return flow and
supply line pressure: max. 200 kPa (2 bar)
Attention:
The water pressure in the IRHC must not exceed
max. 200 kPa (2 bar) with the pump at standstill.
b) with the pump at running:

Return flow pressure: min. 50 kPa (0,5 bar)
Supply line pressure: max. 300 kPa (3 bar)
When the minimum setpoint is not reached, top up with

water (see putting the IRHC into service).
When the setpoints are exceeded, drain cooling water
of the circuit.

Maintenance
10. Maintenance 10.2 Maintenance intervals
10.1 General Note:

BALDWIN Combined Refrigerated Circulating Water Replacing the filter foam in the fountain solution
Levels require only little maintenance. The necessary return line and/or the filter candle in the fountain
upkeep serves to keep the units ready for service. solution supply are not included in the main-
tenance jobs, since a contamination will be
The periods between servicing depend on the operating indicated by alarm messages in time.
conditions concerned.
daily Checking the fountain solution-

filter foam
Attention:
The intervals for maintenance stated are mini- Weekly Clean the fountain solution
mum recommendations. storage tank
Exceeding the intervals as well as failure to
observe the instructions contained in this oper-
ating manual may result in an impairment of the Monthly Clean the condenser
perfect performance of the units. Moreover pos- (air-cooled design)
sible liability claims can be called in question.
Clean the Alcohol Control
Checking the pneumatic

maintenance unit
Warning:
Make the unit dead for maintenance work by Every 6 Clean the entire fountain solution
means of the master switch and/or by deselecting
months system
it from the central control console.
The maintenance switches F1, F2, F3 and F4 Clean the filters for fresh water,
must be set to "OFF" (see 8.1 "Description of alcohol and additive
function).
Warning:
There are hot components behind the covers.
When the covers are removed for maintenance
or repair work, make sure not to touch these
components !

Maintenance
Fig. 10-1
CRCWL 852-.. HS AD (air-cooled design)
1. Control unit
2. Automatic premixing unit AMX (see Fig. 10-2)
3. Heat exchanger pump
4. Supply line pump (mounted behind heat exchanger pump)
5. Condenser
6. Fountain solution storage tank
7. Fountain solution filter foam
8. Standpipe (overflow and discharge)
9. Alcohol Control BC 743
10. Expansion vessel
11. IRHC-pump
12. Water-water-heat exchanger
13. Bypass valve
14. Dirt trap (IRHC)

Maintenance
Metering pump for

additive
Metering pump for

alcohol
4/2 way valve

(additive)
4/2 way valve

(alcohol)
Nonreturn valve
for additive Flow meter
Nonreturn valve
for alcohol Flow regulator
2/2 way valve

(fresh water)
Fresh water filter
Food filter
with integrated
nonreturn valve
Fig. 10-2

Maintenance
10.3 Replacing the fountain solution filters 10.5 Cleaning the entire fountain solution system
Preparatory steps:
The F3 maintenance switch remains on. Mark the
Warning:
position of the supply line valve at the supply line pump,
Dispose of the filter foam in accordance with the then close it.
relevant rules in force!
As a result, the entire fountain solution circuit and the
connected return flow filters will be pumped empty.
a) Pull out filter module, wrap up used filter foam and
Attention:
take them out.
Operate the supply line pump only with an
adequate filling of water. Failing this, it may run
Attention:
dry!
When mounting a new filter foam make sure that
the filter cage is locked properly.
Next steps see 10.4 a) to e)
Note:
f) After the fountain solution circuit has been emptied,
Use original BALDWIN filter foam!
set the supply line valve at the supply line pump to
the marked position.
g) Subsequently fill the tank with water and cleaning

agent for fountain solution systems (in accordance
with the manufacturer´s instructions), then switch
the unit on to rinse the entire fountain solution circuit.
Duration of cleaning depending on the degree of
10.4 Cleaning the fountain solution storage tank soiling and/or the manufacturer´s instructions.
h) Repeatedly drain the tank and flush the circuit with

a) Switch the unit off.
clean water to ensure that no cleaning agent is left
b) Pull out filter module, wrap up used filter foam and
in the unit (also see “Preparatory steps”).
take it out.
c) Drain the fountain solution tank by unscrewing the
Attention:
standpipe and by opening the ball valve.
After draining the soiled cleaning agent, flush
the system with clean water until all residues are
removed without fail!
Warning:
Dispose of the fountain solution in accordance i) Replace the filter foam in the return flow line by a
with the relevant rules in force! new one.
Note:
d) Wipe out the tank and the float switch with a solvent Use original BALDWIN filter foam!
that is commercially available for fountain solution
circuits (in accordance with the manufacturer´s k) Put the unit into service (same as initial operation)
instructions).
e) Mount standpipe with flat packing and close ball
valve for tank discharge.
f) Place the filter cage in the tank and mount filter foam
(see paragraph 10.3).
g) Put the unit into service (same as initial operation).

Maintenance
10.6 Cleaning the Alcohol Control Unit (Fig. 10-3)
The method of cleaning used depends on the user´s

experience. Generally the following method has stood
the test in practice:
a) Switch the cooling unit off.

b) Disconnect electric coupler (1) and remove water
supply hose (2).
c) Remove housing top (3) after loosening the fastening
screws (4).
Attention:
When you do not remove the housing top but
take out the entire Alcohol Control, be sure that
it is kept in a vertical position without fail. Since
the analysis box is filled with water up to
standpipe level, water would penetrate into the
housing top when the entire unit is laid on the
side and would damage electronic components.
Notes regarding d) e):

Be sure to use hot water. Failing this, some
deposits such as e.g. gum arabic will not be
removed.
d) Take aerometer (5) out of the analysis box and

remove the deposits by means of a lint-free rag.
e) Take out analysis box, drain and clean. Clean

standpipe by means of a bottle brush, if required.
Fig. 10-3
f) Mounting is in reverse order.
10.7 Cleaning the fresh water filter (Fig. 10-4)

1 a) Switch the unit off.
b) Shut the water supply.
2 c) Loosen and remove screw plug (1).
d) Take out filter element (3), rinse in clear water and
blow out with clean compressed air.
3
Note:
Should the filter element (3) be defective, replace
the complete dirt trap by a new one.
d) Mount filter, replace gasket (2) by a new one, if

required, and tighten screw plug (1).
Fig. 10-4

Maintenance
10.8 Checking the maintenance unit (Fig. 10-5)
a) Set maintenance unit to 0 bar (1)

b) Drain condensate water (2)
c) Top up oil (3)
3
1
We recommend that you use the following oils for the
maintenance unit:
Suitable oil grades Viscosity at 40°C

mm˛/s (cSt)
Aral Vitam GF 46 46
BP Energol HPL 46 46
Esso Nuto H 68 68
Shell Tellus C 46 46
2 Texaco Rando Oil 38
HD C 38 38
Fig. 10-5
10.9 Cleaning the filter in alcohol and/or additive

containers
a) Switch the unit off.

b) Pull supply line out of alcohol and/or additive con-
tainers .
c) Unscrew filter, rinse in clear water and blow out with
clean compressed air or replace by a new filter.
d) Mount and tighten filter.
10.10 Cleaning the ribs of the condenser

(Fig. 10-6)
(with air-cooled design)
Warning:
Keep your hands out of the range of rotation of
the fan blades because of the risk of injuries at
the start of the fan blade.
a) Switch the unit off, open the cabinet doors.

The condenser (1) is located at the top of the unit.
b) Unscrew housing cover (2), blow out the ribs of the
condenser with compressed air in opposite direction
to the air intake.
Note:
Use clean compressed air free of oil at max. 200
kPa (2 bar).
Fig. 10-6
c) Screw down housing cover, the cover must fit tightly.

Repairs
11. Repairs
11.1 General
We know from experience that mounting and dis-
mounting the components described in the following
may be done by shop mechanics and/or works
electricians. Should adjustments be required subse-
quently, these should be carried out by BALDWIN.
Warning:
There are hot components behind the covers.
When the covers are removed for maintenance
or repair work, make sure not to touch these
components!
Warning:
Work at the closed cooling circuit may be carried
out by expert personnel only (expert for refriger-
ation engineering).
Warning:
The compressed air and the fountain solution
circuit must be pressureless before any repair is
carried out at the unit. Danger of injuries by
heavily splashing fountain solution and/or
escaping compressed air.
1 11.2 Replacing the supply line pump or heat

exchanger pump; type KTB 200 / KTE 142
(Fig. 11-1)
11.2.1 Dismounting
3
a) Switch the unit off, open both doors.
2 b) Disconnect the electric line of the pump (works
electrician)
c) Shut fresh water supply and fountain pan supplies
d) Unscrew screwed connection (3) at pump supply
line
e) Loosen 4 screws at the pump flange
g) Take out the pump (1)
11.2.2 Mounting
Mounting is in reverse order.
Fig. 11-1

Repairs
11.3 Replacing the circulating pump IRHC;

type CHI 4-20 / CH 12-20 (Fig. 11-2)
11.3.1 Dismounting
a) Switch the unit off, open both doors.
b) Disconnect electric line (2) at the pump (1) (works
electrician).
c) Close supply and return line valves of the ink roll
heating/cooling (IRHC).
Warning:
The circuit of the IRHC in the unit must be pres-
sureless before the hoses are removed. Danger
of injuries by heavily splashing cooling water.
d) Drain the water of the IRHC circuit only in the unit.

The circuit must be pressureless!
e) Pull off hose at the pump supply line (3).
f) Pull off hose at the pump return line (4).
3 2 5 1 4 g) Loosen 4 screws (5).
h) Remove pump (1).
Fig. 11-2
11.3.2 Mounting
Mounting is in reverse order.
11.4 Replacing the thermostat (Fig. 11-3)

2
11.4.1 Dismounting
5
a) Switch the unit off
b) Disconnect power supply
3 c) Remove rear wall
d) Pull capillary measuring line (1) out of the temperature
sensor tube.
e) Loosen housing cover (5) at the thermostat (2).
f) Remove fastening screws (3).
g) Disconnect electrical connections (4).
h) Take out the thermostat with capillary measuring
line.
4
11.4.2 Mounting
Note:
1 The end of the capillary line has been twisted at
the factory.
Attention:
Make sure that the twisted end reaches at least
to the lower third of the temperature sensor.
Fig. 11-3 Replace insulation, if required.
a) Mounting is in reverse order.

Trouble shooting
12. Trouble shooting
Attention:
Elimination of faults by Messrs. BALDWIN and/
or authorized personnel only.
Warning:
A wiring diagram will be supplied with each unit.
Fig. 12-1
Warning:
Work at the closed cooling circuit may be carried
out by expert personnel only (expert for
refrigeration engineering).
Fig. 12-2

Trouble shooting
12.1 Error messages at display
Trouble Possible causes Eliminating the fault Notes

ERROR WATER - Fresh water valve closed - Check water supply line/valve Carry out H2O
- Check desired pressure (150 - -counter test in the
FEED - Low flow pressure (min. 1 bar)
service mode (see
- Fresh water filter clogged 500 kPa / 1.5 - 5 bar) separate "Service
Instructions for
Digital Control
- When the float ball is at position 1 Unit") to check the
- Solenoid valve Y5 does not open
flowmeter
-> LED will light and water must
be supplied, otherwise -> replace Check the
electronics section
solenoid valve Y5 via service menu
INPUTS/OUT-
PUTS (see
- Solenoid valve Y5 clogged - Loosen solenoid valve head and separate "Service
Instructions for
clean tappet Digital Control
Unit")
- Solenoid valve Y5 without voltage - Check electrical connections
- Water flowmeter does not give - Clean filter, replace, if required

signal - Mechanical check -> clean
- Electrical check -> replace
- Check flowmeter, replace, if
required
HIGH LEVEL - Solenoid valve Y5 does not close - Mechanical check -> clean; Check the water flow
rate with
(if the LED does not light, water Electrical check -> replace
H 2O-counter test
must not be supplied) (see separate "Ser-
vice Instructions for
- Water flowmeter defective - Check flowmeter, replace, if Digital Control Unit",
233 pulses = 1 l of
required
H 2 O). Check the
- Float switch defective - Replace switch amount of water by
- Close valve for fresh water supply gauging by liters.
Check the
electronics section
via service menu
INPUTS/OUT-
PUTS (see
separate "Service
Instructions for
Digital Control
Unit")
LOW LEVEL - See trouble “Error water feed”
- Middle float switching point defective - Check float, replace, if required Check the
/ float got caught electronics section
via service menu
INPUTS/OUT-
- Standpipe not screwed down - Check standpipe, replace seal, if PUTS (see
properly and/or seal defective required separate "Service
Instructions for
Digital Control
- Leakages in the fountain solution - Check hoses, screw connections Unit")
system

Trouble shooting
ERROR - Container for additive empty - Check container / suction line

ADDITIVE - Suction line not in container
1 FEED
- Foot filter, filter clogged - Check filter, replace, if required
Option: - Elektronic unit A1 - Replace elektronic unit

ERROR
ADDITIVE 2 - Compressed air supply missing and/ - Check compressed air supply Check the electro-
FEED nics section via
or incorrectly set air pressure (desired value: 400 kPa / 4 bar) service menu
- Stop valve leaky or clogged - Clean stop valve, replace, if INPUTS/OUTPUTS
required (see separate
"Service Instruc-
tions for Digital
- Air valve Y3 fouled by oil - Blow out the oil Control Unit")
- Air valve Y4 defective - Check valve Y4 / metering pump, too much oil in the
(press red button at the valve, replace, if required air valve indicates
switching of the 4/2 way valve (after replacement of the 4/2 way excess oil con-
sumption -> reduce
metering of additive will be audible) valve, check the function by oil metering
pressing the red button at the
- Metering pump defective valve/pump)
(press red button at the pump, piston
movement will be audible)
ERROR - Container for alcohol empty - Check container / suction line

ALCOHOL - Suction line not in container
FEED
- Foot filter, filter clogged - Check filter, replace, if required
- Elektronic unit A1 - Replace elektronic unit
- Compressed air supply missing and/ - Check compressed air supply Check the electro-
nics section via
or incorrectly set air pressure (desired value: 400 kPa / 4 bar) service menu
- Stop valve leaky or clogged - Clean stop valve, replace, if INPUTS/OUTPUTS
required (see separate
"Service Instruc-
tions for Digital
- Air valve Y3 fouled by oil - Blow out the oil Control Unit")
too much oil in the
- Air valve Y3 defective - Check valve Y3 / metering pump, air valve indicates
(press red button at the valve, replace, if required excess oil con-
switching of the 4/2 way valve (after replacement of the 4/2 way sumption -> reduce
metering of alcohol will be audible) valve, check the function by oil metering
pressing the red button at the
- Metering pump defective valve/pump)
(press red button at the pump, piston
movement will be audible)

Trouble shooting

ACTUAL - Contactor K1 defective - Replace contactor K1
TEMPERATURE
OUT OF ALARM - Supplied fresh water too warm - Cool fresh water
LIMITS
- The variance is above 3°C - Check by means of thermometer
whether indication is correct
- Refrigerating set (F2) switched off - Turn on cooling unit by key F2
- Heat exchanger clogged - Clean heat exchanger by means

of adequate cleansing agent
- “Not ready" time is active - “Not ready” phase not completed,

(also see “Error cooling unit”) since tank temperature is high,
wait until unit advances
- Lack of refrigerant, bubbles in sight - Top up refrigerant

glass
- Temperature sensor defective - Check temperature sensor at 100W
- Expansion valve defective - Replace expansion valve
ERROR - The measured actual alcohol value - Check actual alcohol content by see 9.3
ALCOHOL exceeds 20% means of hydrometer
MEASURING
- The position pick up of the Alcohol - Check / clean position pick up, see 5.2
Control is tight replace, if require
(measurement
- Protection for transport (protective - Replace protective cap at Alcohol see 6.1
pick-up faulty)
cap) Control
- Float immersed too deeply, leaky - Replace float of the Alcohol Control
- Heavy formation of foam in fountain - Adjust return flow filter unit and/or also see Oper-
solution injector at IRE ating Manual
"Return Flow
Filter" and "IRE"
- BC 743 defective - Check BC 743 (the optoelectronic see 5.2

reticle is soiled)
- Measuring vessel must be filled first - Wait until photogrammetric cam-

era is filled
- Metering pipe not adjusted correctly - Adjust see 9.4
EMERGENCY - Emergency mode switch S4 turned - Turn off emergency mode In emergeny
operation, the
MODE on switch, check cooling unit control output of
the supply line
Electrician pump, the heat
exchanger pump
and the
Expert for refrigeration refrigerating set is
engineering bridged to maintain
the fountain
solution circuit
from and to the
press and/or the
cooling.

Trouble shooting

ERROR - Protective motor switch Q2 heating - Turn on protective motor switch
HEATER IRHC has tripped Q2 and check setting
Electrician
- Water temperature in IRHC circuit - Check whether IRHC circuit (F4)

too high (>45°C), safety switch is on, switch on, if required. Check
“excess temperature” has tripped thermostat setting at heating and
readjust, if required.
- Mixing valve defective - Check / replace mixing valve

(after-sales service)
ERROR PUMP - Protective motor switch Q4 has - Turn on protective motor switch
IRHC tripped Q4
(NEWSTART -> Electrician
OFF/ON)
- Supply or return line valve in IRHC - Open valves
circuit closed
- Air bubbles in IRHC circuit - Vent IRHC circuit
- Low water pressure - Check pressure indicated at see 9.7
pressure gauge (pressure in
return line min. 0.5 bar), inade-
quate amount of water in circuit
—> top up with water
- Flow monitoring switch B5 has not - Check, whether the water flow is
switched due to inadequate water blocked at the press see 9.7
flow rate, with the pump running - Check the pressure
- Filter clogged - Clean filter

- Pump defective - Replace pump
PRINT - Difference between set RCWL - Readjust via setting the desired
TEMPERATURE desired temperature and set IRHC value (see 8 "Operation of
IRHC NOT desired temperature too small display")
POSSIBLE (difference min. 5°C)
- Mixing valve defective - Replace mixing valve
- Pump or pump impeller defective - Replace pump

- Water flow governor defective - Check water flow governor, re-
place, if required
OVERLOAD - Overload switch of circulating pump - Turn on overload switch

SWITCH or heat exchanger pump has tripped
Electrician
PUMPS (P1/
HEP/RETURN
- Check setting of overload switch
FLOW) - Overload switch of pump for return
(see wiring diagram)
flow filter (option) has tripped
- 24 VAC missing, fuses F4 / F7 - Check fuse

defective
- 24 VAC module defective - Replace 24 VAC module

Trouble shooting
ERROR FLOAT- - Float switch defective - Check float switch, replace, if

SWITCH - Float switch tight required
- Float switch or connecting line to - Check switch and/or connecting
float switch defective line, replace, if required
- Reed contacts soiled - Clean Reed contacts
RCWL FOUN- - Automix (F1) OFF, see failure “Error

TAIN SOLU- water feed ”
TION EMPTY
ERROR PLUG - Plug at BC 743 disconnected - Check plug / connection to BC

BC 743 - Connection to BC 743 interrupted 743 (X7 - X7.1)
ACTUAL - The variance is above 3% - See trouble

ALCOHOL OUT "Error alcohol feed"
OF ALARM "Error alcohol measuring"
LIMITS - New exact alcohol setting
- See trouble “Error alcohol feed”
- Measuring vessel must be filled first - Wait until photogrammetric cam-

- Float switch defective era is filled
- Check switch, replace, if required
RETURN FIL- - Filter foam in the fountain solution - Clean/replace filter foam and/or also see Operating
TER DIRTY Manual "Return
storage tank and/or filter mat in filter mat
Flow Filter"
return flow filter clogged
when the LED at
- The capacitive filter sensor in the - Clean and/or dry sensor the filter sensor
does not light ->
CRCWL is fouled or wet clean or adjust
intensity by means
of screw driver
HIGH - High pressure manostat has trip-

PRESSURE ped,
PRESSURE air-cooled design:
SWITCH - Condenser fouled / blocked - Clean condenser, provide Check fan (sense
of rotation)
adequate ventilation
- Ambient temperature above 44°C Check air outlet
- Diameter of exhaust air line inade-

quate / exhaust air line too long
- Cooling unit is placed near a heat - Protect from heat generator, place
generator unit elsewhere
water-cooled design:
- Cooling water control valve set - Check / adjust valve, replace, if
incorrectly or defective required (also see page 6.4
- No cooling water supply from "Connection to cooling centres")
cooling centre
- Preliminary filter clogged - Clean filter

- Stop valve closed - Open stop valve

Trouble shooting
ERROR - Overload switch Q1 has tripped - Turn on overload switch

COOLING-
Electrician Check
UNIT
compressor
winding
- Low pressure manostat has tripped - Low water temperature

- Low water flow rate through heat
exchanger and/or clogged
- Refrigerant missing - Top up refrigerant

Expert for refrigeration
engineering
- Pump (F3) switched off - Turn on pump (F3)
- 24 VAC missing - Replace fuse F4
- 24 VDC missing - Replace fuse F7

Trouble shooting
12.2 Failures not shown at display
Refrigerating - Mains feeder missing or dis- - Electric trouble shooting by means

set and connected of the circuit diagram
circulating - Back-up fuse defective
pump do not - Master switch not turned on or
Electrician
start running defective
- Transformer defective
Refrigerating - Overload switch of refrigerating set - Turn on overload switch

set does not (mutual interlocking) has tripped
Electrician
start running
- Fountain solution temp. may - Set temperature at the thermostat
already be below adjusted to a higher value, if required
temperature
- Thermostat may be defective - Remove housing at thermostat and only in the

bridge connections (Fig. 12-1) - emergency
Unit is running - Replace thermo- mode
stat (also see failure
“EMERGENCY
MODE”)
- Manostat may be defective Remove housing cover at manostat The refrigerating

and bridge connections (Fig. 12-2) - set may only be
operated on the
Unit is running - Check at start
refrigerants listed
whether the sight glass (Fig. 9-5) is under the
filled with liquid refrigerant to 3/4. „Technical Data“.
When this is not the case or when
bubbles occur, have refrigerant
topped up (specialized firm).
When the refrigerant filling is found
to be perfect during topping up, the
manostat must be replaced
(specialized firm).
No fountain - Supply line pump (circulating pump) - Turn on overload switch and check
solution supply not running pump and/or return flow filter pump
Electrician
- Wrong sense of rotation of pump - Check power supply at the

terminals
Electrician
- Fountain solution supply line valve - Open fountain solution supply

shut line valve
- Low fountain solution level in storage - see trouble "LOW LEVEL"
tank
- Hose kinked - Check running of hoses
- Pump impeller got loose - Fasten pump impeller

Trouble shooting
Motor of the cir- - Pump impeller at motor shaft end - Check (after-sales service)
culating pump loose
seems to over- - Fresh air outlet at motor clogged
heat - Fan blade wheel at motor loose
Note:
The in-service temperature
may be up to 70°C, therefore
the motor may feel hot to the
touch. Since the motor is
designed for operation on 50
and 60 Hz, a higher
temperature with operation on
60 Hz is considered normal.
Cooling unit (water-cooled condenser) see 6.4 "Connection to cooling

heavily oscil- centres"
lating in high
pressure range (air-cooled condenser) see trouble "HIGH PRESSURE
PRESSURE SWITCH"
Fountain - Position of temperature sensor in - Check (after-sales service)

solution warm feeler tube not ok
- see trouble “Refrigerating set does
not start running”
in "Emergency mode":
- Thermostat set too high - Check
Fountain - Thermostat set too low - Check (after-sales service)

solution cold - Position of temperature sensor in
feeler tube not ok
Circulating - Overload switch of circulating pump - Turn on overload switch also see Oper-
pump does not and/or return flow filter pump has ating Manual
Electrician "Return Flow
start running tripped (mutual interlocking)
Filter" and "IRE"
- Pump may be defective - Replace pump
No fountain Return flow line: also see Oper-

solution return - Filter in the return flow filter unit - Clean filter ating Manual
flow and/or clogged "Return Flow
inadequate - Return flow hose kinked - Check Filter" and "IRE"
circulation and/ - Pump performance inadequate - Check (after-sales service)
or fountain pans
in press over- Injector Recirculation Equipment (IRE):
flowing - Injector restricted excessively - Release restriction of injector
- Injector clogged - Clean injector

Trouble shooting
Additives - Additive pump does not draw in 100 - Clean foot valve
missing ml - Replace metering pump
- Position of the Reed switch - Set Reed switch to correct position
at the front of the centre flange
- Reed contacts soiled - Clean Reed contacts
- Power supply Reed switch missing - Check power supply, make

(LED does not light) connection
Alcohol - Low metering amount - Clean foot valve

missing - Clean nonreturn valve
- Replace metering pump
- Reed switch - Set Reed switch to correct position

at the front of the centre flange
- When the LED at the Reed switch - Check power supply, make
does not light, power is missing connection, replace Reed switch,
if required

Dismounting
13. Dismounting 13.4 Antifreezer and anticorrosive
13.1 Electric connection
Warning:
When antifreezer and anticorrosive are conta-
minated or are not required any longer they
Warning:
must be disposed of in accordance with the
relevant rules in force.
Make the unit dead.

13.5 Refrigerant
Disconnect the unit from all electrical connections.
Warning:
13.2 Hose connections The refrigerant may only be drained by a
specialised firm for refrigeration and air-
Shut all connections for water, compressed air, additi- condition engineering and must then be dis-
ves and alcohol and/or alcohol substitutes, drain the posed of in accordance with the relevant rules
lines. and regulations.
Warning:
The closed circuit for compressed air and the 13.6 Scrapping
fountain solution must be pressureless before
dismounting the unit. Danger of injuries by
heavily splashing fountain solution and/or
escaping compressed air. Warning:
All parts of the unit must be disposed of in
Loosen and unplug supply lines. accordance with the relevant rules and regu-
lations.
13.3 Fountain solution, alcohol (alcohol substi-

tutes) and additives
Warning:
Dispose of the fountain solution and the used
filters as well as alcohol and/or alcohol substi-
tutes in accordance with the relevant rules in
force.
Drain the fountain solution system and the storage

tank.
Close containers for alcohol and/or alcohol substitutes
and additives.

Parts list
14. Parts list

14.1 General
The following illustrated parts list includes only those

parts that can be replaced without any difficulties by
shop mechanics or works electricians according to
experience. A list of recommended spare parts is given
in the annex to this parts list. This list is based on our
experience gained up to now. If the user keeps these
parts in stock, he will be in a position to repair the unit
without delay.
Note:
When ordering spare parts, please indicate the
works number of the unit and the model number.
14.2 Notes for using
Abbreviations:
"Fig" item = Number of illustration and the

corresponding items
"No" Pcs = Number of parts per subassembly; the

term subassembly refers to the
principal subassembly part, part of the
plant or the entire plant.
14.3 Illustrated parts list
(please turn over)


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Operating Manual

Combined Refrigerated Circulating

BALDWIN - Ident.-Nr. DOC.0.090151.02 GB

BALDWIN EUROPA BALDWIN-GRAFOTEC GMBH

Baldwin (UK) Ltd. DERCHINGER STR.137

Baldwin France Sarl TELEFAX: (08 21) 7942-222

Baldwin Graphic Products

Baldwin Graphic Equip. Pty. Ltd.

Baldwin Japan Ltd.

Baldwin Printing Controls Ltd.

01.98/CRCWL852/GB Seite / Page 3

Seite / Page 4 01.98/CRCWL852/GB

1. Introduction ................................................ 7 9.3 Density measuring with commercial

11. Repairs ...................................................... 72

7. Start-up and Shut-down ........................... 44

8. Operation of display ................................. 53 14. Parts list .................................................... 85

9. Adjusting and checking ........................... 59

01.98/CRCWL852/GB Seite / Page 5

1.0 Foreword to the operating instructions

This manual contains important notes which are to be

- operation including setting up, troubleshooting in

In addition to the operating instructions and to the

01.98/CRCWL852/GB Seite / Page 7

2.0 Fundamental safety instructions 2.3 Organizational measures

2.3.3 For reasons of security, long hair must be tied

2.3.5 Observe all safety instructions and warnings

Note: 2.3.6 In the event of safety-relevant modifications or

2.3.7 Never make any modifications, additions or

Seite / Page 8 01.98/CRCWL852/GB

Work at the cooling unit may only be drained by a

2.6.1 Electric energy Leaks (e.g. tube connections) of dangerous liquids

2.6.1.2 If provided for in the regulations, the power

01.98/CRCWL852/GB Seite / Page 9

3. Description alcohol substitutes are metered proportional to volume,

The ink roll heating/cooling is controlled by a special

- Fountain solution temperature

are forbidden for safety reasons.

A conductivity and pH measuring device may be fitted

Depending on the configuration concerned, the fountain

Cooling of the fountain solution is by an integrated

Control of the refrigerating unit is by the electronics of

Cleaning of the fountain solution is by integrated filters

The CRCWL is provided with an integrated premixing

01.98/CRCWL852/GB Seite / Page 11

The main components of the BALDWIN CRCWL are:

- Condensator with fans f) Digital control unit

with central refrigeration (type "WWAD") g) Temperature control

The filter unit cleans the fountain solution recirculated

An integrated alarm sensor signals any conta-

d) Fountain solution premixing

Seite / Page 12 01.98/CRCWL852/GB

Key to Fig. 3-1

1 Digital control unit 10 Bypass valve

01.98/CRCWL852/GB Seite / Page 13

Water-cooled design Air-cooled design

Key to model designation

Example: CRCWL 85 2 - 600 - 160 HS / WW A D

Basic performance number of

Tank contents in litres (in this case: 160 l)

Omitted = heat dissipation via refrigerant and air-cooled condenser

Integrated mixing unit

Digital control unit