CD102 excessive water below pan

[rich8606]

Any idea what's causing these excessive water below the pan? It never happened before until today. And it's not condensation from the pan above, the chiller was set to 8 degrees Celcius.

 

[Mechanica Speedmaster]

Never seen splash like that but it only can come from dampening rollers, take water pan roller and Chrom roller out of pan and check distance between pan and water distributor. Maybe the insolation or old dry ink touches the water distributor...

 

[Adil]

It is an overflow of the dampening solution at the level of the water tank, and it is because of an imbalance between the flow of going and the return of the solution,
You must clean the return pipe, surely there is a blockage (ink, paper residue, etc.) blow the return pipe with compressed air
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[Jack liston]

I agree with Adil not draining at same rate it is filling clogged somewhere.

 

[rich8606]

It has been 10 days, we checked the distance between the pans and distributors, as you can see we covered our pans with insulation sheets. The 5 mm sheet is not touching any of the distributors. To be safe, we even cut the sheets to expose the pan a bit at the back and the problem still persists.

Next we checked the pipes, we regularly clean our pipes so we're sure they're not clogged, so we checked the water levels between our pipes and the chiller. We found that our pipes are only slightly higher than our chiller. So we raised the pipes by 15 cm and lower our chiller by 2 cm, this way we can be sure the returning water level is higher than the chiller, and it's still flooding.

This is what it looks like today, no difference at all despite everything we did:

What else could've caused this?

 

[Adil]

Mr rich 8606 do you have feed flow adjustment valves in each group??
If you do not have them, you must add them to each group so that it is independent of the setting in relation to the other group.
The problem you have is an imbalance between the going and the return of the wetting solution (you have to decrease the feed flow of the pan).
Does this problem occur without turning the machine??

 

[realaqu]

It has been 10 days, we checked the distance between the pans and distributors, as you can see we covered our pans with insulation sheets. The 5 mm sheet is not touching any of the distributors. To be safe, we even cut the sheets to expose the pan a bit at the back and the problem still persists.

Next we checked the pipes, we regularly clean our pipes so we're sure they're not clogged, so we checked the water levels between our pipes and the chiller. We found that our pipes are only slightly higher than our chiller. So we raised the pipes by 15 cm and lower our chiller by 2 cm, this way we can be sure the returning water level is higher than the chiller, and it's still flooding.

This is what it looks like today, no difference at all despite everything we did:

What else could've caused this?

Maybe the roller touch the insulation layer of water pan, just my guess

 

[mrheidelberg]

It only happens when the dampers drop on .....is that correct ?

 

[realaqu]

It only happens when the dampers drop on .....is that correct ?

You can just remove roller each by each so you can tell which one cause the problem

 

[Mechanica Speedmaster]

Plese describe when this problem accours. Is it only when dampening system goes to position "on", according the video i can see that this happens only at specific moment. Does it stop by itself as well or is it like when it starts it doesnt stop?

 

[rich8606]

Yes, it only happens when the dampening system is turned on. We think the problem is a combination of uneven water levels and excessive condensation. We're making a control tank with a separate water pump to save the uneven water levels. As for the condensation, the insulation we use is not sufficient. What is the best material to use to come true pan? Is there such thing as a 100% water proof material to prevent condensation?

 

[Adil]

Can you describe to me how you adjust dampending rollers ??

 

[georgbob]

have you checked the IPA content?
I have seen this at very high IPA values.

 

[mrheidelberg]

Yes, it only happens when the dampening system is turned on. We think the problem is a combination of uneven water levels and excessive condensation. We're making a control tank with a separate water pump to save the uneven water levels. As for the condensation, the insulation we use is not sufficient. What is the best material to use to come true pan? Is there such thing as a 100% water proof material to prevent condensation?

So when the press is idling or you are not using that unit when printing....there is no leakage....is that correct ??

 

[Ade]

You may have a blockage in the technotrans ejector block one of the blue nozzles may have some debris stuck in them, be careful on removing and refitting them.

 

[Andrei83]

Do you have problems with printing? It looks like the submersible and metering shaft is not configured, weak contact. Because of this, the water is transmitted in a thick layer and splashes. You must have big problems with printing.

 

[Andrei83]

And yes, it is not necessary to make a solution below 10 degrees Celsius, there will be condensation.

 

[Adil]

Can you describe to me how you adjust dampending rollers ??

If it is not a fountain solution flow imbalance then tell me how you adjust the rollers.

 

[turbotom1052]

Yes, it only happens when the dampening system is turned on. We think the problem is a combination of uneven water levels and excessive condensation. We're making a control tank with a separate water pump to save the uneven water levels. As for the condensation, the insulation we use is not sufficient. What is the best material to use to come true pan? Is there such thing as a 100% water proof material to prevent condensation?

There is a product sold here in the United States that has been recommended as a possible solution by a member named junker. When I heard his solution it seemed like a winner. The product is known as Flex Seal, and its either a spray on or a paint on substance that I bet would work pretty well in insulating the bottom of your fountain solution trough. I would think you would want to do a multiple coat application of this stuff to build it up to the desired thickness. Be careful that you dont go too thick. because there is the potential for this stuff to act as a squeegee and wipe dampener solution off of the water vibrator roller.

 

[rich8606]

Thanks for all the suggestions. But it has been almost 3 months and the problem still persists.

Let me summarize the problem:
- The problem doesn't affect our printing whatsoever.
- The only problem is just excessive water dripping into our blanket washup that we need to constantly clean.
- The problem only happens when we engage the dampening roller onto the plate cylinder.
- This has never happened before, not since we got our machine in 2010.
- Our chiller has always been set to 8 degrees Celcius & our IPA has always been set to 10-15% (with very low water usage) for 10+ years and we have never had this problem.
- We have used our own quick drying fountain solution for 25+ years on three different machines and never had this problem.
- The problem started 3 months ago after we cleaned our chiller. We regularly cleaned our chiller for years without this problem.

What we've done:
- Resealed our water pans with thinner insulation foam = No effect
- Raised the returning water pipes by 15 cm from its original height, lowering our chiller by 4 cm to make the returning water flow better = No effect
- Installed a control tank with its own water pump for the returning water = No effect.
- We dismantled our chiller this week and found there was a cracked pipe on the water pump, After replacing this pipe, THE PROBLEM STOPPED FOR THE WHOLE DAY, only to return the next morning.

We checked the pipe again and there is no more crack. We are stumped, this is such a small, seemingly simple problem that we can't fix. Maybe there's something we missed?