Operation manual

FW 992 XL– 993 XXL.NXT Micro Processor Anilox Roll Cleaner

FW 2000.NXT-2500.NXT Micro Processor Anilox Roll Cleaner

Original Instructions
 Flexo Wash Apes North America:

Langs Skoven 38 Flexo Wash LLC

8541 Skødstrup 2010 Plantside Drive
Denmark Louisville, KY 40299
USA
Tel: 0045 86 99 36 31 Tel: 001 888 493 5396
Fax: 0045 86 99 13 43 Fax: 001 888 543 5396

Liquids and filters: Spare parts:

E-mail: [email protected] [email protected]

Spare parts:
E-mail: [email protected]

When ordering spare parts, please inform us about:

Machine model and Serial number:

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 Table of Contents

FW 992 XL – 993 XXL.NXT and FW 2000-2500.NXT

Anilox Roll Cleaner
1. General Safety Precautions .................................................. 5

2. Power requirements and Connections .................................... 7

3. Installation Instructions ...................................................... 9

4. Operating Instructions ...................................................... 13

Workstation ............................................................................................................. 13
Signal tower lights ................................................................................................... 14

5. Maintenance Instructions................................................... 22

6. Display ........................................................................... 25

Access Cleanlink ...................................................................................................... 26

7. Options and special solutions ............................................. 35

8. Troubleshooting ............................................................... 38

9. Recipe structure ............................................................... 41

10. Declaration of Conformity ................................................ 42

READ BEFORE UNPACKING ........................................................................................ 43

Service interval ........................................................................................................ 44

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CAF - Commissioning Acceptance Form

Customer information
Customer
Installation address
Contact person
Machine model
Serial no.
Auxiliary equipment
Date
Training
Trained personal Trained in
Machine Machine Trouble Use of
Name
operation maintenance shooting manuals

Liquids
Liquid Tank 1: Tank 1 Temp:
Liquid Tank 2: Tank 2 Temp:
Installation data
Electrical power: V Ventilation:
A
Air inlet: Bar Drain:
Machine level: Lid function:
Water inlet temp: Water inlet flow:
Settings recipe 1
Wash time Min. Drain time Min.
Rinse cycles Cycles Drying air cycles Cycles
Ventilation time Min. Rotation during drain Min.
Rotation speed rinse % Rotation speed dry %
Slide speed rinse % Slide speed dry %
Additional information and remarks

Cleaning result

____________________________________________ ____________________________________________
Commissioned by technician, sign Commissioning approved by (customer), sign

When installation is completed, please mail the form to Flexo Wash Denmark:
[email protected]

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1. General Safety Precautions
• Do not use flammable liquids in the machine (with flash point below 68°C)

• Do not install machine in an Ex or ATEX zoned area.

• The machine should be operated by trained personal and only used as specified.

• Do not operate machine without proper ventilation of machine or room. Check

installation instruction and local regulation.

• Do not touch valve actuators, gears, or drives unless the machine is disconnected from
power supply and compressed air.

• Do not dismantle or open pump, pipe or filter system before pressure is completely
released.

• Check all safety devises on a regular basis and keep the machine well maintained.

• Use only genuine spare parts from Flexo Wash.

• Check piping, valves, and filter housings for leakage. Any leakage of cleaning liquid
should be avoided.

• Empty tank before moving the machine.

• Wear adequate protection of eyes, skin, and respiration when there is a risk of
exposure to liquid.

• Use only liquids and filters approved by Flexo Wash.

• Side plates must stay on the machine during cleaning.

Safety Signs on Machine:

Safety sign on the machine must be placed easy visible on front or side of the machine.

Wear glasses and gloves when operating the machine – especially during
filterchange, liquid handling, emptying, filling and cleaning of tanks.

Be careful when closing the lid and during manuel roll rotation.

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Disposal of chemical substances:
Cleaning liquid and filters used in the machine must be treated as chemical waste.
It must not be led to the sewer or normal waste disposal.
Disposal of chemicals must follow the regulations.
Contact local authorities about the disposal of chemical waste.

Disconnection and disposal of machine:

Empty tank, pump, filter, and pipe system before taking the machine out of service and rinse
with water.

Drain off lubrication oil from high pressure pump and lubrication devise in air system (when
applicable).

The machine must be treated as industrial waste. It consists of electronics, wiring and various
highly resistant metals and synthetic materials.
The machine must be scrapped and disposed by authorised companies or persons, only.

Contact local authorities about disposal of industrial machinery.

Warranty:
It is of great importance for our service and warranty obligations that Flexo Wash liquids and
spare parts are used in the machines. The machines have been thoroughly tested with Flexo
Wash liquid to ensure the guaranteed cleaning results and compatibility with parts.
Our warranty does not cover parts which are broken due to incorrect installation or faulty
repair by the purchaser, incorrect use, wear, or lack of maintenance. See your spare parts
manual for information about wear parts.
Use of non-Flexo Wash liquid and spare parts can cause end of warranty for the unit.

Contact:
By Malfunction:
Please call a Flexo Wash Technician or e-mail: [email protected]

By Ordering:
Of e.g., spare parts, filters, or liquids.
Please contact us:

Flexo Wash ApS

Langs Skoven 38
8541 Skødstrup
Denmark

Tel: 0045 86 99 36 31
Fax: 0045 86 99 13 43

Liquids and filters

E-mail: [email protected]

Spare parts
E-mail: [email protected]

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2. Power requirements and Connections
Electricity

FW 993 XL and XXL.NXT FW 992 XL-XXL.NXT

FW 2000-2500.NXT

Standard 3 x 400 V + PE, 50 Hz, 20,9 A 3 x 400 V + PE, 50 Hz, 20,4 A

USA models 3 x 480 V + PE, 60 Hz, 19,9 A 3 x 480 V + PE, 60 Hz, 17,7 A

Others 3 x 220 V + PE, 60 Hz, 28 A

Air 6-7 bar (85-100 PSI), 100 l/min [3.5 cfm] hose 6-7 bar (85-100 PSI), 100 l/min [3.5
16 mm hose [5/8 in] I.D. cfm] Hose 16 mm [5/8 in] I.D.

Water supply min. 21 l/min [5,5 USgpm] (20 mm [3/4”] min. 13 l/min [3,5 USgpm] (20 mm
Standard hose) I.D. at 30o C - 35o C [85 - 95 F] [3/4”] hose) I.D. at 30o - 35o C [85 -
95 F]
PE: 1 yellow-green wire

NOTE: The machine can be built different other electrical specifications. Therefore, please
check on the machine what kind of electricity is stated, before connecting the machine to the
local main power, to avoid mistakes.

Air
Air must be clean and dry.

Water
Do not start the machine before water is connected.
Water supply from local water supply, or water reservoir with possibility of heating the water.

IMPORTANT! The water must be clean without any kind of dirt and particles.
Dirty water or too little water pressure will damage the pump.
Damage caused by external supply is NOT covered by our warranty.

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Outlet
The water from the after-rinse cycle goes directly into the sewer. Alternatively, the water can
be led to a drain tank with pump for re-circulation or to a Flexo Wash water treatment system.
Check with the local authorities.

Cleaning liquid
The machine is designed and manufactured to be used with the following cleaning liquid:
The use of other liquids can result in safety hazards and damage of machine parts.

FW Anilox+ Cleaner: mix 50% in water.

This is the gentlest and environmentally friendly liquid for safe deep cleaning of aniloxes.

FW Anilox Deep Cleaner: mix 50% in water.

Tank 1 + 2 settings Recipe

(PIN: 2000)
Min. Max Set temp.
temp. temp.
FW .NXT 50 °C 60 °C 55 °C

Fill the tank and heat up the liquid using the internal heater.

Ventilation
The unit can be connected to a ventilating system to avoid steam in production facility.
Ventilation damper Ø80 mm must be adjusted to prevent too much vacuum. Otherwise, there
will be problems with draining cleaning liquid, as the vacuum holds the liquid back.

Ventilation
damper Ø80 mm

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3. Installation Instructions
Place the unit in the designated installation area. Be sure that connections are available for the
connection requirements.

Level out
Make sure the machine is levelled, front to back and side to side. Adjust the feet of the
machine to change the level.

Machine foot

Air connection
Connect the air supply to the air regulator and adjust the regulator until 7 Bar is seen on the
gauge.

Connection
point

Air regulator

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Filling the tank with new liquid

Fill until maximum filling

level is reached

Use his knob to turn the

pump on/off
(Shown in ‘off’)

Set the 3-way valve in this

position when filling

Connect the supplied filling

hose to the filling inlet

Container with new liquid

Filling from container:

1. Make sure the 3-way valve is positioned correct (crosswise to the pipe).
BE AWARE when turning the valve that there is a little amount of liquid remaining in the
suction hose that will run out.
2. Place the suction hose in the desired liquids container.
3. Make sure that the multi-use hose is placed in its socket (the hose with the bend).
4. To start the filling process, turn the pump control to vertical.
5. Keep an eye on the maximum filling level indicator on the tank
6. When finished, turn the 3-way valve back (straight with the pipe) and make sure that there
is no remaining liquid in the suction hose (either by shaking or gently knocking against the
inside of the liquids container). This will minimize liquid spill at next filling.
7. Place the hose inside the pump-room.

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Emptying the tank
Use this knob to
turn the pump
on/off
(Shown in ‘off’)

Set the 3-way valve

in this position
when emptying

Move the multi-use

hose from its socket
into the receiving
container

Container for used

liquid

Emptying into container:

1. Move the multi-use hose from its socket and place it in the receiving liquid container.
2. Make sure the 3-way valve is positioned correct (straight with the pipe).
3. To start the emptying (or transfer) process, turn the pump control to vertical.
4. When finished, turn of the pump.
5. Move the multi-use hose from the receiving liquid container and place it in its socket.
BE AWARE of Siphon principle.
The multi-use hose has no one-way valve, so if the tank is full and you place the hose
on the ground, it can empty the tank without the pump is running.

Maximum filling level indicator

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Water inlet and outlet
Connect after-rinse water inlet and wastewater outlet to their hose connections at the back of
the machine. If possible, use fresh water and adjust the temperature of the after-rinse water
to 30° - 35° C (85-95 F).

Water inlet
(No hose
supplied)

The wastewater can often be led directly into the sewer but check with the local authorities.
Alternatively, wastewater can be collected in a drain tank (optional equipment) for water
treatment/recirculation.

Wastewater
outlet

Supplied hose.
connect to drain.

Turn on main switch.

Main switch

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4. Operating Instructions
Workstation

Workstation for operator is in the green zone with access to emergency stop.

The work zone is only for operators trained for using this machine.

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Signal tower lights

Light flashing: Standby / Ready

Light on: Machine running

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Adjustment of roller length
The roller is placed on the rotation wheels on traction stations.
The traction stations can be adjusted according to roller length.
Lift the handle and moved the traction station to the desired position, push down the handle to
lock the traction station.
To see if the rotation is correct, use manual rotation.
Press “start” with open lid.
Make sure that the Anilox roll does not touch the machine.

FW 2000
FW 992

FW 2500M Stationary sleeve holders (options)

Stationary end

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Adjustment of cleaning length
The rings can block the cleaning liquid pipe.
This will reduce the amount of liquid on the gears and bearings.

The turning point of the nozzle traverse is set by adjustment of the end stop.
In this way, the amount of high-pressure water on gears and bearings will be limited.
Set the stop about 10cm from the left traction system.

Turning point Liquid stop ring

(to be adjusted)

Choose Wash Time

The wash time can be adjusted on the display. Three wash times are pre-set:

Recipe 1: 10 min.
Recipe 2: 15 min.
Recipe 3: 20 min.

All recipes are pre-set with:

▪ 3 min drain.
▪ 1 x rinse cycle.
▪ 1 x drying cycle.

Choose the setting depending on how dirty the roller is.

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Lid Closing/Opening
For security reasons the lid is controlled by a two-hand system.
When closing the lid, the two buttons need to be held until the lid
is firmly closed.
The lid will automatically stop if either one of the buttons are
released.
When opening the lid, press and hold the two buttons shortly and
the lid will open.
The emergency stop button can always be used to stop the lid at
any given time.
Two-hand system

Start Wash
Close the lid and start by activating the start button (black button in green circle).
The lid is now locked and cannot be opened before ended process.
The machine will automatically go through the cleaning process.

If necessary, the machine can always be stopped by activating the red emergency button.

1 - Emergency stop button

2 - Start button

3 and 4 - Lid button

5 - Main switch

Emergency stop button

The emergency stop button can always be used to stop the machine at any given time.
If the machine has been shut down by activating the emergency stop button, the reset button
must be pressed to reset the machine.

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The cleaning process:
The roll rotates during the cleaning process. The speed is pre-set to 85%.

Washing: Cleaning liquid is poured on the roller. The time depends on the setting in
the recipe.

Draining: The cleaning liquid is drained back to the tank. The time is pre-set to 3 min.

Rinsing: The roller is rinsed with water at high pressure. The time depends on the
distance between the sensors. The speed is pre-set to 65% and will run one
cycle.

Drying: The roller is dried by means of air stream. The time depends on the distance
between the sensors. The speed is pre-set to 65% and will run one cycle.

Manual rotation
Start/stop the rotation by pressing the start button (with open lid).
Manual rotation is convenient for checking correct placing of roller on the wheels and for
manual drying of the roll with a towel.

IMPORTANT: When manual rotation is on, you must be careful while operating inside the
machine.
The rotating gears can squeeze fingers! Do not wear loose hanging clothes.

Automatic Lid
The lid can be set to automatically open when washing is finished. Contact FlexoWash for
guidance.

Pause
To pause the washing process, press and hold the start button for 3 seconds.
Press the start button again to continue the wash.

Machine Power ON
When the machine is powered on or when the emergency stop is pressed, the reset button
must be pressed before the machine is ready to operate.

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Adjusting the high-pressure pump

The high-pressure for the after rinse may not exceed 90-100 bar, see manometer (A).
It can be adjusted by the regulator (B).

B A

High pressure pump

Adjusting the membrane pump

You may adjust the speed of the membrane pump by means of the throttle valve (see below)
on the air tube. The speed is right when the cleaning liquid is pumped up in an even dose.

Membrane pump with throttle valve

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Semi-automatic liquid filling system (Optional)

The filling pump is controlled via the control display and is used to fill the tank when the liquid-
level in tank drops below the minimum level.

The semi-automatic liquid filling system is not useable while the machine is operating due to
the risk of overfilling.

You may adjust the speed of the membrane pump by means of the throttle valve (see arrow)
on the air tube. The speed is right when the cleaning liquid is pumped up in an even dose.

Semi-automatic liquid filling pump placed on backside of the tank.

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Automatic dosing of antifoam (optional):
Machines for use with water-based liquid can be equipped with a dosing pump for anti-foam.
The dosing pump is placed in the pump cabinet beneath the washing area. The feeding hose
for the anti-foam liquid must be placed in the anti-foam container.
The dosing pump is pre-set to fit the most requirements. If foam should occur adjust the
settings on the dosing pump display.

Anti-foam dosing pump

Adjustment of anti-foam pump

The pump is activated in parallel with the wash pump. The pump is pre-set to add a suitable
amount anti foam, but if necessary, it is possible to adjust this setting. The pump can be set to
0-100%, max is 0,5 l/min.

- If the pump is running too fast, it will add too much anti foam and the water may be
saturated and start to foam.
- If the pump is running to slow, it will add too little anti foam and the water will start to
foam. The correct amount is depending on the anilox cleaner, water hardness and ink
type.
- If the cleaning liquid starts to foam after a short period of time, it is probably caused by
too low or too high-speed setting of the antifoam dosing pump.

NOTE: The temperature of the Aqua Cleaner must always be more than 45ºC (113ºF)
when washing otherwise the liquid will foam.

Test for correct setting of anti-foam pump.

Remove a sample (0,1 liter) of water from the buffer tank and put it into a small bottle (½ li-
ter). Shake the bottle, if the foam disappears after a few seconds, the setting is correct. If the
bottle is filled with foam, add a FEW droplets of antifoam to the bottle and shake the bottle.
If the foam disappears, then add approx. 0,01% anti-foam to the buffer tank and increase the
speed of the antifoam dosing pump by 10%.
If the foam does not disappear then change the water in the buffer tank and reduce the speed
of the anti-foam pump.

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5. Maintenance Instructions
1. A program is built in display menu, which shows “change filter” or “service”.
After changing filter, reset the filter alarm.

2. There is a little consumption of cleaning solution at each wash, and it will therefore have
to be ‘topped up’ at a regular basis.
Check the fluid level on the control display.
The display will also show if more washing liquid is needed.
When filling the tank, stop filling as the indicator is at the ‘maximum filling’ sign.

After some months or depending on the use of the machine of operating ink sludge will
accumulate in the bottom of the tank.
After some hours of standby (or after a weekend) the sludge can be emptied by using the
emptying system (see section ‘emptying the tank’ in chapter 3).
Use the same safety precaution as when handling new liquid.

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Change the filter cartridge by unscrewing the filter house using the special tool.
Remove the old filter cartridge, rinse the house, and insert a new filter.
Remember to change the sealing O-ring.
Filters should be changed on a regularly basis.
Use safety instruction when operating the machine.
Take out the tank for easy maintenance, loosen the lock bolt on the side.
To make the operation easier, loosen the clamp sealing.

Clamp seal

3. Periodically check if water is caught in the plastic bowl.

Collected water can be released by the screw on the bottom of the bowl.
Water in the system will damage air valves.

4. To avoid that the high-pressure pump is damaged, the water filter on the high-pressure
pump entrance must be checked regularly and cleaned.

Water filter

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 5. The oil level in the gear that connects the engine and high pressure pump should be
checked periodically.
The level is shown on the unscrewed bayonet plug.
Mineral oil, type SAE 30W, must be changed every 3000 operating hours.

The operator must always ensure that the sleeve adaptor is liquid tight.
The seals (pos. 1+2) must be greased to prevent it from drying out.
The adaptor seal must be replaced at any sign of wear or damage, that might cause liquid to
enter the anilox sleeve.
If liquid is entering the sleeve during wash, the operator must check the adaptor seal
and the end ring of the sleeve to determine the cause of the leakage.

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6. Display
Home screen

Press to view and edit recipes.

(Button 1) PIN: 2000

Press to view alarms.

(Button 2) PIN: no pin

Press to view service.

(Button 3) PIN: 2500
Call FlexoWash for assistance

Press to view configuration.

(Button 4) PIN: XXXX
Call FlexoWash for assistance

Emergency stop

Start button.

Open lid:
Starts manual rotation.
Closed lid:
Starts the machine.

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Access Cleanlink

Cleanlink shows: Machine status, Total washes, Washes left before service, Active alarms,
Washes left before service, Cleaning history, Alarm history.
Provides online access to this manual and the sparepart manual.

Use the machine serie number and pin code to access the machine on the Web
https://cleanlink.flexowash.com/ or get the app in google play or app store.

Insert
serial number
and pin

Web portal

App

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6.1 Recipes

From the Home screen, push the ‘Recipes’ button. Following image will appear.

Information
only.
Locked with
configuration
PIN.

Up

Down
Return to Confirm
the previ-
ous screen

If you want to change recipe:

There are 10 selectable (and changeable) recipes in total.

• Highlight (using up/down) the ‘recipe selected’ line, then press ‘confirm’.
• Select the desired recipe (using up/down), then press ‘confirm’.
• You return to the recipe main page.

Confirm Confirm
Select + -

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If you want to edit recipe:
First you need to choose the recipe, that you want to edit. Activate the recipe in question by
following the previous instructions.

• Highlight (using up/down) the ‘edit recipe’ line, then press ‘confirm’.
• Select the desired item to change (using up/down), then press ‘confirm’.
• Enter PIN 2000, then press ‘confirm’.
• Change the value (using up/down), then press ‘confirm’.

Confirm Confirm
Select

Confirm

+ -

Confirm

+ -
Next digit

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If you want to change the tank 1 temperature:
The temperature setpoint in tank 1 is used for all recipes, this is a factory setting protected by
configuration PIN code.

• Highlight (using up/down) the ‘Tank 1 temperature’ line, then press ‘confirm’
• Select the desired temperature (using up/down), then press ‘confirm’.
• Enter PIN 2000, then press ‘confirm’.
• Change the value (using up/down), then press ‘confirm’.

Confirm
Select

Confirm Confirm
+ -
+ -
Next digit

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6.2 Alarms

Any alarms or fault modes will appear on the Home screen, as shown below:

Push the ‘Alarms’ button . Following image will appear.

• Check and react on all alarms.

• When all faults are handled, highlight (using up/down) the ‘Clear all alarms’ line,
then press ‘confirm’.
• The screen turns blue, then press ‘return’.

Up

Down
Confirm
Return to
the previ-
ous screen
Release emergency
stop, and press
confirm.

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6.3 Alarm overview

Alarm No. Alarm log text Alarm description

A901 Emergency stop Emergency stop or emergency circuit not ok

A902 Filter alarm - Manual Filter has to be cleaned
A903 Filter alarm - Auto Filter has to be cleaned
A904 Slide alarm End sensors not activated in a given time
A905 Valve alarm - Tank 1 Valve is in wrong position
A906 Valve alarm - Tank 2 Valve is in wrong position
A907 Valve alarm - Out Valve is in wrong position
A908 Min. level - Tank 1 Minimum level - Tank 1
A909 Min. temperature - Tank 1 Minimum temperature - Tank 1
A910 Max. level - Tank 1 Maximum level - Tank 1
A911 Max. temperature - Tank 1 Maximum temperature - Tank 1
A912 Min. level - Tank 2 Minimum level - Tank 2
A913 Min. temperature - Tank 2 Minimum temperature - Tank 2
A914 Max. level - Tank 2 Maximum level - Tank 2
A915 Max. temperature - Tank 2 Maximum temperature - Tank 2
A916 Phase sequence Phase sequence incorrect
A917 Air pressure Air supply pressure is too low
A918 Water pressure Water supply pressure is too low
A919 Max. level auxiliary 1 Auxiliary equipment 1 alarm
A920 Max. level auxiliary 2 Auxiliary equipment 2 alarm
A921 Overload rotation motor Motor for rotation consumes too much current
A922 Overload slide motor Motor for slide consumes too much current
A923 Lid alarm Lid open in operation mode
A924 Two hand operation Indication for incorrect use of two hand control
A925 Sensor fault Both sensors registered the spray arm
A926 Heat up alarm - Tank 1 Set temp. in tank not reached after two hours
A927 Heat up alarm - Tank 2 Set temp. in tank not reached after two hours

A928 Service alarm Service machine

A929 Below OK level - Tank 1 Level sensor is below OK level
A930 Below OK level - Tank 2 Level sensor is below OK level
A931 Autofill alarm - Tank 1 OK level has not been reached in a given time
A932 Autofill alarm - Tank 2 OK level has not been reached in a given time
A933 Max. level auxiliary Auxiliary equipment alarm

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 Alarm No. Assistance
A901 Clear alarm to operate machine
A902 Replace filter
A903 Replace filter
A904 Check coupling and sensor bracket for slide
A905 Check if valve is stuck or air supply
A906 Check if valve is stuck or air supply
A907 Check if valve is stuck or air supply
A908 Add cleaner to tank 1
A909 Check fuse and electrical supply (Heating)
A910 Check drain position or auto fill function. To continue please remove excessive liquid
from tank 1.
A911 Check relay and electrical supply (Heating)
A912 Add cleaner to tank 2
A913 Check fuse and electrical supply (Heating)
A914 Check drain position or auto fill function. To continue please remove excessive liquid
from tank 2.
A915 Check relay and electrical supply (Heating)
A916 Please change the sequence of phases connected to the machine
A917 Please connect compressed air to the machine
A918 Please connect water supply to the machine
A919 Please check auxiliary equipment for high liquid level etc.
A920 Please check auxiliary equipment for high liquid level etc.
A921 Please check gear wheels in washroom and position of objects placed in washroom. If
heavy objects are placed on rotation gears - increase ramp for rotation acceleration.
A922 Please check that the slide is not stuck on objects in the washroom
A923 Close the lid to continue
A924 Release buttons and push both simultaneously
A925 Check for defective sensor
A926 Check heating element
A927 Check heating element
A928 Contact FlexoWash for service
A929 Add cleaner to tank 1
A930 Add cleaner to tank 2
A931 Check filling pump
A932 Check filling pump
A933 Please check auxiliary equipment for high liquid level etc.

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6.4 Service

From the Home screen, push the ‘Service’ button. Following image will appear.

The machine
Amount of serial num-
total wash ber
hours

Amount of
total wash
hours since
service re-
Wash hours
set
left before
service is
needed

Wash
hours left
Up Down before filter
change
Return to
the previ- Confirm
ous screen

• Navigate using up/down. The missing text will scroll from right to left when
highlighted.
• Return to the previous screen by pressing ‘return’.
• Below the four information numbers, there is following items:

- Fill tank 1.
- Check outputs (Service PIN 2500)
- Check inputs (Service PIN 2500)
- Reset ‘Wash hours left before service’ (Service PIN 2500)
- Reset ‘Wash hours left before filter change’ (Service PIN 2500)

The above-mentioned options are described in the following section.

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Fill tank 1
• Visual level indicator to aid when filling the tank.
• Press double arrow button open/close drain (OPTIONAL)

Return to the
previous
screen

Check outputs
Manual operation of all outputs, mainly for service purposes, contact Flexowash for
configuration PIN. Several options listed may not be relevant to your specific machine.

All outputs can be turned ON and OFF individually using the service PIN. The pump for the tank
requires certain outputs to be active to turn on, e.g., ‘Tank 1 drain’ must be ON.

Check inputs
List of inputs with status, mainly for service purposes. Several options listed may not be rele-
vant to your specific machine.

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Reset service DD.MM.YY (date of last reset) (PIN protected)
When “Washes left before service” reaches 0, the machine must undergo service. Once service
has been completed, the service counter must be reset. Contact Flexowash for service.

Reset filter DD.MM.YY (date of last reset) (PIN protected)

When “Washes left before change of filter” reaches 0, the machine must undergo service.
Once service has been completed, the service counter must be reset. Contact Flexowash for
service.

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7. Options and special solutions
High pressure reduction system

High pressure reduction system enables the option to changes the High presure(Bar) used to
clean the rolls, directly from the touch screen.

The standard setting is 120 bar on the normal valve and 90 bar on the reduction valve.
The pressure can be changed by turning the valves.
Reduction
Front Back Valve

Normal
Valve
Reduction touch screen
If “HP reduction” is turn on the machine uses the reduction valve presure.

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Semi-automatic filling system

Semi-automatic filling system can be used to automatically fill the liquid tank.

Connect the tank to an extern liquid tank .

Connect to
liquid tank

• From the Home screen, push the Service’ button.

Enter PIN 2500, then press ‘confirm’.
• Then select “Fill tank 1” here the Semi automatic filling buttom is enabled

When the
display
shows ” ok”
The tank is
full

Push to
fill

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8. Troubleshooting
A: The machine does not start

1) Check power supply/main switch.

2) Check if air is connected.

3) Is the compressor started?

4) Min. pressure 7 BAR.

5) Is the emergency stop button released (turned to the right position)?

6) Have you closed the lid and activated the lid-sensor?

7) Make sure that traverse slide is in start position.

8) Check fuses in electrical box (see electrical drawing).

9) Display of error message, liquid, emergency stop and slide alarm.

B: The cleaning liquid does not return to the tank

1) Make sure the machine is in level.

2) Is the air pressure correct, 7 BAR?

3) Is the drain time 3-4 minutes?

4) Is the outlet drain valve or hose blocked?

5) Adjust the damper on ventilation.

C: The cleaning liquid disappears from the tank

1) Is the valve for emptying the tank closed?

2) Is the air pressure correct?

3) Is the machine in level?

4) Is the drain time long enough, 3-4 minutes?

5) Is the indicator on the three-way valve, the actuator, in the correct position?

6) Adjust the damper down on ventilation.

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D: Liquid level is rising in the tank

1) Does water come through drain hose during after rinse? If not check the position
of the 3-way valve during after rinse.

E: The high-pressure pump does not run

1) Have you switched on the electricity?

F: The high-pressure pump does not work / Insufficient water pressure

1) Check water connection and supply.

2) Clean the inlet filter at the high-pressure pump.

3) Water leakage on the high-pressure side (hose, spray bar etc.).

4) Is the water supply correct?

5) Check if HP nozzle is blocked.

6) Motor break on, pump is off.

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G: The pump does not draw liquid

1) Does the pump run?

2) Check the level of cleaning liquid.

3) Check the air pressure.

4) Check O-ring at the filter house.

5) Is the filter blocked?

6) Have you tightened the filter house?

7) Has the pump run dry?

H: The liquid is not heated

1) Is the heating element turned on?

2) Check overheating fuse (black button) in heating element box.

3) Check power supply for heater.

4) Check fuses.

5) Check display for Heater alarm.

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9. Recipe structure

Yellow = Option

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10. Declaration of Conformity

DECLARATION OF CONFORMITY
Manufacturer:
FLEXO WASH ApS
Langs Skoven 38
8541 Skødstrup
DENMARK

Herewith declare that:

The machine:

An industrial washing machine for cleaning

mainly large-scale printing equipment. Is
produced in accordance with the following
directives and applicable standards:

Directives:
2006/42/EC Machine directive
2014/35/EU Low Voltage directive
2014/30/EU EMC directive

Set CE label here Applicable standards:

EN ISO 12100:2011
EN 60204-1:2018
EN ISO 13851:2019

Date:

Information of signatory: Anders Kongstad – Technical Director

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 READ BEFORE UNPACKING
Unpacking of FW .NXT washing machine and parts

The FW washing machine is delivered in a wooden crate for shipment.

To avoid damaging the equipment, please follow these instructions during unpacking the
machine.

1. Unscrew and remove the lid. 2. Loosen the screws that secure the sides.

3. Pull the sides away from the machine. 4. Remove the restraining blocks of wood
and packing.

5. The machine is now ready to lift from the 6. The machine must only be lifted from
pallet and put into place. underneath.

Be aware of any loose parts in the crate!

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 Service interval
FW Micro Machines

Check points Weekly Monthly ½ Yearly Yearly

Check/change wash and rinse filter X

Check/change nozzles X

Change the cleaning liquid X

Clean water filter for the high-pressure

X
pump
Empty and clean the filter regulator
X
and empty water separator

Check oil level in HP pump X

Change v - rings (rotary shaft seals) X

Check wear on gears for rollers X

Change hoses inside the wash area X

Empty and clean the tanks X

Complete service check X

Check adaptor seal X

This is our recommended service intervals.

The actual need of changing parts or the liquid varies from customer to customer due to differ-
ent operation requirements such as hours of operation and the variation of ink levels/types on
parts.
We recommend you check above points to make sure your machine always is in a good condi-
tion. Especially the cleaning liquid and filters should be changed regularly to maintain a good
cleaning result and to reduce downtime.

Spare parts
If you need any spare parts or technical service, please contact us on mail:
[email protected] or phone +45 86993631
USA area: e-mail: [email protected] or phone: 001 888 493 5396

Consumables
If you need consumables (liquid or filters) or maintenance packs for your
Flexo Wash machine, please contact:
[email protected] or on phone: +45 86993631.

Flexo Wash ApS . Langs Skoven 38 . 8541 Skødstrup . Denmark . T: +45 86 99 36 31 . F: +45 86 99 13 43 . [email protected]
www.flexowash.com
V 3.1 April 2021