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1. USER MANUAL InterPlater 66 88 InterPlater 66 88 Edition September 1996 G J No 21850 GB A GB GENERAL INFORMATION This manual is published by Glunz amp Jensen A S 13 15 Haslevvej DK 4100 Ringsted Denmark Phone 4557 68 81 81 Fax 45 57 68 83 40 Telex 45135 gj dk Copyright O 1995 by Glunz amp Jensen A S The manual was written and illustrated using the best possible information available at the time of publication Any differences between the manual and the equipment reflect improvements introduced after the publication of the manual Changes technical inaccuracies and typographic errors will be corrected in subsequent editions IMPORTANT e Intended use of equipment Development of positive and negative offset plates e Installation service and repair must be performed only by authorized personnel trained to carry out plumb ing and electrical installations e tis the responsibility of the owner and operator s of this machine that the installation is made in accor dance with local regulations The manufacturer cannot be held responsible for any damage caused by incorrect installation service or repair of this machine e Observe technical data from the nameplate located on the backside left underneath the exit table e The noise emmision of the equipment is below 70 dB A 2 34 9539 GB NOTES Throughout the manual notes are written in bold on a grey background like the
2. example below NOTE Charcoal filter must be washed prior to use Explanation The operator should observe and or act according to the information in order to obtain the best possible function of the equipment 9539 3 34 GB Table of Contents LER RR NM RUE UR EUR RN UR E ku ER SW NN DEM ER S Page INTRODUCTION 7 34 SAFETY INSTRUCTIONS 8 34 GENERAL 8 34 ELECTRICAE 2293 924 cee kuyka PERS k 666 8 34 MECHANICAL donadas aaa a cn 8 34 Samuel LR copar rodadas sa oes A AA 8 34 ENVIRONMENTAL PROTECTION 9 34 DISPOSAL OF 5 9 34 GENERAL ABOUT PLATE PROCESSORS 11 34 THE CONTROL PANEL 12 34 13 34 2 242422 020425 eas 13 34 SEP BO DONA Z Z A s k UR sosa a 13 34 SELECTION BUTTONS 4 amp 5 14 34 GUM RINSE BUTTON 6 2 an Ow DER ea 14 34 REWASH 15 34 8 15 34 DIGITAL DISPLAY 9 au amp ow a en ee a 16 34 PLATE SPEED T0 s z 20 2 lt MEE a w W a Q oe Q 3 S sa 16 34 BRUSH SPEED Tl dom S s x 20 S w a ken ee Pees GE eee S 16 34 DEVELOPER 2 16 34 DRYER TEMPERATURE T3 4 4 4 u 0 wa u u och a we OE x Xx 16 34 D
3. is being emptied After 1 min the processor automatically switches to OFF mode NOTE If GUM RINSE program is not executed according to description above you may get problems with water entering the gum system O 12 D 15 16 Q D D 27 14 34 9539 GB REWASH BUTTON 7 To start the REWASH function press this button The built in lamp flashes for 2 secs and is then lit constantly The wash gum and dryer functions start while the replenishment system remains deactivated If the plate has not been entered for rewashing within 15 seconds after the REWASH button has been pushed the WAIT lamp will be lit indicating that the HEWASH button must be pushed again before the plate is inserted The duration of the rewash process depends of the speed When the rewashing is finished the processor returns to STAND BY mode and the REWASH and WAIT lamps turn off NOTE The REWASH button must be pressed once for each plate that is entered for rewashing and regumming This Is to reset the timer function To exit the REWASH program manually push the HEWASH button for 2 secs until the built in lamp turns off The processor stops and returns to STAND BY mode REPLENISHMENT BUTTON 8 If low level is detected in the developer section WAIT lamp 16 and LOW LEVEL lamp 18 lit refill the bath by pressing this button to activate the developer replenishmen
4. the starting pages of this manual before attempting any of these procedures NOTE Be sure to disconnect electrical power before performing any cleaning or maintenance 28 34 When using water for cleaning purposes use warm water 35 40 95 104 F NOTE Do not cover the machine with a cloth or piece of plastic to protect it from dust as this prevents free circulation around the machine and can lead to condensation and overheating NOTE Never use hard tools or abrasive materials when cleaning guides and rollers 9539 GB BEARING BLOCKS All bearing blocks are fabricated with coarse chamfers in one end When a bearing has been rermoved from the processor for cleaning etc it is very important for the correct function of the machine that this end is mounted downwards in the tank CLEANING OF THE WATER FILTER Close the external water supply valve Locate the water valve under the machine Disconnect the water supply hose from the valve by unscrewing the union nut and remove the water filter with a pair of pliers Clean the filter and reinstall it 9539 29 34 GB CLEANING OF THE GUM GRATE The processor is equipped with a special grate in the drain opening of the gum section The grate is designed to prevent the gum solenoid valve from being blocked if something mistakenly drops into the opening The grate should be taken out regularly and cleaned Remember to reinstall after cleaning CLEA
5. 539 26 34 GB SHUT DOWN PROCEDURE See illustration opposite Run the GUM RINSE program see description earlier in this manual NOTE The processor should only be shut down Close the external water supply valve M completely for holidays or for maintanance and To shut down the machine completely turn the main servicing purposes switch J to OFF NOTE When shutting the machine down without running the GUM RINSE program always first push the OFF button on the control panel 9539 27 34 GB CLEANING AND MAINTENANCE GENERAL Performing cleaning and maintenance regularly reduces the chances of equipment failure and the loss of processing quality Only one person should be responsible for performing the preventive maintenance program That person should be familiar with the equipment as well as its operational characteristics and maintenance requirements A periodic major clean up of the equipment is essential to the maintenance of processing quality and the reliability of the machine This clean up should be performed either monthly or after processing approx 1000m2 of plate The major clean up procedure can be performed in two to four hours depending on the condition of the machine and on the proficiency of the person cleaning it NOTE Personnel performing any maintenance cleaning or servicing must familiarize themselves with the safety instructions and environmental protection described on
6. EVELOPER REPLENISHMENT RATE 14 17 34 COUNTER lo een 17 34 WAL 16 s 4 z w s lt k Q kU k Qa a R aQ Q h a W 0 kan 17 34 I7 s am eee QU E amp ju 3 QUN 18 34 EOW LEVEE T8 2 Z Z 2 s lt EUR NQ Q S S RUSO gt N 18 34 DEV TEMP OUT OF RANGE I9 x 18 34 4 34 9539 GB Table of Contents SWITCHES AND SENSORS INTERLOCK SWITCH INPUT SENSOR MAIN SWITCH OPERATING MODES ORE MODE STAND BY MODE PROCES MODE 4 24 32 4246s oe ea eee oes V PIE S Ps REWASH GUM RINSE MODE DAILY START UP PROCESSING FROM THE FEED TABLE USING THE REWASH SLOT RUNNING THE GUM RINSE PROGRAM SHUT DOWN PROCEDURE CLEANING AND MAINTENANCE GENERAL sa cece E E ERE ER EE E EE S BEARING BLOCKS 2 CLEANING OF THE WATER FILTER CLEANING OF THE GUM GRATE CLEANING OF DEVELOPER FILTER DAILY CLEANING WEEKLY MONTHLY CLEANING CHECK OF DEVELOPER REPLENISHMENT 9539 5 34 GB 6 34 9539 GB INTRODUCTION The OPERATING INSTRUCTIONS con
7. G See illustration opposite Remove all guides and wash them in warm water Remove the wash section spray tubes M Flush them with warm water If algae buildup is visible clean the tubes with a longhandled bottle brush Remove all worm gears and bearings and inspect for excessive wear Replace worn or damaged parts Clean the components of any residual chemistry Lubricate the bearings Clean the developer tank H the wash tank J and the gum tank K thoroughly with warm water and a soft cloth Do not use ordinary household detergent or abrasive materials to clean the tanks When needed use a good tank cleaner in the developer section Be very careful to get all the cleaner out of the developer section after cleaning Remove the rollers from the dryer section L and rinse them in warm water Wipe the teflon coated rollers with a moist cloth Reinstall all parts after cleaning 33 34 GB CHECK OF DEVELOPER REPLENISHMENT The developer can either be checked with a control strip ask your local dealer of chemicals or you can use a well exposed and well processed plate as reference If the density of your plate decreases after a week s work the replenishment is probably too low and a higher setting of the REPLENISHMENT RATE should be selected However if the density is good the replenishment is sufficient A lower setting can then be tried until it is established which setting is enough for satisfactory replenish
8. NING OF DEVELOPER FILTER Clean the filter regularly as described below Close the two valves A one on each side of the filter housing B Open the drain valve C to empty the filter vessel D of chemicals Unscrew the filter vessel D carefully Take the filter element E out and clean it or change it whatever is necessary Install the filter element again The O ring F must be properly fitted in the groove in the filter vessel D Hemember to open the valves A again If the filter is fitted with an airbleeding screw an allen screw in the top of the filter housing B this should be opened momentarily to allow trapped air to escape 30 34 9539 GB 9539 31 34 GB DAILY CLEANING See illustration opposite Wipe the feed table C and the exit table N with a moist cloth Do not use abrasive materials on the processor Remove and clean the developer oxidation cover A Check the level in the developer replenishment tank F and gum container G and refill if needed Empty the container for waste chemicals E Run the gum rinse program at the end of the day Start the program by pressing the GUM RINSE button on the Control Panel WEEKLY CLEANING See illustration opposite Hemove all rollers and clean them in warm water Remove the developer spray tube B from the processor and wash it in warm water Clean the holes in the spray tube and reinstall 9539 MONTHLY CLEANIN
9. T button 8 The circulation pump and the heating element automatically switch off until the correct level has been reestablished NOTE If the developer bath is empty and has to be filled do this from a suitable container as It Is quite time consuming to fill the tank by using the replenishment pump DEV TEMP OUT OF RANGE 19 This indicator lamp is lit if the temperature in the developer bath is out of range out of range means that the actual temperature in the bath is ex 2 C higher or lower than the preset value na 40 12 D 15 D Q D D 27 18 34 9539 GB SWITCHES AND SENSORS INTERLOCK SWITCH The interlock switch 1 is mounted in the right side of the tank see illustration and is activated by the weight of the topcover When the topcover is lifted off e g for servicing the switch turns the machine off INPUT SENSOR Entering a plate activate s the mechanical input sensor s 2 built into the feed table at the processor entrance see illustration The input sensor s start s the processor and the WAIT indicator on the Control Panel is lit The counter function counts every activation of the input sensor s and makes it possible to check the number of jobs processed in the machine MAIN SWITCH All power to the machine is switched off when the main switch 3 is set to position OFF or if the built in thermal overload switch cuts out The switch is
10. e exposed To maintain a good performance and processing plate into a fully developed and dry plate ready for quality it is necessary to renew the developer at handling intervals depending on the type of material you are processing The plate material is fed into the machine from the feed table 5 At this stage the machine normally is in Also the temperature of the developer and the STAND BY mode but activating the input sensor s transport speed of the material has a great influence makes the machine start up in PROCES mode on the processing result The different modes are described later in this manual 9539 11 34 GB THE CONTROL PANEL The operation of the processor is controlled from the The Control Panel holds buttons and indicator lamps Control Panel built into the left side of the feed table for all the main processor functions buttons for setting of the various speeds and temperatures of the system and a display showing the set values The functions of the Control Panel lamps and buttons are described on the next pages 12 34 9539 GB ON BUTTON 1 Lamp built in Switches the processor from OFF mode into STAND BY mode provided that the main switch underneath the feed table is switched ON When the processor is on the built in lamp is lit OFF BUTTON 2 Lamp built in This button switches the machine from STAND BY mode into OFF mode When the processor is off on
11. each plate that is entered for rewashing and regumming This is to reset the NOTE The plate must be entered into the timer function rewash slot within 15 seconds after the REWASH button has been pushed Otherwise To exit the REWASH program manually push the the WAIT lamp 16 will be lit indicating that REWASH button for 2 secs until the built in lamp the REWASH button must be pushed again turns off The processor stops and returns to before the plate is inserted STAND BY mode Insert the plate into the REWASH slot C with the emulsion side upwards until it engages the drive system RUNNING THE GUM RINSE PROGRAM See illustration opposite When the rinsing part of the program is finished the ON lamp 1 turns off and the OFF lamp 2 starts The processor must be in STAND BY mode to flash indicating that the gum section is being Press the button for the automatic gum rinse emptied program 6 and hold it for 3 secs After 1 min the processor automatically switches to The GUM RINSE program will start the OFF mode GUM RINSE lamp 17 and the WAIT lamp 16 Will start to flash asynchronously WAIT lamp is on when the GUM RINSE lamp is off and opposite The rest of the display is off except for the ON lamp 1 To skip the GUM RINSE program before time out push the OFF button 2 9539 25 34 GB O v N o N 00 9
12. erature is established in the developer tank When the WAIT indicator turns off the processor is ready for use PROCESSING FROM THE FEED TABLE See illustration opposite Always feed plate material from the left side of the feed table with the emulsion side upwards using the plate feed guide E on the table Feed the plate slowly into the processor until it engages the entrance rollers The input sensor s D switch es the processor into PROCES mode and the machine starts up with the preset speed and temperature values 9539 Verify that the WAIT indicator 16 is lit indicating that a plate is being fed into the machine The WAIT indicator turns off shortly after the plate has left the input sensor s A new plate can then be inserted The machine returns to STAND BY mode shortly after the plate has left the dryer section 23 34 GB O N o o N 00 9539 24 34 GB USING THE REWASH SLOT See illustration opposite The duration of the rewash proces depends of the speed When the rewashing is finished the processor The processor must be in STAND BY mode returns to STAND BY mode and the REWASH Press the REWASH button 7 The built in lamp will lamp turns off flash for 2 secs and then light up constantly The wash gum and dryer functions start while the NOTE The REWASH button 7 must be replenishment system remains deactivated pressed once for
13. g fixtures Provide adequate ventilation avoid prolonged breathing of solution vapours Avoid splashing and spilling Wipe up spills immediately 9539 GB ENVIRONMENTAL PROTECTION DISPOSAL OF CHEMICALS Most chemicals used in plate processors are strong pollutants and do not belong in the public sewer system Therefore chemicals must be led to waste containers in order to protect the environment Many countries have strong regulations on this subject and disposal of containers with waste chemicals must be made according to these regulations Refer to local authorities for information regarding disposal of waste chemicals Contact your supplier of chemicals if you need more information about safety and disposal DO NOT LEAD CHEMICALS DOWN THE DRAIN 9539 9 34 GB 10 34 9539 GB GENERAL ABOUT PLATE PROCESSORS The new range of plate processors are designed to When the plate is fed into the processor the provide rapid processing of singlesided negative or transport roller system takes over and leads it safely positive offset plates and smoothly through each of the four sections Shortly after the plate material has left the machine In principle all processors are designed with 4 major and has landed on the exit table 6 the machine sections see illustration below DEVELOPER 1 returns to STAND BY mode WASH 2 GUM 3 and DRYER 4 Each section performs a basic function to change th
14. located to the right underneath the feed table see illustration 9539 19 34 GB SIART or Timeout GUM RINSE ON button button timer on OFF button timer off Timeout STAND BY Input sensor REWASH button Timeout REWASH button 2 sec T 2207 20 34 9539 GB OPERATING MODES The processor can be in one of 5 different modes see illustration opposite OFF mode STAND BY mode REWASH mode PROCES mode and GUM RINSE mode When the main switch is switched on the processor is automatically in OFF mode OFF MODE All pumps motors and temperature controls are off Control panel display is off except for the lamp in the OFF button If value in parameter 04 Operation mode is set to 1 test the testprogram is active 4STAND BY MODE Pushing the button switches the processor into STAND BY mode Developer temperature control is on display is on and all processing parameters are adjustable The lamp in the ON button is lit The anticrystalisation program parameter 7 can be switched on off on the processorboard 9539 PROCES MODE Activating an inputsensor with a plate makes the processor switch from STAND BY mode into PROCES mode see also description in PROCESSING FROM THE FEED TABLE The processor now executes a developing program While the program runs the display is on and the processing parameters are adjus
15. ly the built in lamp is lit SET BUTTON 3 The SET button makes it possible to change the value in one of the processing parameters The lamp for the selected processing parameter 10 15 is lit Use the selection buttons 4 and 5 to select the processing parameter in which the value has to be changed Push the SET button and the selected processing parameter lamp 10 15 will start to flash Adjust the value using the selection buttons 4 amp 5 and push the SET button again to confirm the new setting 10 12 D 15 16 Q D 27 9539 13 34 GB SELECTION BUTTONS 4 amp 5 Use the selection buttons to select the processor parameter to be displayed or changed The lamp for the selected processing parameter 10 15 will light up When changing a value in a processing parameter use the buttons to increase or decrease the value See also description for SET button 3 GUM RINSE BUTTON 6 Push the button and hold it for 3 secs The GUM RINSE program will start the GUM RINSE lamp 17 and the WAIT lamp 16 will start to flash asynchronously which means that the WAIT lamp is on when the GUM RINSE lamp is off and opposite The rest of the display is off except for the ON lamp 1 When the rinsing part of the program is finished the ON lamp 1 turns off and the OFF lamp 2 starts to flash indicating that the gum section
16. ment 34 34 9539
17. set plate width in cm inch Use this function in conjunction with the PAR 32 to obtain the best and necessary replenishment If necessary the values should be readjusted once the correct amount of replenishment for a certain plate developer combination has been found COUNTER 15 The counter function makes it possible to check the number of jobs processed in the machine as it counts every activation of the input sensor s The SET button 3 resets the counter but only when the counter function has been selected using the Selection buttons 4 amp 5 indicator lamp lit Use the value in PAR 05 to select the display factor for the counter WAIT 16 This indicator is lit constantly if any of the following situations occur Low level in developer section Developer temperature out of range Plate feed sensor s activated and it flashes asynchronously with GUM RINSE lamp 17 when GUM RINSE program runs na 10 12 D 15 16 Q D 27 9539 17 34 GB GUM RINSE 17 This indicator flashes asynchronously with WAIT lamp 16 when GUM RINSE program runs on LOW LEVEL 18 If low level is detected in the developer bath this lamp is lit lf automatic replenishment has been selected the replenishment pump automatically starts to reestablish the correct level Otherwise top up to correct level manually by pressing the REPLENISHMEN
18. t pump The built in lamp is lit while the replenishment pump runs either when pressing this button and or when controlled by the automatic replenishment system NOTE If the developer bath is empty it should be filled from suitable containers as it is quite time consuming to fill it by using the pump 10 12 D 15 16 Q D 27 9539 15 34 GB DIGITAL DISPLAY 9 The display shows the values for the different functions During proces the display will always show the default processing parameter The default processing parameter is selected in parameter 3 If another function has been selected the display returns to show the default processing parameter shortly after PLATE SPEED 10 Indicator for plate speed function When selected the displays shows the set plate speed in cm min inch min BRUSH SPEED 11 Indicator for brush speed function When selected the displays shows the set brush speed in rpm DEVELOPER TEMPERATURE 12 Indicator for developer temperature function When selected the displays shows the set developer temperature in F DRYER TEMPERATURE 13 Indicator for dryer temperature function When selected the displays shows the set dryer temperature in F 40 12 D 15 16 Q D D 27 16 34 9539 GB DEVELOPER REPLENISHMENT RATE 14 Indicator for developer replenishment function When selected the displays shows the
19. table The processor automatically returns to STAND BY mode shortly after the plate exits REWASH MODE Pushing the REWASH button on the control panel switches the processor into REWASH mode Within the next 15 secs the operator must insert the plate into the REWASH slot see also description in USING THE REWASH SLOT The processor returns to STAND BY mode either automatically timeout or if REWASH button is pushed for 2 secs GUM RINSE MODE See also description in RUNNING THE GUM RINSE PROGRAM Push the GUM RINSE button to start the GUM RINSE program During the program the control panel can not be used except for the OFF button When the GUM RINSE program is finished the processor automatically switches to OFF mode 21 34 GB O N c o N 0 9539 22 34 GB DAILY START UP See illustration opposite Check that the developer replenishment container H and the gum container L are sufficiently filled and that the container for waste chemicals G is empty Open the external water supply valve M Turn the main switch J to ON Underneath the feed table Press the ON button 1 and verify that the built in lamp is lit The processor is now in STAND BY mode with the rollers idling Make the appropriate adjustments on the Control Panel The WAIT indicator 16 will be lit until the correct level and temp
20. tains the The OPERATING INSTRUCTIONS is available in an information that is necessary for the daily user to English German French Spanish Italian Greek operate clean and maintain the equipment Dutch Finnish Portuguese and Danish version NOTE Always keep the OPERATING INSTRUCTIONS together with the machine 9539 7 34 GB SAFETY INSTRUCTIONS Personnel operating and maintaining the machine must be familiar with all aspects of its operation and be proficient in maintenance Such personnel should review the following precautions to promote safety awareness GENERAL Wear safety glasses and gloves when maintaining or servicing the equipment Do not wear a necktie jewelry or loose fitting clothing while operating the machine ELECTRICAL All electrical matters must be dealt with by qualified service technicians 8 34 MECHANICAL Keep hands fingers and tools clear of moving parts Install all panels and covers after servicing CHEMICAL Always refer to first aid recommendations provided by the chemical manufacturer Wear eye protection and special clothing such as an apron and gloves when handling chemicals In case of chemical contact with eyes or skin immediately flush affected area with plenty of fresh water for 15 minutes Wash affected clothing In case of ingestion contact a physician immediately Do not mix chemicals Shut off water supply and reduce system pressure before disconnecting plumbin
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