InterPlater 85/135 HD Service Manual
Contents
1. 4 11 Adjustment method 4 11 Adjustment of gears for wash brush 4 13 4 13 Procedure of lt 4 13 Replacement of bearing 4 13 Preventive Maintenance Kit Program 4 15 Part 5 Trouble shooting 5 1 5 1 Before starting trouble shooting 5 2 cote ee eck 5 2 Problems with the processor 5 2 Problems with processed material 5 4 Appendix 1 Electrical Al Main power A 2 Fuse panel and 5 A 2 Motors and internal A 4 24V DC distribution 5 n oana 4 Fab VIE 23254425592 6 230V control 6 LOW voltage d ssa rrei eenid 8 Sensors and control 8 1244 Service Manual Plate Processors 68 85 co General information Manuals2. Old punoly 17864001 njg uMOJg 2 lt 29864001 our umy 04864001 njg LZS 5 N ME 99141 peu peu SUM SHUM Old punoly suenen uo Aquo asn 125 5 Id N ML 10 MZ A0 z Z 901 Z E 901 SUN Z eun mn Ta Oa mi x 02864001 5 2 Tem i 11829001 peu peu UM enig Old punoly enig 126 5 ME A0 Z yL 21 1 3d 71 c1 1 3d v Motors in
3. 1 1 The processor does 1 1 14 21 0 64 072 4 M 6 a6 4 44 0 59 04 Ge 1 1 Batteries ouaaa 1 1 ENCORE 1 1 icon o Q 1 1 ws ccu TPF v 1 1 EMISSION suu as e bonuses ee 1 1 Chemical 5 1 2 CWSslOW 55425 a eee eee Cee eee ee oe eee eos 1 2 Mechanical specifications 1 2 1 2 TANK GCODACWNeS 2 444506 6 1 2 Noise emission lt 1 3 1 3 Water requirements 1 3 Water CONSUIMPUON i a e a a s me i dance Gk Gade week eed ae edb 1 3 lig possessore sais 4 89 40 eee eee ewe 1 3 DIMENSIONS 2a vee steed P Oo eee Bee ee ee pees eae 1 4 Electrical specificati nS se aoc a n oum ORO iena 1 5 ew 1 5 Voltage tolerances l 5 Power consumption 1 5 NOISE level aio lecita 1 6 Service Manual Plate Processors 68 85 1244 Part 2 2 1 1244 SCUO
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7. Performance 68 85 Plate types polymer offset plates Plate width 200 675 mm 200 850 mm min max 7 9 26 6 7 9 33 5 Plate length 274 1100 mm 2 4 1100 mm min max 10 8 43 3 10 8 43 3 Plate thickness 0 15 0 30 mm 0 15 0 30 mm min max 0 006 0 012 0 006 0 012 Plate speed 40 140 cm min 15 7 55 1 min 40 140 cm min 15 7 55 1 min Brush speed at 50 Hz 60 150 rpm at 60 Hz Tank capacities 68 85 Prewash 10 5 13 9 2 8 US gal 3 5 US gal Developer total 17 01 22 01 filter pumps etc 4 5 US gal 5 8 US gal Wash 11 01 15 54 ex filter pumps etc 2 9 US gal 3 6 US gal Service Manual Plate Processors 68 85 1244 Noise emission Technical specifications Mechanical specifications 68 85 Noise emission max 63 5dB Temperatures 68 85 Developer 20 40 C min max 68 104 F Dryer process 350 0270 95 131 F Pre heat 70 145 C min max 158 293 F Water requirements 68 85 Pressure gt 2 bar 29 psi Water consumption 68 85 Operation 28 l min 32 l min if no wash recirculation 7 4 US gal min 8 4 US gal min Stand by if no wash recirculation 0 0 l min 0 0 US gal min 0 0 l min 0 0 US gal min 1244 Weights
8. Manuals A complete set of manuals consists of the following Service manuals The manuals listed below are for service technicians only In addition the service technicians will need the manuals listed opposite as User Manuals Processor Service Manual 1 Language English Contents Installation of the processor Technical specifications Functional description Maintenance Trouble shooting Electrical diagrams Processor Spare Parts Manual 2 Language English Contents Spare parts Software Service Information 3 Language English Contents Menu structure service menus Control Panel Service Information Calibration Procedures Service Manual Plate Processors 68 85 1244 General information Manuals 0 11 User manuals User manuals available for the processor CE Declaration of Conformity 4 Language Various Contents Survey of the directives to which the products conform Safety Instruction Manual 5 Language Various Contents General Safety Information Processor User Manual 6 Language 4 Contents Operating and cleaning procedures in cartoon version Control Panel user manual 7 Contents Functional description Menu structure user available Operation and programming Alarm list Quick Guide 8 Language English Contents Survey of Control Panel User Functions Keep the manuals with the machine for reference at all times 1244 Service Manual Plate Processors 6
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10. TAP WATER K8 VALVE FLOW LIMITERS SPRAY TUBE CIRCULATION WATER WASH A WATER FO REPLENISH 7 7 K8 4 VALVE FLOW LIMITERS OVERFLOW SPRAY TUBE WASH TANK r B2 MIN SENSOR V DRAIN E A VALVE CIRC PUMP M10 DRAIN T1990 Service Manual Plate Processors 68 85 1244 Functional description General GUM APPLICATION TUBE M23 GUM CIRC PUMP Me a gt gt ce lt i ee OPTIONAL GUM CONT MIN SENSOR T1991 GUM FINISHER DRYER 52 OUTPUT SENSOR R2 DRYER TEMP SENSOR M9 NW EN HEATING ELEMENT E2 E3 T1979 1244 Service Manual Plate Processors 68 85 Functional description Transport system Transport system See illustration below The plate is transported through the processor by a series of rollers and roller guides The rollers are driven by a drive motor and a worm gear drive system The pre heat section rollers 1 transport the plate through the pre heat section The first roller pair 2 in the pre wash section leads the plate underneath the brush 3 optional and the spray tubes 4 wash the plate on both sides The roller 5 makes sure of proper contact between brush and plate The stop roller 6 ensures that water does not run back into the pre heat section The rollers 7 at the section exit squeeze any residual water off the plate The rubb
11. 2 25 Service Manual Plate Processors 68 85 mis nA 2 26 Mounting panels 2 26 Installation of setter 2 26 2 28 Software service 5 2 29 Configuration and 5 2 29 Calibration of valves and 2 29 Setter interfaces 2 29 Software 5 lt 2 29 Part 3 Functional 3 1 CONC dl C 3 1 Processor SECTIONS ye ee OP S 3 1 Replenishment anti oxidation system 3 5 3 5 Time 3 5 2554 kon doch Paco i 3 5 SVSICUY ua lt acn 3 8 mete eee 8 88 0 8 8 Ri 3 9 Master input output unit MIO 3 9 Power control unit PCU 3 9 Touch screen control panel
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13. Defective PCB Replace PCB Cables not properly Check cables and make connected proper connections MMU PCB defective MACHINE WILL NOT Replace defective part START UP MACHINE DOES NOT START WHEN A PLATE IS INSERTED NO WASH WATER Water tap closed ALTHOUGH MACHINE 5 e Water solenoid valve Input sensor s defective e Replace defective sensor Open water tap Replace valve IN PROCESS MODE defective e Water solenoid valve filter e Clean filter clogged Processor with filter Filter Open valve valve closed e Processor with level sensor Check sensors and clean Level sensor in wash dirty replace whatever is or defective necessary Electronics defective Replace defective electronics Service Manual Plate Processors 68 85 1244 Trouble shooting Problems with the processor SYMPTOM PROBABLE CAUSE REMEDY DRYER BLOWER WORK HEATER DOES NOT e Fuse s blown e Temperature sensor defective Heating element defective Electronics defective Replace fuse Replace temperature sensor Replace heating element Replace defective electronics DRYER BLOWER DOES NOT WORK Fuse s blown Blower defective Electronics defective Capacitor defective Replace fuse Replace blower Replace defective electronics Replace capacitor NO GUM ALTHOUGH MACHINE IS IN PROCESS MODE Gum container empty Gum hose blocked P
14. Lower side panels left right Top covers front rear Inner covers Covers electronics boxes Make sure covers are secured by screws Fuses Fuses for motors are placed on the motors behind the left fender Other fuses for the various functions are located in the electronics cabinet behind the upper right fender The fuses are placed on the fuse behind the cover A fuse label on the inside of the cover for the wiring box shows the position and rate of the fuses When changing a fuse first switch off all power to the machine Always ensure that the new fuse is of the correct rating according to the label The unit has double pole fusing See the table on the following page for a description of the fuses Service Manual Plate Processors 68 85 1244 Maintenance Fuses Fuse Fuse for Type Part no Fl F6 Main power supply i F8 Emergency stop 2AT 6 3 x 32 mm F10 Stacker 10057566 PCB PCU fuses Fuse Fuse for Type Part no 1AT 5 mm round F6 Dev fill up pump M11 10011284 1AT 5 mm round 10011284 1AT 5 mm round no a pamp 10011284 Motor fuses Fuse Fuse for Type Part no F17 Transport motor M1 uL ponds F18 Brush motor M2 E p n 19 Prewash brush motor ol 7 1224 Service Manual Plate Processors 68 85 Maintenance Cleaning Clea
15. Threee phase 3W PE 230 V e Connect conductors in power cord to terminals L1 1 12 2 3 3 Protective earth Ground symbol Changing from 3W N PE to 3W PE Modification on the Ground Fault Circuit Relay F10 Loosen screw in terminal 1 3 5 and N and remove all wires e Mount red and orange wire in terminal 1 Mount black and yellowwire in terminal 3 Mount blue and brown wire in terminal 5 e Add a jumper see spare part box from terminal 2 to N The unit has double pole neutral fusing during servicing Service Manual Plate Processors 68 85 MESE Q 3181 OC X 02 m 5 mim 1 3 5 N T2668 The unit is fused in the neutral conductor where after operation of the fuse parts of the equipment remain energized This might represent a hazard 1244 Installation Power supply units Power supply units The Electronics is powered by switching power supply units which incorporate universal AC input in the full voltage range from 90 to 264 V No adjustments or modifications are available on these units A LED green light emitting diode is indicating power on LED is located near the 24 Vdc output connector The output is protected by an electronic limiter which recovers automatically after fault condition is removed e The primary AC input is protected by fuse F8 rated 6 3 AT lo
16. 123 gt Configuration gt Choices Calibration of valves and pumps Pumps Refer to Calibration in Part 4 in the Software Manual Setter interfaces If the processor is installed as an online system you should now install the setter interface as described in the Interface Manual Software user settings A few adjustments of user program parameters are also needed before the installation is finished Please refer to Part 5 in the User s Guide Control Panel for information of the settings to be made before taking the processor into operation 1244 Service Manual Plate Processors 68 85 Installation Service Manual Plate Processors 68 85 1244 Functional description General Part 3 Functional description General Processor sections The processor contains six major sections each performing a basic function to change the exposed plate into a fully developed and dry plate ready for handling see illustration below 1 Pre heat Hardening of the emulsion of the exposed plate by ciculation of hot air 2 Pre wash Washing and brushing off the PVA coating from the plate 3 Developer Developing of the plate and removing of the remaining unexposed exposed emulsion d Wash Washing off the developer chemicals from the developed plate Application of a thin layer of gum onto the developed and washed plate 5 Gum to protect it from oxidation dirt fingerprints etc
17. 3 9 Part 4 Maintenance 4 1 Ce E E an 4 1 4 2 d Ud es 4 2 4 2 PUO osa WEE ERES 4 2 giuria Mii 4 4 4 4 Cleaning 4 4 Cleaning 4 4 Cleaning of developer heating 4 5 Cleaning of the circulation PUMPS 4 6 Cleaning of valves in the replenish 4 7 Adjustment of spray tubes nannaa aaa 4 7 Cleaning of Spray TUDOS 5555555 4 7 Chane gt cee oun ad eee NIA GS eee 47 ea ees 4 8 4 8 Rollers and brush rollers sace eS ee iena 4 9 4 9 WOM eda a oe ered Sd a ee hee 4 9 Removing brush 4 10 Installing brush rollers 4 10 Adjusting the 5 4 11 4 11 Service Manual Plate Processors 68 85 1244 Processor CONDITIONS Nue Se Re 4 11 Preparations 4 11 Adjustment
18. 6 DIVER Drying of the plate to ensure immediate handling of the plate y The processor sections are described in detail on the following pages 1244 T11001 Service Manual Plate Processors 68 85 Functional description General 3 2 PRE HEAT 51 INPUT SENSOR 10 11 HEATING ELEMENTS R6 PRE HEAT TEMP SENSOR M7 T1996 E EAT AIR Service Manual Plate Processors 68 85 1244 Functional description General TAP WATER PRE WASH TAP WATER K6 VALVE FLOW LIMITERS SPRAY TUBE CIRCULATION WATER PRE WASH TAP WATER VALVE SPRAY TUBE OVERFLOW M8 PRE WASH B16 PRE WASH TANK amp MAX SENSOR V DRAIN A VALVE M5 PRE WASH DRAIN CIRC PUMP IWAKI 1244 Service Manual Plate Processors 68 85 Functional description General DEVELOPER S1 INPUT SENSOR I OVERFLOW SPRAY TUBE 1 TRANSPORT B1 DEV TANK OPTIONAL ROLLER MIN SENSOR M2 ud d CHILLER TUBE BRUSH R1 E1 DEV HEATING MOTOR TEMP SENSOR FILTER 1x10 20 150 my M3 DEV CIRC PUMP IWAKI CHILLER FILL UP DEV DEVELOPER SENSOR P OPTIONAL ___ WASTE CONT OPTIONAL MAX SENSOR M4 DEV REPLENISH DEV REPL CONT MIN B10 SENSOR RANA E T1989 OPTIONAL Service Manual Plate Processors 68 85
19. Processor type 68 85 Weight empty 265 kg 307 kg 584 Ibs 677 165 Weight shipping 370 kg 430 kg 816 Ibs 948 Ibs Weight with liquids approx 300 kg 650 Ibs approx 350 kg 750 165 Service Manual Plate Processors 68 85 Technical specifications Mechanical specifications Dimensions The processor dimensions are specified in the following illustration For CTP Online processors the height and input height may have been changed in order to fit the setter height and thus not as illustrated Side view 304 8 cm 120 with feed table 344 7 cm 135 7 not all models 101 0 110 0 cm 39 8 43 3 82 8 91 8 cm 32 6 36 1 76 3 85 3 cm 30 0 33 6 129 3 cm 50 9 Top view 195 4 cm 76 9 50 0 cm 19 7 38 3 cm 15 8 68 79 9 cm 31 5 85 97 4 cm 38 3 68 108 0 cm 42 5 85 125 5 cm 49 4 39 9 cm 15 7 30 0 cm 11 8 71 1 cm 28 0 711282 Service Manual Plate Processors 68 85 1244 Technical specifications Electrical specifications Electrical specifications Power supply The requirements below are specifications for preparing the installation protection It is important to prepare the fuses circuit breakers with adequate capacity as specified here nm Specifications on the processor s name plate is the actual input current and will thus not be identical t
20. or trouble shooting etc it may be necessary to override the function of the processor s interlock switches In these cases please be aware that the processor s JOG function is still active making the drive system run idle at intervals There will be NO advice when the JOG function starts Also be aware that the processor s heaters and motors will be in operation during the initial startup if you have overridden the machine s safety functions Service Manual Plate Processors 68 85 Trouble shooting Before starting trouble shooting Before starting trouble shooting Important Plates and chemicals are very sensitive materials and correct storage is vital to obtain a satisfactory production result Incorrect storage may very well result in unsatisfactory processing quality etc Contact your local supplier for information about storage requirements for plates and chemicals Before making adjustments of the equipment make sure that incorrect storage of plates and chemicals can be excluded Problems with the processor SYMPTOM PROBABLE CAUSE REMEDY NO FUNCTION ACTIVE e Mains switch turned off or Connect cable to main power cable not connected power outlet and or turn to main power outlet main switch on Fuse s blown Replace fuse Reload software PROCESSOR CANNOT Configuration error INITIALIZE If main power has been cut off temporarily the processor Switches to off mode green led flashes
21. NA A 1 p H Ar 4 4 LIA 3 AAA 1 IT 2 Se MAD TAKA E 12 5 DINI LIT dI mE M M viale EPP 12 l z e t lz e IZ i Levey ei Lex ZEN Lex 02x vix ZEX 92x SIX ex L s s x 6X Tx x 2 gt gt lt Ps x x x D x x x x x E X x SL a ES IBS e eu SL A X X lt lt lt lt S AS tN 3 83 88 2g e En 28 2 221 RRSS II RSS DI ot SO D DA mw 9 7 N om o o Ln w o m w BON joo om E v 819 218 6 SH gt gt gt PX Sg ee R 09619001 a um lu 14299001 46869001 punog Q T e x xs lt are Ko m x x m s be T Mo X x 2 D XXX EX 2 X SS R x x x x lt x x x Ko so a 3 lt S 13 78 o o gt S 3 x N lt 9 Ko R ho SHEE 8 2 RR YIN qx Ih N m o N m m DD o o 52 gt o o N EH P mi o 5 o
22. PE to 2W PE or IW N PE 2 1l Threee phase 3W PE 230 2 12 Changing trom 3W FN FPE to SW PE 2 12 Power supply 2 13 LED location on PSU 22 OV gee rare oe eet 2 13 Stacker CONNCCUON RAE OS ox 2 14 Processor setter connections ctp online 55015 2 14 Conveyor CONNECTION eeu cua da eae Oh 2 14 Mechanical lt 2 15 Installation of hand 2 15 Ed Ron Pc E eh ks tee apes 2 16 Installing the cooler unit 2 16 Adjustment of lid switches 2 18 Cleaning the processor 1 5 2 19 2 19 Mounting the exit table 2 ee odes oa eee oe ee 2 20 Mounting the feed table 2 20 Installation of level sensors for replenish and waste 2 22 Placing CONTAINGTS 2 23 Mounting 5 2 24 2 25 Filling up developer and
23. RM TOUTS RAR RT 2 1 Installation hours for off line Machine 2 1 Standard installation hours for on line 2 1 Customer training NOUS einer nn 2 1 Preparing the installation 2 2 Space requirements s Lai ERA i 2 2 ROLO can er ren 2 3 Cleaning 2 3 2 3 Environmental requirements 2 3 Unpacking preparing the 2 4 2 222 RE V EN E SX EUR 2 4 2 4 Transport through narrow doorways 2 4 Removing the fenders and stand 5 2 4 Lifting the processor off the pallet 2 6 Transport security MOMS cm u a a u ae an 2 aiee 2 6 2 2 2 eee 2 7 Electrical 5 2 8 JUMP 2 8 Connecting the main 2 9 _______ _ 2 10 Standard wiring 3BW N PE 400V 2 10 Single phase 2W PE or 230 2 11 Changing from 3W N
24. and chemical type etc Tools 5mm hex T key Test plate 100 x 200 x 0 15 mm developed Processor conditions The processor must be running and ready to process Set developer brush speed according to recommendations from the plate manufacturer Preparations See the illustration on the following page Open the processor top cover Remove the upper roller 1 in the developer section and activate the interlock switch 2 Adjustment method A e While the brush 3 runs use the test plate 4 to test the brush pressure in both sides and in the middle Make sure that the test plate 4 is entered at right angles 4a to the rollers e Adjust the brush pressure on the screws 5 clockwise tighten until you feel a slight grip kiss n touch Make sure that you obtain a uniform grip in both sides and in the middle e From this point turn the screws 5 1 4 turn clockwise in each side 1 4 turn is a common pressure which will work in most occasions Please refer to plate manufacturer s specifications Adjustment method B Use a strip of film and a spring balance and proceed as follows e Fill the tank with water Insert a strip of polyester film 7 10 cm wide approximately 50 cm long 0 10 mm thick 4 x 20 x 1 128 6 between the brush roller 8 and the lower roller or pressure plate Activate the brush drive 120 rpm and hold the film strip with the spring balance 7 against the rotation of t
25. conductors in the power supply cable must be of copper Jumper fuses The fuse board is located in the electronics cabinet and holds a number of fuses and jumpers which should be either installed or removed depending of the power supply Supply fuse 68 85 230 1 x 25 Amps 50 60 Hz ds 3W N PE 400 VAC 3 x 15 Amps 50 60 Hz 2W PE 230 1 x 30 Amps 50 60 Hz e e gt 3W 230 VAC 3 x 20 Amps 50 60 Hz 2W 200 VAC 1 20 Amps 50 60 Hz 3W 200 3 x 15 Amps 50 60 Hz Service Manual Plate Processors 68 85 1244 Installation Electrical specifications Connecting the main power cable See illustration below The main power connection must be made in the field wiring box located on the left side of the processor next to the electronic cabinet When delivered your processor is wired for 3W N PE 400V EUR MODELS Before operating the processor you may need to perform a rewiring to match your local supply voltage Connect the cable to the terminal block 1 Lead the cable as shown below f required make rewiring as described on the following pages Processor Front 132068 1244 Service Manual Plate Processors 68 85 27 Installation Rewiring Standard wiring 3W N PE 400 V e arrival
26. gt to P RS 55 m L fo LR Z x 4 5 2 o ES l l 9 r lt T 1 T 1 T T 1 KCN T 1 i 1 FA T T T a T T 1 1 1 T 1 T TX T 1 1 T T T Te 9 r L Te 2 v LS v ps e p 2 8 E SELLE LL LE LT e p 2 B z z x x x z x x x X lt IVI 2 IVI E 2 E 3 2 IVI E 3 S 13 84 ui 94 gt 1 190 o 1 690 eo zo 990 190 o EN i Q PN Q 2 ogr T i Daf no 170 Q o Q 91 VLE 91 VLE 3 91 VIE 3 9I VIE 8 91 VIE 3 91 VIE 3 94 V19 3 91 VIE 3 91 VLE Si 91 VLE 91 VIE 3 9I VIE 3 91 V19 3 91 VLE 3 L 91 VLE 3 L 91 0 9LAH SLAY LEAY 9cAd OZAY 6LAY LeNY SLAY ELAY LLAH 9x 5 5 La Lg 8 Umi L E E E amp amp 10472 g unal uo LIX P G 21041 9 09105 Low voltage wiring Low voltage wiring Sensors and control devices Service Manual Plate Processors 68 85 1218 qvo40 ON 3 62919001 uoissiuued Jno uosied pezuouineun JO pesn jou 1snu pue S N
27. illustration the hose end is never below the gum surface 3 Blue Blau Bleu Azul Blu Blauw Sininen Azul Bla Bla Bla Blatt When inserting the gum return hose into the gum container make sure that 182073 Rot Rouge Rojo Rosso K kkivo Rood Punainen Vermelho Rod Red Red Rautt DEV FILL White Wiess Blanc Blanco Bianco Wit Valkoinen Branco Vit Hvid Hvit Hvitt Service Manual Plate Processors 68 85 2 23 273 Installation Mechanical installation Mounting fenders e Mount the 1 with the screws 2 132074 Service Manual Plate Processors 68 85 1244 Installation Mechanical installation Mounting filter Some models only Install the filter insert s enclosed in the installation kit The filter s are placed underneath the processor in the right side and mounted in a drawer unit for easy access 131557 Filling up developer and wash At the control panel under level set up define mode how the pump will operate e Manual If the processor has low level by starting up or goes low level during production pump will be activated from Manual mode in the Tool box Confirm If the machine has low level by starting or goes low level during production note on the display will ask to fill up Filling up will start upon confirmation e Auto I
28. the processor is wired as shown 2 opposite Connect conductors in power cord ol 6 5 lt to terminals 11 1 52 2 L3 3 N 4 Protective earth Ground symbol The unit has double pole neutral fusing The unit is fused in the neutral conductor where after operation of the fuse parts of the equipment remain energized This might represent a hazard during servicing L1 L2 L3 PE T2666 Service Manual Plate Processors 68 85 1244 Installation 2 11 Rewiring Single phase 2W PE or 1W N PE 230 V Connect conductors in power cord to terminals 11 1 L2orN 3 Protective earth Ground symbol Changing from 3W N PE to 2W PE or 1W N PE This configuration must only be used on Plate Processors without preheat due to the power consumption Modification on the Ground Fault Circuit Relay F10 Loosen screw in terminal 1 3 5 and N and T2667 remove all wires e Mount red yellow and brown wire in terminal 1 Mount black blue and orange wire in terminal 5 Adda jumper see spare part box from terminal 2 to The unit has double pole neutral fusing The unit is fused in the neutral conductor where after operation of the fuse parts of the equipment remain energized This might represent a hazard during servicing 1244 Service Manual Plate Processors 68 85 Installation Rewiring
29. 1218 PLATE PROCESSOR 68 85 1244 3 11
30. 1244 Functional description 3 5 General Replenishment anti oxidation system The replenishment system automatically adds fresh developer to the developer section to compensate for chemicals expended during processing and for lost activity caused by plate development The processor measures the plate size to determine the correct amount of replenisher for each plate Plate sizes must be entered in the PLATE SIZES menu in order to optain exact calculation of replenishment Top up replenishment The top up function can be set up to add fresh developer from the fill container to the developer section based of plates processed Also the developer top up function automatically adds fresh developer to the developer section when low level is detected Time replenishment The time replenishment system adds fresh developer or replenish concentrate to the developer section to compensate for lost activity caused by oxidation and evaporation The replenish amounts can be set individually for stand by mode and off mode Off replenishment The replenishment system also features an off replenishment function which adds an amount of developer into the developer bath when the processor is turned on after being off for a long period The replenishment anti oxidation developer is added to the section by means of a pump 1244 Service Manual Plate Processors 68 85 Functional description General TAP WATER WASH
31. 1537 1244 Service Manual Plate Processors 68 85 Installation Mechanical installation Adjustment of lid switches See illustration below Adjustment of the lid switches may be needed after leveling of the processor Loosen the screws 1 and adjust the actuator 2 sidewards until it fits smoothly 3 into the switch 4 132070 Service Manual Plate Processors 68 85 1244 Installation Mechanical installation Cleaning the processor tanks Before installing rollers and covers it is necessary to vacuum clean the tank to remove sponge rubber remains and dust etc Labels with roller configuration Na 132071 Mounting of rollers Inside the top cover is mounted a label showing the roller configuration Install the rollers as shown on the label Install the rollers standing on the left side of the processor Delivered with the processor is a tool for installation of brush rollers Installation and adjustment of brush rollers are described in chapter 3 in the processor service manual 1244 Service Manual Plate Processors 68 85 273 Installation Mechanical installation Mounting the exit table Some models only The exit table is mounted from the factory and prepared for slanted position A Follow the description below when mounting the supports for position A If straight position B is wanted please follow the description for B pe position A Lift the exit table t
32. 8 85 General information Manuals 0 12 Service Manual Plate Processors 68 85 1244 General LIE Part 1 Technical specifications General environmental information The processor does not contain Ozone depleting substances according to Montreal protocol Asbestos e Polychlorinated biphenyl or Poly Cyclohexylenedimethylene Terephthalate Mercury Cadmium Lead as additive to plastic parts Plastic parts Plastic parts gt 50g are marked according to ISO 11469 Batteries No batteries in this equipment End of life Estimated product life 10 years parts and service period 7 years after last sales Recycling The processor should be disposed at a certified appliance recycling centre or processing centre Recycling Passport with specifications of components and materials used in this processor is available on www glunz jensen com support Packaging Plastic packaging materials are marked according to ISO 11469 Noise emission Acoustical noise according to ISO 11201 1996 Sound pressure level Operational mode 63 5 dB Stand by mode 48 dB 1244 Service Manual Plate Processors 68 85 Technical specifications Mechanical specifications 1 2 Chemical emissions Ozone mg m Dust 0mg m Styrene 0mg m Heat emission Stand by 1200 W 4000 BTU hour Process 3600 W 12000 BTU hour Maximum 5000 W 17000 BTU hour Mechanical specifications
33. IO The electrical control system is controlled by the MIO board via the SOM System on Module There are two separate communication lines buses GNUIB for all internal communication in the processor 5485 ETHERNET for Remote Enabling System The MIO board is equipped with a platesetter interface for communication between the processor and platesetter Power control unit PCU The PCU board holds all the high voltage in and outputs for the control of heaters motors etc Touch screen control panel MMI A graphical user interface colour display The processor is operated on the touch screen display Control panel service information is described in the Software Manual 1244 Service Manual Plate Processors 68 85 Functional description Electronic control REMOTE ENABLING ETHERNET Optional Online installations only INTERFACE MASTER I O BOARD GNUIB 5485 131649 SLAVE I O BOARD PC U Service Manual Plate Processors 68 85 1244 Maintenance General Part 4 Maintenance General This section contains special service information such as fuse list and roller adjusting procedures etc For software related service information please refer to the separate Software Service Information manual WARNING Please note that where this label ELECTRICAL SHOCK HAZARD appears
34. LE CAUSE REMEDY NO WATER CIRCULATION Pump defective or clogged Water filter clogged Water spray bar clogged Fuse blown Level sensor in wash dirty or defective e Clean and or repair pump Replace filters Clean spray bar See Part 3 Replace fuse Check sensor and clean replace whatever is necessary ROLLER DRIVE MOTOR RUNS BUT NO PLATE TRANSPORT e Drive gears and or worms defective Check all gears and worms gears on rollers and make sure they move freely Replace any defective part Problems with processed material SYMPTOM PROBABLE CAUSE REMEDY PLATE 15 NOT e Dryer temperature is set too Set dryer temperature a COMPLETELY DRY low little higher Gum section applying to much gum Dryer section 15 malfunctioning Check gum section Check dryer section PLATE HAS STRIPES LENGTH WISE OR CROSSWISE Defective or dirty rollers or guides Wash spray tubes clogged Take rollers and or guides out inspect and wash them Rollers with dents or other marks must be changed Clean the spray tubes See Part 3 WASHING NOT SUFFICIENT Spray tube clogged Brush not turning Brush pressure not Sufficient Water circulation pump does not run Rollers dirty in wash section see earlier in this chapter Clean spray tube Check the brush and fix the problem Adjust brush pressure See Cleaning of the pumps in Part 4 Clean roller
35. O OPA dojs 3 peidnuejur c NSd uo NO OPA vc Primary wiring Primary wiring 230V AC control devices Service Manual Plate Processors 68 85 1218 v z eDeg avo uoissiuued 2142905 noum uosied peziioyineun jenoiddy SeoiA e OVA 052 4 629 1900
36. Service Manual Plate Processort 68 85 Polymer GLUNZ 6 JENSEN Service manual Plate Processor t 68 85 Polymer A This manual is for Service Technicians only The directions given must not be followed by unauthorized personnel Always read the Safety Instruction Manual part No 21741 before installing or operating the equipment This manual is published by GLUNZ amp JENSEN A S Selandia Park 1 DK 4100 Ringsted Denmark 45 57 68 81 81 E mail gjhqQglunz jensen com Internet www glunz jensen com Copyright O 2011 by GLUNZ amp JENSEN A S Service Manual Plate Processors 68 85 1244 General information 0 3 processor Part General information Reservations e This manual was written and illustrated using the best possible information available at the time of publication Any differences between this 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 Asa part of our policy of continuous improvement we reserve the right to alter design and specifications without further notice Notes cautions and warnings Throughout the manual notes cautions and warnings are written in bold like the example below Always replace a fuse with one of the same size and rating as the old one Symbol Meaning Explanat
37. allation Mechanical installation Installation of level sensors for replenish and waste Enclosed in the installation kit are 4 sets of level sensor kits for developer waste developer fill up and developer and gum replenishment containers Installing level sensor kit requires configuration of replenishment parameters in the software This is done when installation of the processor has been completed The parameters to be configured are DATA gt CONFIGURATION gt HARDWARE DEVELOPER CONFIGURATION gt WASTE FULL LEVEL SENSOR YES REPLENISH LOW LEVEL SENSOR YES FILL LOW LEVEL SENSOR YES GUM CONFIGURATION gt CONTAINER LOW LEVEL SENSOR YES Locate the cables for level sensors 1 The cables are marked with name tags for each sensor e Connect the enclosed sensor cables and mount sensors as shown on the illustrations Dev repl min cont B10 to developer replenishment container 2 Cont min to developer fill up container 2 Gum min cont B9 to gum replenishment container 2 Locate the hose for developer waste 3 and mount it to the developer waste tube 4 Mount the Dev waste max sensor B15 to developer waste container 5 11999 Service Manual Plate Processors 68 85 1244 Placing containers Installation Mechanical installation Place the waste container 1 underneath the processor in the right side and place the replenishment containers 2 in the left side as shown on the
38. cated on the fuse PCB LED location on PSU 225W 53 CNS 1244 Service Manual Plate Processors 68 85 Installation Power supply units 2 14 Stacker connection Not all models accessory equipment Cable for connection to a stacker is placed underneath the dryer section Unpack the cable and connect it to the stacker see also the stacker manual When the cable is not in use please reel it and secure the receptacle away from liquid and readily accessible areas Processor setter connections ctp online processors nm The interface can be either a feed table or a setter interface Whether or not the processor is already fitted with some kind of interface panel you should refer to the separate INTERFACE MANUAL for installation instructions and other information relevant for your present type of interface Conveyor connection Not all models accessory equipment See separate manual See the description for stacker connecting above Service Manual Plate Processors 68 85 1244 Installation Mechanical installation Mechanical installation Installation of hand shower nm Not all models To mount the handshower please follow the description below and the illustration Opposite The hose 1 is mounted underneath the processor Pullthe hose through the hole in the right side of the front panel 2 e Mount the shower head 3 and the washer 4 on the hose 5 Fix
39. ctrical water and drain installations are in place the estimated installation time is 4 5 hours Ifthe machine must disassembled to get into the room before installation add another 4 5 hours for disassembling and reassembling Unpacking and transportation from pallet to the floor add 2 3 hours Standard installation hours for on line machine Provided the machine is unpacked and will stay in the room and all electrical water and drain installations are in place the estimated installation time including interface installation and connection to the setter is 6 8 hours Ifthe machine must be disassembled to get into the room before installation add another 4 5 hours for disassembling and reassembling Unpacking and transportation from pallet to the floor add 2 3 hours Customer training hours How many working hours are planned for training the customer Introduction and training of the customer daily user in normal use of the processor operating etc is estimated to 2 3 hours Training of the customer daily user in normal daily cleaning and maintenance is estimated to 2 3 hours 1244 Service Manual Plate Processors 68 85 Installation Preparing the installation site Preparing the installation site Space requirements Make sure that the free space around the machine at the installation site makes servicing possible The recommended minimum free space around
40. duction hours or every year what comes first e Major Preventive Maintenance at 2000 production hours or every year what comes first nm Please refer to the Spare Parts manual for order numbers for particular kits Read more about our Preventive Maintenance Kits onwww glunz jensen com and see the content of the Preventive Maintenance Kits or contact us at order department glunz jensen com 1244 Service Manual Plate Processors 68 85 Maintenance Preventive Maintenance Kit Program 4 16 Service Manual Plate Processors 68 85 1244 Trouble shooting General Part 5 Trouble shooting General 1244 If the processor does not work properly refer to the following pages to find the paragraph that comes closest to your problem The troubleshooting guide is divided into two sections a Problems with the processor b Problems with the processed material For information about alarm messages see the Control Panel manual For cleaning and maintenance subjects see the processor user manual For information about fuses see page 4 2 Use the test function via the touch screen control panel MMI in the processor s sleep mode See the control panel Quick Guide The electrical diagrams are located in Appendix A To change a fuse switch off all power to the machine first Always ensure that the new fuse is of the correct rating according to the diagram WARNING When performing any service maintenance calibration
41. ecified in Technical specifications in Part 1 in this manual Installation Never install the processor in explosive environments tis the responsibility of the owner and operator s of this processor that the installation is made in accordance with local regulations and by engineers authorized to carry out plumbing and electrical installations e Installation service and repair must be performed only by service technicians who are trained in servicing the equipment The installation procedure is described later in this manual e The manufacturer cannot be held responsible for any damage caused by incorrect installation of this processor e The processor is intended for installation in a restricted access location only Technical data Observe technical data from the processor name plate and from Part 1 in this manual Chemicals tis the responsibility of the owner of this equipment that data is available concerning possible health risk from the chemicals used with the equipment End of lifetime disposal The equipment is designed for easy disassembling All disposal of parts from the machine must be made according to local regulations with special regards to following parts For recycling purposes significant components are marked with material specification according to the ISO 11469 standard PVC tank etc must be sent to a waste deposit with recycling in view Alternatively the PVC can be i
42. er rollers 8 at the developer section entrance always run dry to ensure a homogeneous development The rollers 9 ensure that the plate is transported correctly underneath the brushes 10 and the rollers 11 make sure of proper contact between brushes and plate The rollers 12 at the developer tank exit squeeze any residual chemicals off the plate In the wash section the plate is washed on both sides by means of the spray tubes 13 and brushed on the upper side by means of the brush 14 optional The stop roller 15 on top of the entrance rollers 16 prevents that the wash water runs back into the developer section and water is squeezed off the plate by the section exit rollers 17 The gum section contains one roller pair 18 and a smaller roller 19 situated close to the upper roller The gum solution from the application tube 20 forms a small bath between these two rollers and a thin layer of finisher is applied to the plate while the extra finisher is forced backwards The exit roller pair 21 takes the plate when dry and leads it out of the processor 1 6 347 8 9 10 12 15 14 13 17 20 21 wane H J Tras us POR 16 13 Jean 11 19 18 ES E T1100 Service Manual Plate Processors 68 85 1244 Functional description 3 9 Electronic control Electronic control See illustration on the following page The electrical control system consists of Master input output unit M
43. f the machine has low level by starting up or goes low level during production the pump will start automatically filling up to level Developer The processor is equipped with a fill up pump for developer If replenish and fill up containers are installed as described earlier the processor will be ready for automatic fill up when switched on Make sure that the developer drain stand pipe is closed see illustration Wash 131556 Wash water recirculation system Iftheprocessorisequippedwitha wash water recirculation system the wash section will fill up automatically when the processor is switched into A stand by mode wash water recirculation OPEN CLOSED The water solenoid valve will let in water when a plate is entered through the input slot 1244 Service Manual Plate Processors 68 85 Installation Finishing installation Pre wash drain valve Underneath the pre wash section in the right side of the machine is mounted a ball valve for pre wash drain If the processor is configured for pre wash with running tap water the valve must always be in open position Open T32406 Closed Finishing installation Mounting panels See illustration on the following page Install the pre heat unit 8 and fasten it with the 4 screws Install the rollers 7 from the pre heat section e Mount the left and right stand panels 6 and secure
44. ge 4 Tighten the screws 2 on the brackets 3 for the main drive shaft Remove the feeler gauge 4 e Finally make sure that the adjustment has left a small gap between the gears 5 and 7 Replacement of bearing bush Remove the spring 1 from the roller bearing 2 by using screwdriver Replace the bearing bush 3 Compress the spring and insert it into the roller bearing as shown in the illustration T31946 1244 Service Manual Plate Processors 68 85 Maintenance Adjustment of gears for wash brush 131584 Service Manual Plate Processors 68 85 1244 Maintenance Preventive Maintenance Kit Program 4 15 Preventive Maintenance Kit Program To ensure continues high quality and maximize productivity and processor up time it is recommended to carry out preventive maintenance at regular intervals To facilitate this a Preventive Maintenance Program has been developed consisting of a number of relevant service parts to be replaced at specific service intervals It is recommended that the following Preventive Maintenance Kits are implemented at the mentioned intervals at which point the cycle will start over Minor Preventive Maintenance at 500 production hours or every year what comes first e Medium Preventive Maintenance at 1000 production hours or every year what comes first Minor Preventive Maintenance at 1500 pro
45. he brush pulling the spring balance upwards e Adjust the pressure to a balance depending on a recommendation from plate manufacturer over the entire brush roller width Repeat the procedure for the other developer brush roller and the brush rollers in the prewash and rinse section All brushes should be adjusted to the same settings Service Manual Plate Processors 68 85 4 11 Maintenance A djustment of gears for wash brush Adjustment method A 9 S Adjustment method 131942 Service Manual Plate Processors 68 85 1244 Maintenance Adjustment of gears for wash brush 4 13 Adjustment of gears for wash brush Important When the main drive shaft has been dismounted remounted due to change of parts service checks etc it is very important to make a final adjustment according to the description below Procedure of adjustment See illustration on the following page Mount the main drive shaft 1 on the tank wall and tighten the 2 screws 2 on each of the 4 brackets 3 holding the shaft Loosen the screws 2 on each bracket 3 1 4 turn Place a 0 5 mm feeler gauge 4 between the gear 5 and the bearing 6 Alternatively use pieces of offset plate equal to 0 4 mm 0 6 mm e g 2 x 0 3 mm offset plate e Turn the gear 7 manually to adjust the space gap between the gear 5 and the bearing 6 to fit the feeler gau
46. ion d Note The operator should observe and or act according to the information in order to obtain the best possible function of the equipment Caution The operator must observe and or act according to the information in order to avoid any mechanical or electrical damage to the equipment A Warning The operator must observe and or act according to the information in order to avoid any personnal injury Other manuals Please see description of Manuals available for the plate processor later in this chapter The processor Approvals Approvals will appear from the labels attached to the name plate or the frame part of the processor 1244 Service Manual Plate Processors 68 85 General information The processor Unintended use of the equipment Glunz amp Jensen A S do not take any responsibility for any damage or accidents caused by unintended use of the equipment As the equipment is certified by accredited test laboratory UL International Demko A S it is absolutely prohibited to make any modifications electrical nor mechanical of the equipment If however this prohibition is disregarded Glunz amp Jensen s warranty will no longer apply and the certification labels for UL C UL and CE certification of the equipment shall be removed as the certification will no longer apply to the equipment Intended use of the equipment Development of photographic materials as sp
47. ls Loosen the filter vessel 4 by means of the filter key 3 and unscrew the vessel Take the filter element 5 out and clean it in water or change with the new 6 whatever is necessary Install the filter element 5 again Mount filter vessel 4 and make sure the O ring 7 fits properly into the groove in the filter vessel Tighten with the filter key 3 Open the valve 1 T31592 Service Manual Plate Processors 68 85 1244 Maintenance Rollers and brush rollers Rollers and brush rollers General On the top cover from inner side there is a label showing the roller configuration a Each brush roller is marked with a small number b Install the rollers by referring to the roller numbers on the label Press down in each side on the upper rollers as indicated NB Drive side first to lock them When the roller bearings c click they are properly secured T 2076 Installation of rollers See illustration below Make sure to align the gears on the upper and lower rollers The gear on the lower rollers has a plate guide that must fit into the gear of the upper rollers T31590 1244 Service Manual Plate Processors 68 85 Maintenance Adjusting the brushes Removing brush rollers Follow the instruction below Stand to the right of the processor Remove the spray tubes from the de
48. ncinerated at a suitable incinerating plant PCB s and other electric equipment must be sent to a suitable waste deposit Service Manual Plate Processors 68 85 1244 General information The processor Service assistance If help is needed to correct any problem with the equipment please contact your local supplier 1244 Service Manual Plate Processors 68 85 Table of contents Part 0 General information 0 3 PESCE RERO RES tanh 0 3 Notes cautions warnings 0 3 Other 5 0 3 0 3 ADDIOUSIS esa pa iaia LIL 0 3 Unintended use of the 0 4 Intended use of the 0 4 0 4 0 4 Eem o eae 0 4 End of lifetime 5 0 4 Service assistance 0 5 Table of CONTENTS e vu a s 0 6 22 052 E 6800806054985 ME 2 8 2 ESS 0 10 Service 0 10 5 0 11 Part 1 Technical 5 1 1 General environmental information
49. ning IMPORTANT Thorough cleaning of the processor tank interior tank parts pumps filters etc on a regular basis will minimize the risk of sediment build up in and around vital parts of the equipment and prolong the lifetime of the equipment Cleaning accessories Never use any hard tools abrasive materials when cleaning any part of the processor Apron rubber gloves and eye goggles For personal protection Lint free cloth sponge and soft brush For cleaning of rollers guides tank walls and all surfaces especially the exit table and the feed table if fitted Long handled bottle brush and thin wire i e Paper clip For cleaning the inside and the holes of the spray tubes Cleaning agents A Never use cleaning agents containing chlorinated solvents acetic or phosphoric acid These constitute a health hazard and could damage the processor Cleaning components with anything other than a mild detergent or a recommended cleaning agent may cause irreversible damage and invalidate any watranty Standard recommendations Warm water 35 40 C 95 104 F For normal cleaning purposes and to rinse after using other cleaning agents Citric acid 10 Nitric acid 5 For major cleaning purposes Commercially available biocide strong alkalic liquid For cleaning off heavy algae fungal or bacterial growth in the wash section Special recommendations As some chemicals may require special cleaning agents contact
50. o below mentioned Supply fuse Recommended cable type 68 85 1W N PE 230 Min 2 5 a 1 x 22 Amps 50 60 Hz type HO5 RNF 3W N PE 400 VAC Min 5x 1 5 mm 3 x 10 Amps 50 60 Hz type HO7 RNF 2W PE 230 VAC Min 3 x 10 AWG 1 x 22 Amps 50 60 Hz type SJO 3W PE 230 VAC Min 4 x 12 AWG 3 x 15 Amps 50 60 Hz type SJO 2W 200 VAC Min 3 x 12 AWG Japanese n 1 x 20 Amps 50 60 Hz harmonized power cord 3W PE 200 Min 4 x 14 AWG Japanese 3 x 13 Amps 50 60 Hz harmonized power cord Voltage tolerances All Voltage tolerance 10 A Please be aware of double pole neutral fusing Power consumption Max power consumption at 68 85 230 VAC operation 3600 W 12000 BTU hour j peel otand by BTU h JAP 1200 W 4000 BTU hour Maximum 5000 W 17000 BTU hour 1244 Service Manual Plate Processors 68 85 Technical specifications Electrical specifications Noise level See General environmental information on page 1 1 Service Manual Plate Processors 68 85 1244 Installation Installation hours Part 2 Installation Installation hours How many working hours are planned for the installation Installation hours for off line machine Provided the machine is unpacked and will stay in the room and all ele
51. o vertical position 1 Mount the supports through the holes in the exit table 2 turn them to lock them inside the holes Lead the supports through the lower holes in the rear panel 3a and secure them inside using the enclosed locking split pins 3c S position B Dismount the exit table Dismount the 4 screws 4 holding the exit guide 5 Be careful to hold on to the exit guide when removing the screws Do not let is slip down behind the rear panel Move the exit guide a little upwards and mount the 4 screws in the lower holes of the guide 6 Mount the exit table Liftthe exit table to vertical position 1 Mount the supports through the holes in the exit table 2 turn them to lock them inside the holes Lead the supports through the holes in the rear panel 3b and secure them inside using the enclosed locking split pins 3c Mounting the feed table Offline processors only Mounting of the feed table is LOWER HOLES described in the manual for the feed table kit 131292 Service Manual Plate Processors 68 85 1244 Installation Mechanical installation A SLANTED EXIT TABLE STRAIGHT EXIT TABLE J zh X ee i Dre i i i n n i n i i i n gt i n n 132072 1244 Service Manual Plate Processors 68 85 GA Inst
52. on the processor electrical DISGONNECPALEEXTERUAL POWER shock hazard still exists when the SUBE main switch is turned off TO BE SERVICED BY AUTHORIZED PERSONNEL ONLY RISQUE DE CHOC LECTRIQUE AVANT TOUTE INTERVENTION DEBRANCHER TOUTES LES SOURCES DE COURANT MAINTENANCE PAR PERSONNEL AUTORISE SEULEMENT WARNING When performing any service maintenance calibration or trouble shooting etc it may be necessary to override the function of the processor s interlock switches In these cases please be aware that the processor s JOG function may still be active making the drive system run idle at intervals Also be aware that the processor s heaters and motors will be in operation during the initial startup if you have overridden the machine s safety functions 1244 Service Manual Plate Processors 68 85 Maintenance Safety checks Safety checks nm The described safety checks should be performed at least once a year Electrical Refer to the electrical diagrams in the back of this manual Check proper function of Lid switch Processor must stop when the switch is deactivated The COVER OPEN message must appear in the control panel display Main switch Processor must turn off when set to 0 Emergency stop The processor must turn off when activated Mechanical Check proper function location of Side fenders left right Make sure the fenders are properly secured with 2 screws each
53. ounting it and that the O ring 2 is placed correctly in the groove of the impeller housing 1 T31064 Service Manual Plate Processors 68 85 1244 Maintenance Cleaning Cleaning of valves in the replenish pumps If a replenishment pump ceases to VALVE function properly run it with some _ warm water in order to clear the pump SS TO AN MEME of chemicals If this does not help take the pump apart and clean both of the small valves in warm water T436 Adjustment of spray tubes The pressure in the spray tubes can be adjusted to obtain the best possible application of water to the plate Pressure is adjusted as shown on the illustration below The valve is fully open from the factory Normally no adjustments are necessary Cleaning of spray tubes Developer section Clean the spray tubes in the developer section with hot water to remove potential blocking of the holes Wash Prewash section Clean the spray tubes in the wash section with hot water to remove potential blocking of the holes Occasionally depending on the local water quality it may be necessary to use a drill bit to clean the holes and remove sediments mechanically t31558 1244 Service Manual Plate Processors 68 85 Maintenance Changing filters Changing filters General Clean the filter s regularly as described below Close the valve 1 Open the drain valve 2 to empty the filter vessel 4 of chemica
54. own from the pallet Alternatively a forklift truck is recommended Two persons are needed on each side of the processor for lifting Please note that processor without rollers brushes and heat sink model 68 weights app 160 app 253 Ibs 85 model weights app 200 kg app 441 165 Mount the two pipe bars 1 enclosed with the processor as shown on the illustration 2 The processor legs are placed in holes in the pallet Make sure to lift the processor out of the holes 3 when lifting it down the pallet Place the processor on the installation site Transport security items During transportation many of the parts outside and inside the processor have been secured using tape plastic strips and various pieces of sponge rubber Make sure to remove all items T32066 Service Manual Plate Processors 68 85 1244 Installation Unpacking preparing the processor Leveling nm The machine must be placed on a steady surface so that it does not shake easily and the chemicals cannot be spilled from one section to the other Do not rely on the floor being absolutely in level For CTP ONLINE PROCESSORS the final height from floor to bottom of the processor entrance 1 must be SETTER OUTPUT HEIGHT 2 mm e Use the adjustable feet 2 in the legs to level out the processor It will be necessary to use ex a crowbar 3 to lift the legs slightly before being able to turn the feet and coun
55. reception systems for waste chemicals copper or brass should not be used in the draining system as the chemicals involved are highly corrosive Therefor plastic or rubber is recommended Check with the chemicals supplier for details Environmental requirements Provide a heating and ventilating system capable of maintaining room temperature between 15 and 25 C 59 and 77 F and relative humidity on max 80 Capacity of the air condition ventilation system must be adequate for heat emission of 4000 BIU hour 1200 Watt in stand by and 12000 BTU hour 3500 Watt in process 1244 Service Manual Plate Processors 68 85 23 Installation Unpacking preparing the processor General Carefully unpack the machine and check that all parts are present according to the enclosed packing list and in good condition Installation kit Installation and spareparts kits are included with the processor They comprise the different parts necessary to make the installation and some key components as spareparts See the packing list s delivered with the equipment for further information Transport through narrow doorways Dependent on the width of the door s through which the processor has to be transported to the installation site the Service Technician may have to perform the actions described in the table below If width of the doorways are 68 85 Then gt 2140 mm gt 2140 mm No action is required as the crated proce
56. s PLATE HAS AN UNEVEN GUM Gum container nearly empty Gum rollers dirty Gum distributing roller not in place Gum pump clogged Refill container Take rollers out and clean them Correct the placement of the roller Take pump apart and clean valves Service Manual Plate Processors 68 85 1244 Appendix Electrical diagrams A 1 Appendix A Electrical diagrams This chapter includes all electrical diagrams for the processor The diagrams 4 pages cover Page 1 of 4 Main power distribution Fuse panel and interlocks Page 2 of 4 Motors and internal bus wiring 24V DC distribution Page 3 of 4 Primary wiring e 230V AC control devices Page 4 of 4 Low voltage wiring e Sensors and control devices 1244 Service Manual Plate Processors 68 85 Main power distribution Main power distribution Fuse panel and interlocks Service Manual Plate Processors 68 85 1218 3 QqQv910 166919001 ON DOC TVIINVHIAW JINOYLI973A N3SN3f 8 ZNN19 uoissiuued Jno jnoyjim uosiad pezuouineun Aue Jano pepueu JO pesn eq jou 1snu pue S N zunjo Buiweip 5141 SIN 2102 10 Aepsoen v JO L eDeg jlenoiddy puy esnJ uora3ounj 1019N1 SU0D
57. ssor can be 84 3 84 3 transported immediately to the installation site 2140 1100 mm 2140 1270 mm The Service Technician has to unpack the processor 84 3 43 3 84 3 50 1100 mm lt 1270 mm The Service Technician has to unpack and strip down 43 35 50 the processor Removing the fenders and stand panels In order to make the installation it will be necessary to remove covers lids left fender and the stand panels from the processor See illustration on the following page e Lift up the top cover 1 remove the pre heat pre wash cover 2 the pre heat lid 3 and the dryer lid 4 Release the locks 5 of the stand panels by pulling them outwards Lift off the panels 6 Loosen the 4 screws securing the pre heat unit 7 and lift the pre heat unit out of the processor Remove the screws 8 securing the left and right fenders 9 to the stand and lift off the fenders Rollers are placed under the processor in separate boxes due to transport security reasons The boxes need to be removed from the pallet before lifting up the processor from the pallet Service Manual Plate Processors 68 85 1244 Installation Unpacking preparing the processor T32065 1244 Service Manual Plate Processors 68 85 Installation Unpacking preparing the processor Lifting the processor off the pallet Four persons are needed for lifting the processor d
58. t the replenish pumping NO will cancel the pumping Possible explanation The processor has been either off or in sleep mode for more than 72 hours Select NO otherwise the system will start replenishing based on how many hours the machine has been switch off since the machine has been packed The prewash section 2 developer section 3 wash section 4 and gum section 5 will automatically fill up when the processor switches to Ready mode Fill the developer fill container 6 developer replenishment container 7 and gum 2 OO container 9 eo at 98 tum capt 805 cM b c d DEV DEV WASTE FILL REPL 132150 Service Manual Plate Processors 68 85 1244 Installation Software user settings Software service settings The processor is configured from the factory If however any extra features like level sensors for replenish containers etc have been installed an additional configuration is needed in order to adapt the software to the extra features Please refer to the Software Manual Control Panel Service Guide for detailed information of the procedures listed in the following Set control panel access level to Service Configuration and settings Additional configuration might be necessary to suit the individual customer needs Make additional configuration in 123 gt Configuration gt Hardware and check all parameters Also make sure to check all parameters in
59. ter nuts Level out the processor lengthwise by placing a spirit level on the left 4 and right 5 tank side Level out the processor crosswise by placing the spirit level on the guide 6 at the entrance of the dryer section Level out the processor by placing the spirit level inside the preheat 7 or between the preheat and the prewash tank tis necessary to control the level at the preheat also and adjust if necessary Check leveling in all 4 positions and make final leveling if required pus SETTER OUTPUT HEIGHT 2 T32067 1244 Service Manual Plate Processors 68 85 Installation Electrical specifications Electrical specifications The electrical installation must conform to local regulations and guidelines i The required cable plug is usually not delivered with the processor A Please be aware of double pole neutral fusing A The processor is Class 1 equipment It must therefore be connected to earth to avoid electrical shocks The fuses must have a breaking capacity of min 100 kA If using automatic circuit breakers make sure they are Type D When selecting a cable type take the following into account Chemical resistance Chemicals may leak onto cable Mechanical resistance The operator may step onto cable Additional protection Provide for additional cable protection e g cable covers if cable is exposed to heavier transport such as forklift trucks etc The
60. ternal bus wiring Motors and internal bus wiring 24V DC distribution Service Manual Plate Processors 68 85 1218 uojssiuad ojppeds sno uosied pazuoyjneun t JO v P minm nos uonnquisip OPA 1 629 ANY 2 0 12373 n n id n J uequiny N3SN3f ZNAT 2102 9z Aepsuny ejeg ul IM 5 8 jeu SACAN 2 0 029001 v E T E a i gt a j w N ko o N jw jo gt E ibs E 7 2 ENA NA NX E CX ES E V N AN 2 C n A J l NI LNO aay 1no WHLX3 LNO dOLS 3 IWNDIS 20629001 god ur Bnjd Aejdsig vr SJosues pue indui uonoeuuoo Jo p OIN INC pue u Jaise Wed 109 IN su A n Nd AV IdSId HONOL ININ UEN je JON 02900 97719001 8 1 JOJO USNIE S Ts y CN e ne 9 Hng 9 _ HI jut L ds 2 D w e LAI p cy Noo ey 9 2 614 x X X uix x m qm N u ho ES are la o
61. the machine is specified in the illustration below gt 445 cm 175 2 gt 60 cm 23 6 2 1 2 2 2 J E 7 2 lt w Z2 2 2 2 2 5 gt 50 gt 50 2 z f 197 SS S 19 7 58 8 So 2 Mc S 7 94 Pe 2 Z Z AN 2 7 7 5207 j on 7 p 1 2 2 2 7 2 2 2 100 cm 39 4 2 2 2 2 T11281 2 online For the CTP On line processors the space requirements at the processor front has to be decided separately Service Manual Plate Processors 68 85 1244 Installation 2 3 Preparing the installation site 7 Power outlet If not already there a main power outlet should be installed in the room where the machine will be situated Max distance to the machine 2 m 6 ft See power outlet and fusing requirements later in this manual Cleaning facilities It is essential to have easy access to a sink and a water tap with hot water where rollers guides and brushes can be washed The minimum recommended size of the sink is 68 cm processors 90 x 40 cm 35 4 x 16 85 cm processors 100 x 40 cm 39 4 x 16 Drain connections Never lead drain hoses from the developer section to a drain as most developers are strong pollutants and it is strictly forbidden to empty this type of chemistry into the public sewer system When establishing central
62. the shower head to the snap locks 6 inside the front panel SS RN EE 1244 Service Manual Plate Processors 68 85 Installation Mechanical installation 2 16 Water connection The water supply connection is made by means of the plastic hose and the fitting WRG delivered with the processor As shown in the figure below the hose must be connected between the water tap and the water inlet solenoid valve GARET UM located to the left when standing in front of the processor underneath the NIPPLE processor 3 4 1 2 The hose can be connected to a water Use tap with 1 2 or 34 male thread WRG When connecting to 3 4 the reduction nipple shall not be used GASKET N 13225 Installing the cooler unit optional An external cooler unit can be connected to the developer section e Place the cooler a behind the processor Lead the hoses from the cooler unit through the hole for hoses b in the rear panel e Connect the cooler hoses c and d to the in and outlets to the left underneath the developer tank Connect the cooler plug e to the plug f located next to the main power connection box inside the fender on the right side of the processor For more information about the cooling unit please consult the cooler unit manual Service Manual Plate Processors 68 85 1244 Installation Mechanical installation A 13
63. them by closing the locks 5 Mount the pre heat lid 3 the dryer lid 4 the pre heat pre wash cover 2 e Mount the left and right fenders 10 and secure them with the screws 9 e Close the top cover 1 Installation of setter interface See the setter interface manual When installation of the setter interface is complete please return to this manual for finishing the entire installation by continueing with the instructions on the next page Service Manual Plate Processors 68 85 1244 EM Installation Finishing installation 1 32075 1244 Service Manual Plate Processors 68 85 2 28 Installation Initial start up When the processor has been properly installed the initial start up procedure can be carried out Before starting make sure that developer replenishment container 7 is empty or that the hose is disconnected Open the water tap 1 e Make sure that the developer fill container 6 and the gum container 9 are full Turn on the processor with the main switch The processor will initialize and then automatically switch to Ready mode e Press and hold on the control panel for min seconds to switch the processor to Sleep mode When the machine is started up for the first time after have stayed off for more than 72 hours the alarm appears High off 114 The amount of off repl is high maybe a chemistry change would be more appropriate YES will star
64. ump valves blocked or defective Pump defective Fuse s blown Electronics defective Refill container Clean hose Clean or replace valve Replace pump Replace fuse Replace defective electronics GUM PUMP RUNS BUT NO FINISHER Gum hose blocked Pump valves blocked or Clean hose Clean or replace valve NO ALARMS defective DEVELOPER e Fuse s blown e Replace fuse REPLENISHMENT Pump defective e Replace pump PUMP DOES NOT WORK Electronics defective Wrong configuration Replace defective electronics Re configure the processor DEVELOPER e Replenishment hose e Clean hose REPLENISHMENT blocked PUMP RUNS BUT NO e Pump valves blocked or Clean or replace valves REPLENISHMENT CICING NN e Replenish container empty e Refill container REPLENISHMENT SYSTEM Replenishment parameters e Make correct settings DOES NOT WORK settings not correct ALTHOUGH e Electronics defective Replace defective THE MACHINE IS IN electronics PROCESS MODE NO DEVELOPER e Replenish container empty Fill replenish container CIRCULATION e Fuse s blown e Replace fuse Processors with filter Filter clogged Processors with filter Filter valve closed Developer circulation pump defective Replace filter insert Open valve Replace pump Service Manual Plate Processors 68 85 Trouble shooting Problems with processed material SYMPTOM PROBAB
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66. veloper section 1 Use the special tool 2 delivered with the processor when removing brush rollers Insert the roller key between the upper brush roller and the lower support roller as shown 3 Lift up the roller key and force the upper brush roller out of the bearing Use the roller key to lift up the brush roller end 4 out of the bath tank Repeat 3 and 4 for the gear end of the brush roller 131578 Installing brush rollers Inside the top cover is mounted a label showing the position of the rollers page 3 4 Stand on the right side of the processor and hold the brush roller with both hands Place the gear end of the brush roller on the gear of the support roller in the left side of the tank wall Use the roller key 1 to lower the right end of the rollers into the bath tank 2 When mounting upper roller insert the roller key between the upper roller and the lower roller as shown 3 Press the upper roller into the bearing by pressing the roller key upwards 3 Repeat 2 and 3 for the gear end of the brush roller Mount the spray tubes 4 131579 Service Manual Plate Processors 68 85 1244 Adjusting the brushes Maintenance Adjusting the brushes 1244 General The following describes a standard adjustment for the brushes in the prewash developer and wash sections not all models The brush adjustment can vary from one processor to another since it must apply to the specific plate
67. your chemicals supplier for recommendations about cleaning agents for your processor Service Manual Plate Processors 68 85 1224 Maintenance Cleaning Cleaning of developer heating element CAUTION Keeping the developer heating element and it s surroundings clean eleminates the risk of sediment build up underneath the heating element and eleminates the risk of heating damages of the tank When cleaning the tank make sure to wash off all residues around the developer heating element Use plenty of water a soft brush and a soft cloth to clean the gab between the heating element and the tank bottom See illustration below Lp d Y 132302 1244 Service Manual Plate Processors 68 85 Maintenance Cleaning Cleaning of the circulation pumps See illustrations below If the circulation pump ceases to function properly clean the pump following this description Cut off the power to the unit by removing the top cover e Empty the tank section e Dismount the hoses from the pump Be careful not to spill the chemicals on the floor Note the position of the outlet nozzle 5 e Dismount the pump e Dismount the cover 4 and pull out the impeller 3 and the impeller housing 1 e Clean the inside of the cover the impeller and the impeller housing in warm water Reinstall in reverse order observing that the outlet nozzle 5 of the cover is placed as it was before dism
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