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Service Manual Plate Processor+125

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3. 5 2 Problems with processed material 5 3 PCU analizine LED SIENAS qux xu uds EO s Yaku b 5 Level sensor LEDS 5 6 a oye ea ae oe eae eee Ge ee ee ee ee 5 6 MIO analyzing LED signals doom x ROS ac we ose ee 5 MIO pil sad ox uya a Aarne 5 8 Appendix A Electrical diagrams A 1 PHI ha eee ee eee oe eee Rae eee eee ae es A 2 230 VAC control devices A 2 LOW A ecu dg P A 4 sensors and control 5 A 4 Motors and internal A 6 24 aser 6 Service Manual Plate Processor 125 1245 General information 0 11 Manuals 011 Manuals A complete set of manuals consists of the following T32062 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 Spare Parts Manual Plate Processor 1 Language English Contents Spare parts Service Manual Plate Processor 2 Language English Contents Technical specifications Installation Functional description Maintenance Troubleshooting Electrical diagrams 1239 Serv
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5. 20 Roller location U Upper L Lower T31978 Roller pair number Section DV Developer W Wash 1239 Service Manual Plate Processor 125 3 6 Functional description General REMOTE ENABLING ETHERNET Optional X50 MASTER 0 BOARD INTERFACE MEME ______ GNUIB 85485 SETTER 4 22 I PCU Online installations only T32249 Service Manual Plate Processor 125 1239 Functional description 3 7 Electronic control Electronic control See illustration opposite The electrical control system consists of Master input output unit MIO The electrical control system is controlled by the MIO board via the SOM System on Module There are two separate communication lines buses e GNUIB for all internal communication in the processor 5485 ETHERNET for Remote Enabling System Power control unit PCU The PCU board holds all the high voltage in and outputs for the control of heaters motors etc Control panel MMI The user operates the processor from the control panel with one line display Setter connection Connection of a setter interface is made to the terminal block X50 positioned outside the electronics box 732355 1239 Service Manu
6. Click OK GrClient 1 09 27 AN D xl Alarms Gecko 125 Configuration Hardware GLUNZ amp JENSEN Wash configuration System Statu Description E Service mode 482 22 Wash section 506 22 Filter Set Parameter Editor 1 482 Wash section Default 10 Restart Recirc valve Access Leve Service Change ar Cancel Preheat configuration Prewash configuration Developer configuration wash configuration Gum configuration 4 Calibrate Information Hardware number Statistics Settings Configuration Alarms Events Devices Data Help Server Admin Server 10 10 149 91 2012 8 17 10 55 e Click Restart r GrClient 1 09 27 Alarms Gecko 125 Configuration Hardware GLUNZ JENSEN Wash confiquration System A 18 Description ate Uni wre Service mode 482 Wash section Recirc valve 506 Fiter No Service Change Gum configuration M 4 Server Admin Server 10 10 149 91 2012 9 17 10 56 1239 Service Manual Plate Processor 125 EOS Functional description Controls and indicators Configuration file Save a copy of the configuration file locally and on the USB stick once the installation is finished e Set access level to Service Goto Tools gt Remote SW Tools e Click Backup data GrClient 1 09
7. KS gt lt 53 2 method Adjustment method B C P SN p lt N YT Plate Processor 125 Service Manual 1239 Maintenance Adjusting the transport rollers Adjusting the transport rollers Tools 10mm hex key General Make sure that roller locks 1 are properly closed Use key 2 to turn eccentrics 3 Turn eccentric in locking direction to increase roller pressure and against locking direction to decrease pressure Adjust the rollers as follows Turn eccentrics 3 against the locking direction until the roller locks 1 in both sides can move freely between the roller bearings Turn eccentrics 3 in the locking direction until the locks 1 in both sides require a light push to lock feel the click From this point turn eccentrics 3 2 5 marks in the locking direction The adjustment must be made on locks on both sides of the tank in order to reach correct pressure on whole width of the roller T 31642 Service Manual Plate Processor 125 1239 Maintenance Mounting of r clips for gears 4 17 Mounting of r clips for gears Following the lower instructions is very important for the correct function of the processor See the illustration below NEVER mount R clips as shown in the upper illustration ALWAYS mount R clips as shown in the lower
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9. TIT I Mrs Zn e H E x16 fi g Tap water HET Hm Rest 9 ae BB ERR eee EE HHHH L Gum return hose Dev drain Gum 10 Repl 1 Wash drain Dev waste T32354 Service Manual Plate Processor 125 1239 Installation Mechanical installation Power supply cable The cable plug required for main power connection is delivered with some models only See the power supply table earlier in this manual The table also shows recommended power supply cables for processors delivered without cable The conductors in the power supply cable must be of copper When deciding what type of cable to use take into account the chemical resistance chemicals may leak onto cable and the mechanical resistance operator may step onto cable Provide for additional cable protection e g cable covers if cable is exposed to heavier transport such as fork lift trucks etc 32213 Installation of setter interface If the processor is part of an online system now make the installation of the setter interface as described in the Interface Manual When installation of the setter interface is complete please return to this manual for finishing the entire installation 1239 Service Manual Plate Processor 125 Installation Finishing Installation Finishing installation Software settings The processor is configured from the factory The default parame
10. ees 2 9 Water oe ee me 2 10 Mounting of roll rS ___ __ RR RR RR RR hh 2 10 faul D TTD 2 11 Installing the developer filter element 2 12 Filling up developer and wash 2 13 JO 00 2 13 2 13 Mounting the feed table 2 14 Mounting the fenders 2 14 Mounting the delivery table 2 15 Fose CONNECTIONS serre certans eae oe eee eae Ge ee ee 2 15 Gum TBIHB L us REESE E 2 15 2 15 Dey Wess PSP PK E EU Rd dE EE ded X ud ua s 2 15 saw der aaa k Ros OR sch 2 15 2 15 GUM TEMG 2 16 tap WAI ccc eae ae kdb eeawe 2 16 Power supply cable 2 17 Installation of setter 2 17 1239 Service Manual Plate Processor 125 General information Table of contents miss 2 18 Software settings 2 18 j G I C 2 18 Part 3 Functional 3 1 3 1 Controls and I
11. Roller location U Upper L Lower Roller pair number Section DV Developer Installation of rollers At least two persons are required for this operation Open the locks 1 and dismount the brush adjustments 2 Mount the bearings on the transport rollers ensuring that the bearings 3 are turned upwards as shown on the illustration on the opposite page Mount the bearings on the brush rollers ensuring that the bearings 4 are turned downwards with the spring nsert the rollers into the clutches then lower the rollers into the grooves and then close the locks 1 and mount the adjustments 2 132361 Service Manual Plate Processor 125 1239 Maintenance Cleaning Cleaning 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
12. 1239 Service Manual Plate Processor 125 Installation Electrical installation Stacker connection See the Stacker Manual Processor setter connections ctp online processors See the Interface Manual Mechanical installation of the setter can be done now Software settings and test need to be done after the completion of the processor installation Service Manual Plate Processor 125 1239 Installation Mechanical installation 23 Mechanical Installation Adjustment of lid switch See illustration below Adjustment of the lid switch 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 Cleaning the processor tanks Remove all rollers and vacuum clean the tank 5 to remove sponge rubber remains and dust etc a P T32208 1239 Service Manual Plate Processor 125 Installation Mechanical installation 2 10 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 the hose must be connected between the water tap and the GASKET SOLENOID water inlet solenoid valve located at the base panel underneath the processor The hose can be connected to a water tap with 72 34 male thread WRG When connecting to 94 the reduction nipple shall not be used Whe
13. Fuse s blown Developer circulation pump defective Replace fuse s Replace pump NO WATER CIRCULATION Pump defective or clogged Water spray bar clogged Fuse blown Level sensor in wash dirty or defective Clean and or repair pump Clean spray bar See Part 5 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 1239 SYMPTOM PROBABLE CAUSE REMEDY PLATE IS NOT e Gum section applying too e Check gum section COMPLETELY DRY much gum e Dryer section is malfunctioning e Check dryer section Service Manual Plate Processor 125 Trouble shooting Problems with processed material SYMPTOM PROBABLE CAUSE REMEDY PLATE HAS STRIPES LENGTHWISE OR Defective or dirty rollers or guides Take rollers and or guides out inspect and wash them Rollers with dents or other CROSSWISE marks must be changed e Brush es misadjusted e Adjust brush es according to description on page 4 14 e Brush es defective e Replace defective brush es PLATE IS e Developer exhausted e Change developer UNDERDEVELOPED e Machine runs too fast e Reduce the transport speed EXPOSURE IS CORRECT AND PLATE NOT TOO
14. Plate Processor 125 Trouble shooting PCU analyzing LED signals Level sensor LEDs T32013 LED CONNECTOR COMPONENT IN USE D6 X9 5 c and 6 Developer min level sensor D7 X10 3 c and 4 Wash max level sensor Digital ouput LEDs c cC Hulu 9870 veo CO Oy CO o wy gt I 55 mi 9 mi m nmm C 9 Cc am gt c3 132015 LED CONNECTOR COMPONENT IN USE DO1 X9 7 and 8 sink Wash valve Service Manual Plate Processor 125 1245 Trouble shooting MIO analyzing LED signals MIO analyzing LED signals GREEN RED CONDITION LED D16 LED D17 OFF OFF CPU power supply missin
15. Programs PlateSizes Replenishment Preferences Auto Timer Statistics Settings Alarms Events Devices Data Monitor Help Server Admin Server 10 10 148 220 2011 12 21 7 46 Double click on the parameter GrClient 1 09 27 ESI xj Alams Debug Gecko Settings Proqrams G GLUNZ amp JENSEN Unit System Status 1 Speed 89 cm min Ready 4 Developer brush 45140 rpm 5 k mmm enki e s m ENEDETIDUENEENGS x 18 E ME rr 2204 10500 Developer brush speed P1 BD 150 120 DK Help Change Auto Program Programs PlateSizes Replenishment Preferences Auto Timer Statistics Settings Configuration Alams Events Devices Data Help Server Admin Server 10 10 148 220 2011 12 21 7 50 1239 Service Manual Plate Processor 125 Change the value of the parameter Press OK GrClient 1 09 27 Alarms Debug Gecko AL Settings qP Programs Q GLUNZ amp JENSEN Description System Statu 1 Speed 83 cm min 4 Developer brush ME rpm 5 w BEL L lt ES n E E 18 e 2204 10500 Developer brush speed P1 60 150 120 rpm Access Leve Admin Change OK Help Cancel Programs Replenishment Preferences Auto Timer Statistics Settings Configuration Auto Program En Functiona
16. S2 output sensor J10 15 and 16 Output sensor Service Manual Plate Processor 125 1245 Appendix A Electrical diagrams A 1 Appendix A Electrical diagrams This chapter includes all electrical diagrams for the processor The diagrams 3 pages cover Page 1 of 3 Primary wiring 230 VAC control devices Page 2 of 3 Low voltage wiring Sensors and control devices Page 3 of 3 Motors and internal bus wiring 24 VDC distribution 1239 Service Manual Plate Processor 125 Appendix A Electrical diagrams Primary wiring 230 VAC control devices Service Manual Plate Processor 125 1239
17. DEVELOPER S1 INPUT SENSOR E1 HEATING B4 DEV TANK MIN SENSOR OVERFLOW M1 TRANSPORT ROLLER MOTOR DEV BRUSH MOTOR R1 TEMP SENSOR M3 IWAKI IN M4 5 FILTER DEV REPLENISH ee ee COOLER Not all models REPLENISH WASTE 131992 Service Manual Plate Processor 125 1239 Functional description ix sch General WASH 15 WATER K8 V N VALVE FLOW LIMITERS SPRAY TUBE DRAIN WASH CIRCULATION WATER WATER FOX REPLENISH 7 7 K8 4 A VALVE FLOW LIMITERS OVERFLOW SPRAY TUBE WASH TANK 82 MIN SENSOR SPRAY TUBE V DRAIN 54 VALVE N gt CIRC PUMP M10 DRAIN T31993 1239 Service Manual Plate Processor 125 Functional description General GUM APPLICATION TUBE a M23 GUM CIRC PUMP GUM DRYER S2 OUTPUT SENSOR R2 TEMP SENSOR T31994 WQ HEATING M51 M53 HEATING ELEMENT FAN ELEMENT E2 E3 4 5 Service Manual Plate Processor 125 1245 Functional description 3 5 General TRANSPORT NOTE The code indication are mounted on roller brush tap ends DV4U DV2U DV5U DRIU DVSL GAL er ROLLER C ROLLER W BRUSH W GEAR x 09
18. Wash the tank bottom and walls with water using a cloth or soft brush removing all slime Clean the spray bars outside with a cloth or toothbrush and water and the inside using a long handled bottle brush Clean the holes in the spray bars with a piece of thin wire e g paper clip Make sure that all parts are replaced in their original positions after cleaning Mount back the top cover and press the stand by key to start up the processor Major cleaning Follow procedure described for normal cleaning but use a 10 citric acid solution instead of water Service Manual Plate Processor 125 1239 Maintenance Cleaning Gum section Daily cleaning The gum lay on roller ensures a uniform distribution of gum on the gum roller The lay on roller needs to be cleaned each time the processor is shut down in order to ensure proper distribution of gum to the plates Follow the steps below Shut down Shut down the processor at the main switch Remove the top cover Take the gum spray tube a out and clean it Take out the lay on roller and after cleaning place it in the rest position d Release the roller lock b and clean the upper gum roller c with a moist cloth e Place back the top cover Start up Remove the top cover Lower the lay on roller to the process position e Lock the roller lock f Mount back the top cover 132389 1239 Service Manual Pl
19. gt 1 bar 15 psi Water consumption Operation 16 l min tap water in wash 4 2 US gal min Stand by 0 0 l min tap water in wash 0 0 US gal min Hose connections Water supply 12 mm Drain developer 20 mm 0 79 Drain wash 20 mm 0 79 Weights Weight crated 410 kg 903 9 Ib Weight processor 340 kg 749 6 Ib Exit table Capacity max 30 plates NOTE Consider risk of scratches 1245 Service Manual Plate Processor 125 Technical specifications Mechanical specifications 1 4 Dimensions Side view 311 4 cm 122 6 101 116 cm 82 0 97 0 cm 39 8 45 7 32 3 38 2 79 6 94 6 x 31 3 37 2 al mcd Sy ee eee see be oe Sete Top view 123 6 48 7 N E N i gt c O O LO 2 40 15 77 147 8 cm 58 2 131977 Service Manual Plate Processor 125 1245 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 Specifications on the processor s name plate is the actual input current and will thus not be identical to below mentioned Supply fuse Recom cable type EUR single Phas
20. 1 1 The processor does not contain 1 1 upaya o w aw skua S Q s eae wQ ole ea ee 1 1 1 1 2200 ee 1 1 1 1 a 1 1 Noise emission 1 1 Chemical emissions 1 2 Heat emissions a 1 2 Mechanical specifications 1 2 1 2 1 2 1 3 Water requirements 1 3 dE k sql usa RR 1 3 Hose 5 1 3 S FJ PS ee eee eee S ps 1 3 adm cC 1 3 DimensionS 1 4 Electrical specifications ss u u s s uw i Owed ua qu w Q u a 1 5 uus va oh hpa q 1 5 dic se eee se 1 5 ee Ow eae a owe ee 1 5 1 5 Service Manual Plate Processor 125 1239 General information Table of contents Part 2 Installation seem mnm nn 2 1 NOUNS s oe 4 1 1117 2 1 Installation hours for off line mach
21. Developer devices GLUNZ amp JENSEN System Status mode 10701 M2 Brush motor 10707 B1 Process level sensor o 10720 M3 X Circulation pump 10724 M4 X Replenish pump COMME E i0730 F1 v Hastar m 10732 X s 10740 25 7 t Restart Name 10724 M4 Replenish pump Default false C Off On Access Leve Service Change E Help Cancel Display devices Transport devices Developer devices devices Dryer devices Alarms Events Devices Help Server Admin Server 10 10 149 91 2012 9 13 14 57 Fill up the container so it contains 2 litres of developer Letthe pump run for 1 min exactly T 31943 1239 Service Manual Plate Processor 125 Maintenance Calibrating of solenoid valve e Goto Data Configuration gt Calibrate gt Replenish Set the measured value D x Alarms Gecko 125 Configuration Calibrate GLUNZ amp JENSEN 10524 z x Replenish pump capacity 180 E ml min 14508 7 Water valve capacity 3300 ml min ystem Status j Service mode 10524 Replenish pump capacity 1 3000 180 Restart r Access Level Service Change Calibrate Information Hardware Choices Serial number Statistics Settings Configuration Alarms Events Devices Data Monitor Server Admin s emer 10 10 149 91 2
22. PC s harddisk access the Remote Client please activate the grclient exe stored in the folder GrClient Copy Install GrClient Tip Copy a shortcut of the grclient exe to the PC s desktop for easy access to the Remote Client Electrical connection IfaLAN Local Area Network cable is Network cable connected to the processor or the PC is t connected to wireless LAN make sure to e N amp me Yee W N Y W N Y Y EE or Y A dy EFT e W W disconnect the cable connection now Connect the Ethernet cable delivered with the processor between the PC and the processor see illustration T32182 Setting up the service connection between the processor and the Remote Enabling System Enter the menu on the processor s control panel by pressing the A button See also the control panel Quick Intro guide If the display shows Service Code 2 the software configuration is missing e g due to replaced SOM PCB Back up configuration file can be loaded with the Remote Enabling System Please continue as described below Press A to scroll to the Service Info menu and press enter 4 Press to scroll to the LAN IP address marked with D and press enter You will now see a service IP address 169 254 11 xx in the
23. Plate Processor 125 Installation Mechanical Installation 2 14 Mounting the feed table Offline processors only Mount the guide pins 1 on the feed table 2 by using the screws 3 Mount the screws 4 into the front panel Do not tighten the screws Attach the feed table 2 on the screws 4 and then tighten the screws Secure the feed table from the bottom by using the two screws 5 Make sure the lock fits into the counterpart 6 132211 Mounting fenders Mount the left and right fenders with the screws as shown below T32001 Service Manual Plate Processor 125 1239 Installation Mechanical installation W Mounting the delivery table On the front end of the delivery table is a supporting bar Mount the delivery table by attaching the supporting bar inside the exit slot of the plate processor Hose Connections The illustration at the next page shows the hose configuration Make the tollowing hose connections underneath the tank nm All drain hoses must have a positive fall from the processor to the waste containers and drain Never lead drain hoses from the developer section to a drain as most developers are strong pollutants It is also illegal to empty these types of chemicals into the public sewer system is not used in the draining system since the chemicals involved might corrode it Plastic or rubber is therefore recommended Check with your ch
24. display 1 A preset IP address which needs to be changed in case the processor will be connected permanently to the Remote Enabling System via an internal network See the Remote Enabling Installation guide 2 This is a service IP address dedicated for service technicians to connect to the Remote Enabling System either for making settings and configuration of the equipment as described in the following or for setting up the equipment to a permanent Remote Enabling installation permanent LAN IP address at the customers site Service Manual Plate Processor Plate Processor 125 1239 Functional description Controls and indicators Makea note of the service IP address It is needed for connecting to the Remote Enabling System e Start the Remote Client shortcut icon on the desktop In the Remote Client select Server Admin 1 See illustration below Enter IP address from the processor 169 254 11 x in the Server field 2 and click Add This will create the connection between the processor and the Remote Enabling System Click OK Check that connection to the processor is established Re open the Server Admin and make sure that status field 3 for IP address 169 254 11 xx shows When OK the processor tab 4 will appear in the upper left corner of the Remote Client window zx 5 x Ten Seve Staus 7
25. dvel Z ld AO ge unall i 24 100 9 3721 NDd HUN 3 Appendix A Electrical diagrams Low voltage wiring Sensors and control devices Service Manual Plate Processor 125 1239 avo uoissiuued 4 sno pezuoujneun JO u pisc dea Hain OUD puy siosu s 4 TV2INVH23W ANY 21 0 12313 Siionin E eBe3oA T NASNAP 8 ZN 119 2102 LZ 1 ejeg HA HOA TWNOILdO Josuas 1Osu s yue useM yue eq n a 2 Ld zg vZ 8M all X Lt T b U 5 gt x x e w gt N a 9988900
26. illustration T32010 1239 Service Manual Plate Processor 125 Maintenance Calibrating of the replenish pump 4 18 Calibrating of the replenish pump Calibrating of the pump is done via the Remote Enabling System See page 3 10 Activate the service mode in the processor menu 132390 e Place the suction tube from the replenish pump into a measuring container with developer Start up the Remote Enabling client Click Change access level 1 Enter Password 3 GrClient 1 09 27 DJ x Alarms o Gecko 125 0 cm min 12 plates 12 0000m2 4 Input1 gt 1 gt GLUNZ 8 JENSEN System Status N zx 2 m Status to Setter F ddr ef x m 23 6 C Access Level Password hr Access Level Admi Alarms Events Devices Data Tools Monitor Server Admin 10 10 149 91 2012 9113 1322 Service Manual Plate Processor 125 1239 Maintenance Calibrating of the replenish pump Click on Devices gt Developer devices e Double click on Replenisher pump Startthe pump to remove air from the tube and let the pump run till no atr 15 in the tube Stop the pump gt GrClient 1 09 27 91 Alarms Gecko 125 Motors Outputs Sensors Temperature
27. localhost Disabled Syelem Status 11159254110 Ok Modify Access Level User Acces Level 5 u Change 9 s 1 Cancel T2658 Alarms Devices User Setup Service Setup Heb Sever 169254130 For more information about the Remote Enabling System please see the general installation manual enclosed with the Remote Enabling software Static IP address setting In case of a permanent connection to a local installation of the Remote Enabling System via a LAN the IP address of the equipment needs to be set to a static IP address Contact the local IT administrator for obtaining an IP address Enter Server Admin 1 Select the processor IP address 169 254 11 xx 3 and click Change access level 5 e Enter Password duy Select 6 1239 Service Manual Plate Processor Plate Processor 125 e Select Netwotrk a Server Configuration Network ID Hostname 9040798 Domain address 001 1 D E 04 07 38 TFTP server 0 0 0 Automatic IP addresses DHCP Static IP addresses IP address 0 10 149 91 Subnet mask 255 255 240 0 0 10 1441 Default gateway Automatic ONS addresses DHCF Static DNS addresses Primary ONS server 0 10 15 251 Alternate DNS server 10 1016 251 Functional description Controls and indicators e Select the static IP addresses and change the IP addre
28. pressure too high Brush speed too high Adjust brush according to description on page 4 14 Reduce brush speed Service Manual Plate Processor 125 1239 PCU analyzing LED signals Trouble shooting PCU analyzing LED signals GREEN YELLOW RED GREEN CONDITION LED D1 LED D2 LED D3 LED D88 OFF CPU power supply missing OFF FLASHING OFF ON Waiting for SoM MIO to power up If 1 5 sec flashing continues more than 6 pause seconds after power up please check RS485 cable connection and follow up on status stated in this table OFF OFF OFF ON Malfunction PCU OFF ON OFF ON PCU is ready to receive messages from MIO SoM FLASHING ON OFF ON PCU is receiving messages from MIO SoM OFF OFF ON ON Malfunction PCU ON ON ON Possible hardware error detected but trying to continue normal operation 6759 8 NE 558 210 110 C7 NO CO NO L Do unjo T32012 LEDs D5 D12 green show the status of level sensor inputs 0 7 LEDs DII DIS green show the status of digital inputs LEDs DO1 DO8 green show the status of digital outputs LED STATUS INPUT OUTPUT SENSOR STATUS ON OK in level FLASHING Disconnected OFF Not OK not in level or not in use 1245 Service Manual
29. proper function location of Upper side panels left right Make sure they are properly secured with 2 screws each Lid electronics cabinet Make sure the lid is secured by screws Service Manual Plate Processor 125 1239 Maintenance Fuses Fuses Motor fuses F17 and F18 are located in cables leading to connectors X4 and X5 Other fuses for the vartous functions are located in the electronics cabinet behind the right fender The fuses are placed on the PCU board and in the fuseholder on the inside of the cabinet bottom and on the PSU board on the inside of the cabinet lid Motor fuses T32215 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 Motor fuses Fuse Fuse for Type Part no Epl Transport motor M1 zh mm 5 F18 Brush motor M2 fuses for Type Part F amp 22 amp 12 mm 1239 Service Manual Plate Processor 125 Maintenance Rollers and brush rollers Rollers and brush rollers General Label showing the roller configuration a is placed on the top of the upper safety cover and on page 3 5 in this manual Each brush is marked with a small number b Install the rollers by referring to the roller numbers on the label DV 2U LL I
30. the PVC can be incinerated at a suitable incinerating plant PCB s and other electric equipment must be sent to a suitable waste deposit Service Manual Plate Processor 125 1239 General information The processor Service assistance f help is needed to correct any problem with the equipment please contact your local supplier 1239 Service Manual Plate Processor 125 General information Table of contents Table of contents Part General information 0 3 Reservations ee Bee nia ia i is nis nia Ra GE aH i 0 3 Notes cautions and warnings 0 3 Side 0 3 0 3 0 3 Unintended use of the 0 4 Intended use of the 0 4 0 4 sa 0 4 i o 0 4 End of lifetime 0 4 Service assistance 0 5 Table Of CONLEINS 5420065046682 0 6 S 9x 3595 52 baba ses 0 11 0 11 Joers manuals sosa sa ch twee ode 0 12 Part 1 Technical 5 1 1 General environmental information
31. 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 warranty Standard recommendations Warm water 35 40 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 your chemicals supplier for recommendations about cleaning agents for your processor 1239 Service Manual Plate Processor 125 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 o d mam uo Servi
32. 012 9 13 15 04 Calibrating of solenoid valve The processor must be in service mode and access level must be set to Service as described on page 4 18 e Dismount the hose leading from solenoid valve to wash spray fitting and place it into the measuring container Goto Devices gt Wash devices Double click on Water valve and let run for one minute Measure the volume of water pumped into the container e Goto Data gt Configuration gt Calibrate gt Water valve capacity Set the measured value Service Manual Plate Processor 125 1239 Maintenance Chain servicing 4 21 Chain servicing Regular chain servicing is important if maximum life is to be achieved Find data regarding processed m2 and processing hours via Remote Enabling System e Goto data gt Statistics gt Counters gt Plate counters gt GrClient 1 09 27 Gecko 125 Statistics Counters GLUNZ amp JENSEN Plate counters System Status Id Description __ Unt Wite Service mode 22 Processed plates absolute 12 Service 4004 Processed plates relative 12 4005 Processed area absolute 12 0000 m2 Service 4006 Processed area relative 12 0000 m2 4007 process time 0 616 h Service Restart Access Level Admin Change N Plate counters Counters Statistics Settings
33. 1 6 001 UJ UJ A A UJ UJ M N ES N Q a l tA CN Pk jer fer for e Je 79 18 r fe fz er fer fer for fe fe fo o fo fe fz me qo pe ye 2 9 fs Tv PTE i E UI d d j d d L at r r 172 7 GIVA BWA AST CANT TAS x LWA 9IVA 0 snug O9PAO 9pAFPZ gu 9pA 0 pue BAI JUN JO1 UOD 1osu s 1osu s Josues Josuas yndu duu 10 dwa 5 4 5 4 rN 1 4 ON ON ae Jaydns 8919S HOLS ua Jno 263000 JO suonoeuuoo jenjoe Jeyes ees HS 05 is idi ds I a fd Jenes Jld L L wo f ae S c c c c c c 8 8 B 8 8 S S R a om N Jeuondo LOELVOOL o o o 8 a IN N N N N ee ee E E La _ Pak aie 1 1 OLIO fy x XA T E fX Jj aD POE oz le mute L piii 67097 797 oT p a tar fer a clr LU our Wid
34. 100 cm 39 4 732205 online For the On line processors the space requirements at the processor front has to be decided separately Service Manual Plate Processor 125 1239 Installation 2 3 Preparing the installation site Power outlet If not already there a main power outlet should be installed in the room where the machine will be installed Max distance to the machine 2 m 6 ft See power outlet and fusing requirements earlier 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 Minimum recommended size of the sink 150 x 40 cm 59 6 x 15 7 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 reception systems for waste chemicals copper or brass should not be used in the draining system as the chemicals involved are highly corrosive Therefore 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 condit
35. 27 Alams Gecko 125 GLUNZ amp JENSEN SW Update System Statu Off Enable remote Sw Update Restore data Save Log Files pues mun Usb Stick Internal Service Change B Backup Manual tasks Cleaning tasks Brush calibration Software tools Remote SW Tools Alarms Events Devices Data Tools Help Server Admin Server 10 10 149 91 2012 9 17 10 08 Select the folder where the file will be saved and click OK Alarms s MS 25 Update Frahle remote 5 System Status MN Select Directory Directory C Documents and Settings plc Desktop 1 09 27 Directories Files 7z dll Documents and Settings zCon sf 25 plc alarmHiah bmp gt Desktop alarmLow bmp o V 0927 alarmOff bmp applT oContainer bmp gt Drives win Service Change Manual tasks Cleaning tasks Brush calibration Software tools Remote SW Tools Alarms Events Devices Data Tools Help Server Admin Server 10 10 143 31 2012 9 17 10 11 Service Manual Plate Processor 125 1239 Maintenance General Part 4 Maintenance General This chapter holds the special service information such as adjusting procedures cleaning of pumps etc For user related maintenance and cleaning procedures refer to the Plate
36. Configuration Alarms Events Devices Data Help ServerAdmin Server 101014881 2012913 15 32 After processing of 400 hours 6 500 m whatever comes first e Check chain tension and adjust if necessary See chain adjustment procedure on page 4 26 After processing of 2 500 hours 80 000 m whatever comes first Carry out the chain tension check Check for wear on side plates of the chain link Check for chain elongation See the tollowing page for how to check for potential chain wear Check cleanliness of components remove any accumulations of dirt or foreign materials Check for shaft and sprockets alignment Check for wear on sprockets Check the condition of the lubricant lubricate the chain working surfaces 1239 Service Manual Plate Processor 125 Maintenance Chain servicing How to check for potential chain wear The below guides line should be followed after processing 2 500 hours 80 000 m of plates Measure the length of the chain between the given number see latter illustrations of pitches Measurement point Measure between two given numbers of pitches Service Manual Plate Processor 125 1239 Maintenance Chain servicing Control the length Control the length of the chain to measure the extension of the chain by measuring the chain extension between the given numbers of pitches See the recommendation at the dra
37. IN uodsuei k sv y S MEME i Yeter Tz Ye Y LN gt gt gt gt gt S e N N N o LES Jepoou3 ZW usnig k e E y 5 2 S 5 8 LLLI 1 Terr Zk3 N v GX vecZSOOl 814 9 Hi 91986 Li 8 v 9 Br 9 19409 pue 2 z al z dojs 3 8 pos 8 8 8 5 UO NO vC eo b gl b gl h 4 0 8L ZNO 5 SL ZNO 5 d 9 0 6 N18 Je 0o43u02 NO IPA vC F 1v90 L SNO O S sou e S GNO Ajddns i 83 OPA vc 19 614 IPA o 1 9 054 Nd PUN jo4002 JO Wed L NSd uo S NO OQA vc
38. OLD e Developer temperature too low Developer circulation insufficient Brush out of adjustment Replenishment insufficient slightly Increase developer temperature slightly Check function of circulation pump and spray tubes Increase replenishment rate slightly Calibrate replenish pump according to description on page 4 18 Adjust brush according to description on page 4 14 PLATE IS OVERDEVELOPED EXPOSURE IS CORRECT AND PLATE NOT TOO OLD Machine runs too slow e Developer temperature too high Replenishment setting too high Increase the transport speed slightly Reduce developer temperature slightly Reduce replenishment rate slightly Calibrate replenish pump according to description on page 4 18 WASHING NOT SUFFICIENT Water tap closed Water solenoid valve defective or water filter clogged opray tubes clogged or misadjusted Water circulation pump does not run Brush misadjusted Open water tap Check valve and filter Clean or adjust whatever is necessary See page 4 10 Adjust brush according to description on page 4 14 PLATE HAS AN UNEVEN GUMMING e Gum container nearly empty Gum rollers dirty Gum distributing tube clogged or out of adjustment Gum pump clogged Refill container Take rollers out and clean them Take tube out and rinse or readjust Take pump apart and clean valves PLATE S TRAILING EDGE IS BENT e Brush
39. Processor User s Manual Download of software for upgrade or repair purpose is available from the manufacturer s web site www glunz jensen com WARNING Please note that where this label appears on the processor electrical shock hazard still exists when the main switch is turned off ELECTRICAL SHOCK HAZARD DISCONNECT ALL EXTERNAL POWER SUPPLY BEFORE SERVICING 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 is still active making the drive system run idle at intervals 1239 Service Manual Plate Processor 125 Maintenance Safety check Safetv check A Below described safety check 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 es Processor must stop when the switch es is deactivated Main switch Processor must turn off when set to 0 Emergency stop Processor must turn off when activated ai ____ Main switch Electronics cabinet side panel 732214 Mechanical Check
40. Service Manual Plate Processort 125 Service Manual Plate Processor 125 Edition BB November 2012 This book has part No 10065164 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 Phone 45 57 68 81 81 E mail gjhqQglunz jensen com Internet www glunz jensen com Copyright O 2012 by GLUNZ amp JENSEN A S Service Manual Plate Processor 125 1239 General information 0 3 The processor W 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 Symbo
41. a 132002 Scrub chain 2 Adjust the chain tensioner c until the notch is aligned with thread M5 d Chain tension must be between 10 and 22 52 e Mount the lock screw and fasten the chain tensioner 732003 Service Manual Plate Processor 125 1245 Maintenance Preventive Maintenance Kit Program Preventive Maintenance Kit Program To ensure continues high quality and maximize productivity and processor up time it 15 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 1250 production hours or every year what comes first Medium Preventive Maintenance at 2500 production hours or every year what comes first Minor Preventive Maintenance at 3750 production hours or every year what comes first Major Preventive Maintenance at 5000 production hours or every year what comes first nm Please refer to the Spare Parts manual for order numbers for particular kits 1239 Read more about our Preventive Maintenance Kits on www glunz jensen com and see the content of the Preventive Maintenan
42. al Plate Processor 125 Functional description Controls and indicators 3 8 Controls and indicators The processor is equipped with the function keys located on the right fender see illustration below Function keys standard function 1 Eject plate manual function Starts the transport system to eject a plate jammed inside the processor 2 Manual replenisher Gives a fixed amount of replenisher to the finisher section 3 Scroll up Scrolls up in the menu of the control panel 4 Accept Accepts the chosen function 21 AJ amp pr m as T32053 Function keys service mode To enter the service mode press scroll up button 3 until Service Info appears and confirm it by pressing button 4 twice All service activity must be done via Remote Enabling System 2 Pump calibration Calibrating of the pump is done via the Remote Enabling System See page 4 18 for the procedure Service Manual Plate Processor 125 1239 Functional description Controls and indicators Indicators The control panel holds 3 indicators 5 Power white 6 Ready green and 7 Alarm red GREEN RED CONDITION OFF OFF OFF For software older than xxx 20111201 gt minute Power off or initializing For software newer than xxx 20111201 Power off or malfunction SoM MIO Check cable connection to LDM if system stays in this state See PCU analyzing LED signals on
43. ate Processor 125 Maintenance co Cleaning Major cleaning Stop the processor and replace the gum container with a container with hot water Start the cleaning cycle via the control panel and let run Stop the processor and replace the hot water container with the Gum container Cleaning of the circulation pump See illustration 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 Empty the tank section Dismount the hoses from the pump Be careful not to spill the chemicals on the floor Note that the position of the outlet nozzle 5 should point as shown Dismount the pump Dismount the cover 4 and pull out the impeller 3 and the impeller housing 1 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 dismounting it and that the O ring 2 is placed correctly in the groove of the impeller housing 1 T31064 Service Manual Plate Processor 125 1239 Maintenance Cleaning 4 11 Cleaning of valves in the replenish and small circulation pump If a replenishment or a small circulation pump ceases to function properly run it with some warm water in order to clear the pump of chemicals If this does not help take the pump VALVE NS apart and clean the small valve
44. ce Kits or contact us at order department glunz jensen com Service Manual Plate Processor 125 4 27 Maintenance Preventive Maintenance Kit Program Service Manual Plate Processor 125 1239 Trouble shooting General Part 5 Trouble shooting General If the processor does not work properly refer to the following pages to find the paragraph that comes closest to your problem The trouble shooting guide is divided into 4 sections A Problems with the processor B Problems with processed material C PCU analyzing LED signals D MIO analyzing LED signals For cleaning and maintenance subjects see the processor user manual and chapter 5 in this manual Ihe 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 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 1245 Service Manual Plate Processor 125 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 res
45. ce Manual Plate Processor 125 1239 Maintenance Cleaning Removing rollers from clutch case 131626 Removing drive clutch from clutch bearings 131627 1239 Service Manual Plate Processor 125 Maintenance Cleaning Developer section Normal cleaning Turn the processor off Remove the top cover Drain the tank Remove spray tubes and rollers from the section Clean rollers with a cloth or soft brush and water e Wash the tank bottom and walls with water using cloth or soft brush Clean the spray bars outside with a cloth or brush and water and the inside using a long handled bottle brush Clean the holes in the spray bars with a piece of thin wire e g paper clip Make sure that all parts are replaced in their original positions after cleaning Please refer to the label of roller configuration placed on the top of the upper safety covercover Mount back the top cover and press the stand by key to start up the processor Major cleaning Follow the procedure described for normal cleaning but use a solution of tank cleaner if needed Wash section Normal cleaning Turn the processor off Remove the top cover e Drain the tank Remove spray tubes transport rollers and brush from the section Clean transport rollers with a cloth or soft brush and water While running water over the brush roller draw it through your hand use rubber gloves
46. dIGa 0fS 3 1 LC OI CONO 3 7 Master input output unit MIO 3 Power contol 3 7 Control panel NIMI v uy sas 3 7 Setter COMMCCUON 25256425 bas pu g us ae 3 7 3 8 Function keys standard 3 8 1 Eject plate manual function 3 8 2 Manual 3 8 3 8 3 8 Function keys service 3 8 2 Pump calibration aue ue us ado e dod 3 8 DOT SEDIS v x3 415 3 9 5 Power white 6 Ready green and 7 Alarm red 3 9 JOB THHCHO D 2 cases a ua mor EG E Run ke x lt N KW R NCR S S s Qs N W OR eee 3 9 sue 3 9 Connecting to Remote Enabling System 3 10 Electrical connection 3 10 Setting up the service connection between the processor and the RES 3 10 Static IP address setting zoo aor uos ICE s 3 11 Change of processor 3 13 PIMC 3 14 Change of wash configuration 3 15
47. de Roque d Duk 4 8 Normal CIGANE pus ya pu a 4 8 Major 4 8 Gum section 4 9 brune s go way teed eee ee aro yo e sie Qs m ee W eo 4 9 4 10 Cleaning the circulation pump 4 10 Cleaning of valves in the replenish and small circulation pump 4 11 Adjustment of CON pimp ol l 4 11 Cleaning of spray 4 12 Developer and 4 12 VV J lis 4 12 Adjustment of Spray tubes odd eee 4 12 Replacement of 5 4 13 Adjusting the brush pressure 4 14 General a s OE ROS 4 14 Processor 2224255 Pur ERR E ESTE PAS ERI SURE S RO ER a RUE Y d 4 14 Mic 4 14 Adjustment 4 14 Adjustment method 4 14 Adjusting the transport rollers 4 16 4 16 cs ae eae E 4 16 Mounting of r clips for Sears 4 17 NEVER ook et ee ee
48. e IW N PE Min 3x 1 5 m 230V 1 x 16 Amps 50 60 Hz type H03VV F US Single Phase 2W PE Min 3 x 14 AWG 230V 2 x 20 Amps 50 60 Hz type SJ or SJO JAP Single Phase 2W PE Min 3 x 14 AWG 200V 2 x 15 Amps 50 60 Hz type SJ or SJO All Voltage tolerance 10 Fuses The fuses must have a breaking capacity of min 100kA If using automatic circuit breakers make sure that they are Type D Power consumption Power consumption at EUR US 230 VAC operation approx 1 75 kWh 6 000 BTU hour stand by approx 0 06 kWh 200 BTU hour Power maximum 2 9 kWh 10 000 BTU hour Noise level See General environmental information on page 1 1 1239 Service Manual Plate Processor 125 Technical specifications Electrical specifications Service Manual Plate Processor 125 1239 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 electrical water and drain installations are in place the estimated installation time is 4 5 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 Standard installatio
49. eS 3 16 Part 4 Maintenance 4 1 4 1 ou uz dhe se hoe eae eee ee oe ee 4 2 s p i p PPP dae ea ee eee ee ake 4 2 IO T Bee eee ee ROME eee ER 4 2 s S eee 4 3 MUSES 22 cw eee eae eae 4 3 11565 S ka EES ee 4 3 Rollers and brush 5 4 4 4 4 installation of xu 4 4 GI goede s a qusa sa a E S S meted pene deeb ban s cede 4 5 4 5 Cleaning 5 5 4 5 Service Manual Plate Processor 125 1245 1245 General information Table of contents SUED w w S Y ees 4 5 Standard 5 4 5 Special lt 4 5 Cleaning of developer heating element 4 6 Removing rollers from clutch case 4 7 Removing drive clutch from clutch bearings 4 7 Developer 5 4 8 u u c hae wu 4 8 Malor Clea cT 4 8 Wash SOCO uu dog x
50. ecured using tape plastic strips and various pieces of sponge rubber Make sure to remove all items Lifting the processor off the pallet Enter the fork lift under the processor from either the input or exit end of the processor Lift the processor off the pallet and place it on the floor Severe damage will be caused if the fork lift is entered underneath the left or right side of the processor 1239 Service Manual Plate Processor 125 Installation Unpacking preparing the processor Removing the fenders In order to make the electrical installation it will be necessary to remove the fenders from the processor See illustration below Liftand remove the top cover Loosen the screw lift and pull the side fender to remove it T32000 Service Manual Plate Processor 125 1239 Installation op Electrical installation Electrical installation General Electrical installation must conform to local regulations and guidelines The processor is Class 1 equipment Therefore the processor must be connected to earth to avoid electrical shocks Main power connections The main power connection must be made to the main connector a in the electronics cabinet b by the delivered cable Check the processor connections see pages 1 5 for the current wiring type ii MD I L 132207
51. emicals supplier for details Particularly when preparing the drain connection ensure that copper or brass nm Be careful that the drain hoses do not sag or form water traps Gum 10 Blue Connect to gum container The gum hose 10 should be cut off to the shortest possible length to avoid any sagging and formation of water traps and or air pockets Repl 1 Red Connect to developer replenishment container Dev waste Connect to waste container Dev drain Connect to waste container Wash drain Connect to waste container 1239 Service Manual Plate Processor 125 2 16 Installation Mechanical Installation Gum return hose Connect to gum container When inserting the gum return hose into the gum container make sure that the hose ends are never below the gum surface see illustration below T31366 Tap water Make connection from water tap to solenoid valve underneath the processor M23 M34 D a I X39 M34 y 2 i 37 23 zm XI5 M4 B1 HGH VOLTAGE XIZM3 eco P m o ozan fu
52. g or malfunction SoM MIO gt 1 minute Remove all cables from the electronics cabinet except power and emergency switch and try again e Check the SoM board connection e f still not good replace MIO SoM LDM board ON ON Maybe malfunction SoM gt 1 minute e Remove all cables from the electronics cabinet except power emergency switch and 5485 cable P1 P1 and try again Check the SoM board connection If system still don t start up create via PC 2 files a platform and a platform txt file with the platform text inside acu rtp hdx etc Store the 2 files on the memory stick insert it to the processors electronics cabinet and power off and on Wait at least 3 minutes Then check via PC that platform or the platform txt file is renamed to platform old file If no file is renamed replace MIO SoM LDM board TOGGLING ON For software newer than xxx 20111201 Power up sequence Sequence last approximately 1 minute Green LED goes off on approximately 5 times in an irregular pattern ON OFF For software newer than xxx 20111201 Software started Please see display for status 1245 Service Manual Plate Processor 125 Trouble shooting MIO analyzing LED signals MIO inputs SENSOR CONNECTOR COMPONENT IN USE R1 J10 1 and 2 Developer temperature sensor R2 J10 5 and 6 Dryer temperature S1 input sensor J10 13 and 14 Input sensor
53. ice Manual Plate Processor 125 General information Manuals 0 12 User s manuals User s manuals available for the equipment CE Declaration Of Conformity 3 Languages 26 Contents Survey of the directives to which the equipment conform Safety Instruction Manual 4 Languages 28 Contents General safety information User s Manual Plate Processor 5 Languages 5 Contents Operating and cleaning procedures Quick Intro Control Panel 6 Languages 5 Contents Quick guide to control panel user functions Maintenance Chart Plate Processor 7 Languages 5 Contents Maintenance instructions Recycling Passport Plate Processor 8 Languages English Contents Unit material recycling information Keep the manuals with the machine for reference at all times Service Manual Plate Processor 125 1239 General LIE Part 1 Technical specifications General environmental information The processor does not contain Ozone depleting substances according to Montreal protocol Asbestos Polychlorinated biphenyl or Poly Cyclohexylenedimethylene Terephthalate Mercury Cadmium Lead as additive to plastic parts Plastic parts Significant plastic parts are marked according to ISO 11469 Batteries No batteries in this equipment End of life Estimated product life 10 years Spare parts and service period 7 years after last sales Recycling The processor should be disposed at a ce
54. in warm Y INLET water OUTLET NOZZLE T438 Adjustment of gum pump The gum pump is set with a default approx 7 5 mm pulsation from the factory In case the 7 amount of the gum pumped into the application roller is too high or too low adjustment of the pulsation can be changed by adjusting as described below Loosen the nut 1 and adjust the screw 2 on the bottom of the pump bracket to set l up the correct amount of gum by moving the coil of the pump forward or backward T31945 1239 Service Manual Plate Processor 125 Maintenance Adjustment of spray tubes 4 12 Cleaning of spray tubes Developer and gum section Clean the spray tubes in the developer section with hot water to remove potential blocking of the holes Occasionally it may be necessary to use a drill bit to clean the holes and remove sediments mechanically Wash 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 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 illustra
55. ine 2 1 Standard installation hours for on line 2 1 Customer training 2 1 Preparing the installation 2 2 Space requirements 2 2 ORA dI SCC ee pe ees aes ees ans peewee eee eee ee eee eek eae ee 2 2 ee eee ee eo es 2 3 Cleaning acili OSes pirre sste 2 3 Dran CONNECTIONS aed x ace sia Q EREA 2 3 Environmental requirements 2 3 Unpacking preparing the 5 2 4 2 4 u u rv u Lu ee Yi 2 4 Transport through narrow doorways 2 4 Transport security items 2 b Lifting the processor off the pallet 2 b Removing the 5 2 6 Electrical 2 7 PTT 2 Main power 5 2 Stacker CONNCCUOW s wean cu 2 8 Processor setter connections ctp online processors 2 8 Mechanical InstallatlOll T uniri d ew uska x LEE ED Hm k SUR SENE 2 9 Adjustment of lid switch PPP 2 9 Cleaning the processortankS
56. ion ventilation system must be adequate for heat emission see Power consumption on page 1 5 1239 Service Manual Plate Processor 125 Installation Unpacking preparing the processor 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 spare parts kits are included with the processor They comprise the different parts necessary to make the installation and some key components as spare parts See enclosed packing list 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 If width of the door is Then gt 159 No action is required as the crated processor can be transported 62 6 immediately to the installation site 125 159 The Service Technician has to unpack the processor 49 2 62 6 lt 125 The Service Technician has to and strip down the 49 2 processor Service Manual Plate Processor 125 1239 Installation Unpacking preparing the processor Transport security items During transportation many of the parts outside and inside the processor have been s
57. ke final leveling if required SETTER OUTPUT HEIGHT 2 mm ye Ver 132210 1239 Service Manual Plate Processor 125 Installation Mechanical Installation 2 12 Installing the developer filter element The developer tilter element must be installed in the filter vessel at the leftt tank side Unscrew the filter cover 1 counterclockwise and lift it off Mount the filter element 2 underneath the cover and lower it into the vessel Make sure that the O ring 3 is fitted properly in the filter vessel groove then tighten the cover 1 clockwise Remember to open the filter after installing the filter element T32009 Service Manual Plate Processor 125 1245 Installation Mechanical installation Filling up developer and wash Developer Make sure that the developer drain stand pipe is closed see illustration Fill up the developer section manually as shown in the illustration below Wash Wash water recirculation system If the processor is equipped with a wash water recirculation system the wash section will fill up automatically when the processor is switched into stand by mode Remember to calibrate the solenoid valve See description on page 4 20 No wash water recirculation OPEN CLOSED The water solenoid valve will let in water when a plate is entered through the input slot 131981 1239 Service Manual
58. koe oe 4 17 DR YS Mine S a ee eee eed wed eRe eae eee 24 4 17 Calibrating of the replenish 4 18 Calibrating of solenoid 4 20 Chain Seri Iflg 4 21 After processing of 400 hours 6 500 2 4 21 After processing of 2 500 hours 80 000 2 4 21 How to check for potential chain wear 4 22 Measurement 4 22 Measure between two given numbers of pitches 4 22 Control the length 4 23 LOOC 22553 4 24 Idler sleeve bearings 4 24 Chain adjustment procedure 4 26 Service Manual Plate Processor 125 0 10 General information Table of contents 4 26 Main chain 1 4 26 4 26 Preventive Maintenance Kit 4 27 Part 5 Trouble shooting 5 1 5 1 Before starting trouble shooting 5 2 Problems with the processor
59. l Meaning Explanation 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 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 1239 Service Manual Plate Processor 125 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 Asthe equipment is certified by accredited test laboratory UL International Demko A S itis 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 photogra
60. l description Controls and indicators Alarms Events Devices Data Help Server Admin Server 10 10 148 220 2011 12 21 7 48 Plate sizes Plate sizes must be entered in order to obtain exact calculation of replenishment Select Data gt Settings gt Plate sizes Define new or select already used plate sizes GrClient 1 09 27 Alarms Gecko 125 Settings WP PlateSizes Glunz a sensen 9 Description Lengh width ParPlates Unit mm System Statu 1 Plate 1 5000 200 Ho Service mode 2 Plate 2 0 3 Piata a n FE merical Parameter tor 5 B 3201 Plate 2 Length 5000 8 0 Restart 3 10 11 12 2 Help Replenishment Configuration Preferences amp uto Timer Programs PlateSizes Statistics Alarms Events Devices Data Settings mm mm mm mm mm mm mm mm Help Server Admin Server 10 10 149 91 2012 9 13 16 10 Service Manual Plate Processor 125 Functional descripton Controls indicators Change of wash configuration Click Change access level and set to Service e Enter Password duy e Goto Data gt Configuration gt Hardware gt Wash configuration Double click on Tap water and set it to Recirc valve
61. n 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 1239 Service Manual Plate Processor 125 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 the machine is specified in the illustration below 412 cm 162 20 1 ME N SN gt 60 cm 23 6 Exit table optional I Processor op gt 50 cm 19 7 gt 50 cm 19 7 emo eS Se 3 Feed table optional gt 344 cm 135 43 QQ QQ AAA YY UI _ _TNNWOO s gt
62. n water connection has been made open the water tap and check that all connections for water inlet are tight ff 13225 Mounting of rollers On the top of the upper safety cover is placed a label a showing the roller configuration Each roller is marked with a small number b Install the rollers by referring to the roller numbers shown on the label on the top of the upper safety cover DV 2U L ILI Roller location U Upper L Lower Roller pair number Section DV Developer 732209 Service Manual Plate Processor 125 1239 Installation Mechanical Installation Levelling 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 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 Levelout the processor lengthwise by placing a spirit level on the left 4 and right 5 tank side Levelout the processor crosswise by placing the spirit level on the front 6 and on the back of the processor 7 Check levelling in all 4 positions and ma
63. ng has been lubricated from manufacturer of the bearing and it will last longer than the life time of your processor Idler sleeve bearings servicing Once a year or for every 1 000 hours the idler sleeve bearings have to be lubricated as show on the illustation below Recommeded oil type Mineral Oil to ISO VG SAE30 Hold the bearing tight against your palm fill it up with oil and press against the top and then make a tight pressure from both sides The oil will then be squeezed through the bronze and tiny oil drops on the outside of the bronze bearing will appear e Alternative is to let the bearing stay in oil bath for 24 hour until it is completely moisten with oil before mounting 732096 Service Manual Plate Processor 125 1239 The illustation below shows the idler sleeve bearings to be lubricated Maintenance Chain servicing 1239 90000009 omy 00008 099 1 1 31997 Service Manual Plate Processor 125 Maintenance Chain servicing Chain adjustment procedure Follow the procedure below when chain adjustment is needed Complete view Refer to the steps described later and indicated in the drawing below Main chain 1 e Loosen sprocket a on drive plate backside Loosen lock nut e Adjust chain tension on adjustment screw b e Fasten lock nut and fasten sprocket
64. page 5 5 and MIO analyzing LED signals on page 5 7 too TOGGLING OFF OFF For software newer than xxx 20111201 Power up sequence Sequence lasts approximately 1 minute White LED goes off on approximately 5 times in an irregular pattern ON OFF OFF Sleep mode Display shows z Zz Z z Z z Z Error See display for status ON FLASHING OFF Warming up Display shows 5 sec loop Processing plates Display shows ON ON OFF Ready to process plates Display shows ON OFF ON Alarm requiring user intervention Jog function The jog function will make the rollers and brushes turn for a while at intervals to prevent crystallization of chemicals on the rollers and brushes The initial jog after power has been applied to the processor runs for 9 minute After that the jog will run for 32 minute every 10 minutes Change of settings Change of settings is possible only via the Remote Enabling System 1245 Service Manual Plate Processor 125 Functional description Controls and indicators Connecting to Remote Enabling Making settings of this processor requires the Remote Enabling software and connection to a PC If not already installed please download the Remote Enabling System from www glunz jensen com support download software and install on a local PC For this processor select the Remote Enabling System for GNUC 2 Download and unzip the file to a separate folder on the
65. phic materials as specified 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 The manufacturer cannot be held responsible for any damage caused by incorrect installation of this processor 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
66. ronics defective e Replace defective electronics DRYER BLOWER DOES NOT WORK Fuse s blown Blower defective Electronics defective Replace fuse s Replace blower Replace defective electronics Service Manual Plate Processor 125 1239 Trouble shooting Problems with processed material SYMPTOM PROBABLE CAUSE REMEDY NO GUM ALTHOUGH e Gum container empty e Refill container MACHINE IS IN e Gum hose blocked e Clean hose PROCESS MODE e Pump valves blocked or defective Pump defective Fuse s blown Electronics defective Clean or replace valve Replace pump Replace fuse s Replace defective electronics GUM PUMP RUNS BUT NO GUM NO ALARMS Gum hose blocked Pump valves blocked or defective Clean hose Clean or replace valve DEVELOPER e Fuse s blown Replace fuse s REPLENISHMENT PUMP e Pump defective e Replace pump DOES NOT WORK e Electronics defective e Replace defective electronics DEVELOPER e Replenishment hose blocked Clean hose REPLENISHMENT PUMP e Pump valves blocked or e Clean or replace valves RUNS BUT NO defective REPLENISHMENT e Replenish container empty e Refill container REPLENISHMENT SYSTEM Replenishment parameters Make correct settings DOES NOT WORK ALTHOUGH THE MACHINE IS IN PROCESS MODE settings not correct Electronics defective Replace defective electronics NO DEVELOPER CIRCULATION
67. rtified 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 62 dB Stand by mode lt 51 1 dB 1239 Service Manual Plate Processor 125 Technical specifications Mechanical specifications Chemical emissions Ozone 0mg m Dust 0 mg m Styrene 0mg m Heat emissions See Power consumption on pagel 5 Mechanical specifications Performance Plate types single sided thermal offset plates Plate width 240 1250 mm min max 9 5 49 2 Plate length 325 mm min 12 987 Plate thickness 0 20 0 40 mm 0 008 0 016 min max Plate speed 50 240 cm min 19 7 94 5 min Brush speed 40 125 rpm Tank capacities Developer total 64 0 ex pumps etc 16 9 US gal Wash optional with integrated water circulation d 5 15 US gal ex pumps etc Gum N A Service Manual Plate Processor 125 1239 Technical specifications o 1 3 Mechanical specifications Temperatures Developer 18 35 C min max 64 95 F Dryer process 50 C 122 F default non adjustable Water requirements Pressure
68. s use the test plate 5 to test the brush pressure in both sides and in the middle Make sure that the test plate 5 is entered at right angles 5a to the rollers e Adjust the brush pressure on the screws 6 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 From this point turn the screws 6 1 4 turn clockwise in each side 1 4 turn is a common pressure which will work in most occasions Please refer to plate manufacturers specifications Adjustment method B See bottom illustration opposite Use a strip of film and a spring balance and proceed as follows Insert a strip of polyester film 7 10 cm wide approximately 50 cm long 0 10 mm thick 4 x 20 x 1 128 between the brush roller 8 and the lower roller or guide Activate the manual function button and hold the film strip with the spring balance 9 against the rotation of the brush pulling the spring balance upwards Adjust the pressure to a balance depending on a recommendation from plate manufacturer over the entire brush roller width Repeat the procedure for the all brush rollers All brushes should be adjusted to the same settings Service Manual Plate Processor 125 1239 LO lt Maintenance Adjusting the brush pressure dn Sy S lo EDN gt A
69. ss to the IP address informed by the IT administrator e Click OK and confirm Restart by pressing Server Configuration General Email Network Network ID Hoztname 9040798 Domain gilocal address 001 1 00 04 07 98 server 0 0 0 C Automatic IP addresses DHCP Static IP addresses IP address f 0 10 148 223 Subnet mask 255 255 240 0 0 10 144 1 Default gateway DNS server addresse Primary 0145 server Alternate DNS server Cancel When the Remote Enabling is ready please verify on the processors control panel by scrolling to the IP address marked with 8 that the IP address now listed is identical to the one added in Static IP address in the Remote Enabling System Service Manual Plate Processor 125 Functional description Controls indicators Change of processor s parameters Press the processor tab 4 Select Data Settings Programs The processor s parameters list will be shown in the Settings view and new settings can be made GrClient 1 09 27 Alarms Debug Settings Programs e GLUNZ amp JENSEN Description System Status 1 Speed cm min 4 X Developer brush sp 140 5 Settemperature 10 Dwell time 132 3 5 18 cO Parallel plates No Auto Program
70. ters are set as follows Parameter Program 1 Program 2 Program 3 Program 4 Speed 110 cm min 110 cm min 110 cm min 110 cm min Developer 120 120 120 120 brush speed a pm 24 C 24 C 24 C 24 C temperature Developer 29 sec 29 sec 29 sec 29 sec dwell time Parallel plates No No No No Change of settings is possible only via the Remote Enabling System See page 3 10 for more information Safety check A safety check must be performed after installation See page 4 2 Service Manual Plate Processor 125 1239 Functional description 3 1 General Part 3 Functional description General The basis processor contains four major sections OO 111264 1 Developer Developing of the plate removing of the remaining unexposed emulsion 2 Wash Washing off the developer chemicals from the developed plate Application of a thin layer of gum onto the developed and washed plate to 3 Gum a ar protect it from oxidation dirt fingerprints etc 4 Dryer Drying of the plate to ensure immediate handling of the plate The processor sections are described in detail on the following pages Controls and indicators The controls and indicators are described later in this chapter 1239 Service Manual Plate Processor 125 Functional description General 3 2
71. tion below The valve is fully open from the factory Normally no adjustments are necessary 131558 Service Manual Plate Processor 125 1239 Maintenance Replacement of bearings 4 13 Replacement of bearings See the illustration below Pullout the pin 1 at the gear side of the rollers Use a 6 mm mandrel to drive out the pin Remove the roller bearings 2 Remove the springs 3 from the bearings on the brush rollers Replace the bearing Mount back the springs on the new bearings for the brush rollers T32011 1239 Service Manual Plate Processor 125 Maintenance Adjusting the brush pressure 4 14 Adjusting the brush pressure General The following describes a standard adjustment for the brushes in the developer and wash sections The brush adjustment can vary from one processor to another since it must apply to the specific plate and chemical type etc Tools 5mm hex T key Test plate 100 x 200 x 0 15 mm developed Processor conditions Place the plate between the brush roller and the lower guide and activate the manual function button Recommended brush speed setting default brush speed Preparations e Lift up the processor top cover Remove the upper roller 1 in the developer section before adjusting e Activate the interlock switch Start 3 Adjustment method A See top illustration opposite e While the brush 4 run
72. ult 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 Main switch turned off or power cable not connected to main power outlet Fuse s blown See PCU analyzing on page 5 5 Connect cable to main power outlet and or turn main switch on Replace fuse s MACHINE WILL NOT START UP PCB defective See PCU analyzing on page 5 5 Replace defective part MACHINE DOES NOT START WHEN A PLATE IS INSERTED Input sensor s defective See PCU analyzing on page 5 5 Replace defective sensor s NO WASH WATER ALTHOUGH MACHINE IS IN PROCESS MODE Water tap closed Water solenoid valve defective Water solenoid valve filter clogged Processor with level sensor Level sensor in wash dirty Open water tap Replace valve Clean filter Check sensor and clean replace whatever is or defective necessary e Electronics defective e Replace defective electronics DRYER BLOWER WORKS Fuse s blown e Replace fuse s HEATER DOES NOT e Temperature sensor defective e Replace temperature sensor e Heating element defective e Replace heating element e Elect
73. wing below Ifthe chain is over the given maximum length between the given numbers of pitches it is recommended the chain be replaced nm Be aware that in case either the chain or the gears are worn out both chain and gears have to be replaced nm To ensure continues high quality and maximize productivity and processor up time it is recommended to change the chains after 5000 production hours or 4 years what comes first P o o 009009 o9 ooooooooqoooo 900 o9 o9 o9 20 pitches New 378 mm Used 12 pitches New 225 mm Used 1239 Service Manual Plate Processor 125 Maintenance Chain servicing Lubrication Chain drive should be protected against dirt and moisture and be lubricated with good quality non detergent petroleum based oil Re lubrication of chain working surfaces is desirable Heavy oils and greases are generally too thick to enter the chain working surfaces and should NOT be used Mineral Oil to ISO VG SAE30 oil would be suitable Care must be taken to ensure that the lubricant reaches the bearing area of the chain This can be done by directing the oil into the clearances between the inner and outer link plates preferably at the point where the chain enters the sprocket on the bottom strand Please see below Some processors are manufactured with bearing with a lubricator nipple a There will be no need for grease oil as beari

Service Manual Plate Processor+125

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