Service Manual

Gecko 85 T

Service manual
Plate Processor 85 Thermal

PRELIMINARY
T31888

Edition 0C, December 2009 This book has part No. 51658

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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 & JENSEN A/S Haslevvej 13 DK-4100 Ringsted Denmark Phone:+45 57 68 81 81 E-mail: [email protected] Internet: www.glunz-jensen.com

Copyright 2009 by GLUNZ & JENSEN A/S.

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General Information The processor

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Part 0: General information

Reservations
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. As a 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 Note

Explanation
The operator should observe and/or act according to the information in order to obtain the best possible function of the equipment. The operator must observe and/or act according to the information in order to avoid any mechanical or electrical damage to the equipment. The operator must observe and/or act according to the information in order to avoid any personnel injury.

" $ #
Other manuals

Caution

Warning

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.

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General Information The processor

Unintended use of the equipment

Glunz & 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 & 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 specified in Technical specifications in

Part 1 in this manual.

Installation
Never install the processor in explosive environments. It is 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. Installation, service and repair must be performed only by service technicians who are trained in servicing the equipment. The installation procedure is described in the separate Installation manual. The manufacturer cannot be held responsible for any damage caused by incorrect installation of this processor.

Technical data
Observe technical data from the processor name plate and from Part 1 in this

manual.

Chemicals
It is 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 incinerated at a suitable incinerating plant. PCB's and other electric equipment must be sent to a suitable waste deposit.

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Service assistance
If help is needed to correct any problem with the equipment, please contact your

local supplier.

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Table of contents

Table of contents
Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Notes, cautions and warnings ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Unintended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Intended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 "End of lifetime" disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Service assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 User's manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11

Part 1: Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 The processor does not contain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Plastic parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 End of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chemical emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Heat emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Mechanical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Tank capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Water requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Water consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Exit table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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Part 2: Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Preparing the installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 CTP online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Processor dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Power outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Cleaning facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Drain connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Environmental requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Unpacking/preparing the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Transport through narrow doorways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Removing the stand panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Transport security items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Lifting the processor off the pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Removing the fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Main power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Stacker connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Conveyor connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Processor/setter connections (ctp online processors) . . . . . . . . . . . . . . . . . . . . . . . 2-8 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Adjustment of lid switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Cleaning the processor tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Mounting of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Installing the cooler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Filling up developer and wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Mounting fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Placing containers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Mounting the exit table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Slanted position (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Straight position (B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Mounting the feed table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Mounting panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Installation of setter interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Finishing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Switching the processor on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Jog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

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Table of contents

Part 3: PCU firmware/software installation . . . . . . . . . . . . . . . . . . . . 3-1

Installing USB to COM driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Connecting to PCU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Downloading firmware/software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Adjusting firmware/software settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Part 4: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Power control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Printed circuit board foil (PCB foil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 (1) Eject plate/manual function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 (2) Manual replenisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 (3) Power (yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 (4) Ready (green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 (5) Alarm (red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Part 5: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Cleaning of the circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Cleaning of valves in the replenish and small circulation pump . . . . . . . . . . . . . . . 5-6 Cleaning of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Developer section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Wash section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Adjustment of gears for wash brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Adjusting the brush pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Processor conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Adjustment - method A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Adjustment - method B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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Part 6: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Before starting trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Appendix A: Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Motors and internal bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 24V DC distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Primary wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 230V AC, control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Low voltage wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 Sensors and control devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6

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General Information Manuals

Manuals
A complete set of manuals consists of the following:

1
s Part Spare Man ual

2
Servic e Man ual

3
Safety Instru ctions

4
User s Man ual

T31525

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 Spare Parts Manual (1)

Language: Contents: English Spare parts

Processor Service Manual (2)

Language: Contents: English Technical specifications Installation Finishing installation Functional description Maintenance Trouble shooting Electrical diagrams

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General Information Manuals

0-11

User's manuals
User's manuals available for the equipment:

CE Declaration Of Conformity (3)

Languages: Contents: Various Survey of the directives to which the equipment conform

Safety Instruction Manual (4)

Languages: Contents: 28 General Safety Information

User's Manual, Plate Processor (5)

Languages: Contents: 15 Operating and cleaning procedures

Keep the manuals with the machine for reference at all times.

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General Information Manuals

Service Manual - Plate Processor 85

0949

Technical specifications General environmental information

1-1

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: Spare parts and service period: 10 years 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: 61 dB Stand-by mode: 41 dB

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Technical specifications Mechanical specifications

Chemical emissions
Ozone: Dust: Styrene: 0 mg/m3 0 mg/m3 0 mg/m3

Heat emissions
See "Power consumption" at page 1-5.

Mechanical specifications
Performance
85
Plate types Plate width min.- max. Plate length min.- max. Plate thickness min.- max. Plate speed Brush speed Single sided thermal offset plates 200-850 mm (7.9-33.5) 275-1100 mm (10.8-(43.3") 0.15-0.30 mm (0.006-0.012) 40-120 cm/min (15.7-47.21 /min) 60 - 150 rpm

Tank capacities
85
Developer, total ex. pumps etc. Wash ex. pumps etc. 22.0 l (5.8 US gal.) 13.5 l (3.6 US gal.)

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Technical specifications Mechanical specifications

1-3

Temperatures
85
Developer Min. - Max. Dryer, process 20 - 40 C (68 - 104 F) 35 - 55 C (95 - 131 F)

Water requirements
85
Pressure
Min. - max.

1 - 6 bar (29 - 87 psi)

Water consumption
85
Operation (if no wash recirculation) Stand-by (if no wash recirculation) 16 l/min (4.2 US gal/min) 0.0 l/min (0.0 US gal/min)

Weights
85
Weight, empty Weight, shipping Weight, with liquids 235 kg (518 lbs) 305 kg ( 672 lbs) approx.272 kg (600 lbs)

Exit table
85
Capacity Max. 30 plates. NOTE! Consider risk of scratches

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Technical specifications Mechanical specifications

Dimensions

Side view
265 cm (104.3")

82.8 - 91.8 cm (32.6 - 36.1")

75.3 cm (29.6")

76.3 - 85.3 cm (30.0 - 33.6")

101.0 - 110.0 cm (39.8 - 43.3")

98.5 cm (38.8")

Top view
115.8 cm (45.6") 30.3 cm (11.9")

40.1 cm (15.8")
T31886

78.8 cm (31.0")

Service Manual - Plate Processor 85

125.5 cm (49.4")

97.4 cm (38.3")

93.2 cm (36.7")

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Technical specifications Electrical specifications

1-5

Electrical specifications
Power supply
Supply/Fuse EUR/ Single Phase, 2W + PE US 230V / 2x11 Amps, 50-60 Hz JAP
Single Phase, 2W + PE 200V / 2x11 Amps, 50-60 Hz

Recom. cable type

Min. 3 x 10 AWG, type SJO

85

Min. 3 x 10 AWG, type SJO

All

Voltage tolerance +10%/-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
Max power consumption at
230 V AC operation: EUR/ 2500 Watt / 8540 BTU/hour

85

US

Stand-by: 1000 Watt / 3420 BTU/hour

Noise level
See General environmental information on page 1-1.

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Technical specifications Electrical specifications

Service Manual - Plate Processor 85

0949

Installation Preparing the installation site

2-1

Part 2: Installation
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.
> 365 cm ( 143.7")

> 60 cm (23.6")

> 268 cm ( 105.5")

Feed table (optional)

> 50 cm (19.7")

Exit table (optional)

> 50 cm (19.7")

Processor

> 100 cm (39.4")

T31885

CTP online
For the CTP On-line processors the space requirements at the processor front has to be decided separately.

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Installation 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 in 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 85
100 x 40 cm (39.4 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. 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 25C (59 and 77F) and relative humidity on max. 80%.

"

Capacity of the air condition/ventilation system must be adequate for heat emission of 3420 BTU (1000 Watt) in stand-by and 8540 BTU (2500 Watt) in process.

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Installation Unpacking/preparing the processor

2-3

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
> 1400 mm 1250 - 1400 mm < 1250 mm

Then
No action is required as the crated processor can be transported immediately to the installation site. The Service Technician has to unpack the processor. The Service Technician has to unpack and strip down the processor.

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Installation Unpacking/preparing the processor

Removing the stand panels

Closed stand models only In order to lift the processor off the pallet and make the installation it will be necessary to remove the stand panels.
Release the locks (1) of the stand panels by pulling them outwards. Lift off the panels (2) and (3).

1
T31535

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.

Lifting the processor off the pallet

4 persons are needed for lifting the processor down from the pallet. Follow the procedure described below (see illustration on next page). Two persons are needed on each side of the processor for lifting. Mount the two pipe bars (4) enclosed with the processor as shown on the illustration (5). Lift the processor down the pallet and place it on the installation site.

Do not use a fork lift truck or a pallet mover to lift the processor off the pallet.

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Installation Unpacking/preparing the processor

2-5

4 4

5
T31536

Removing the fenders

In order to make the electrical installation it will be necessary to remove the fenders from the processor. See illustration below. Remove the screws (6) securing the fenders (7) to the stand and lift of the left and right fenders.

T31566

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Installation 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). Check the processor connections (see name plate) for the current wiring type. IMPORTANT! If changing from one main power connection type to another the processor must be rewired. Follow the instructions from the table on the next page and make rewiring according to the electrical diagrams in the Appendix A in the processor service manual.

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Installation Electrical installation

2-7

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.

Conveyor connection
Not all models (accessory equipment). See separate manual. See the description for stacker connecting above.

Processor/setter connections (ctp online processors)

Not all models (accessory equipment). See separate interface manual.

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Installation Mechanical 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).

Cleaning the processor tanks

Before installing rollers and covers it is necessary to vacuum clean the tank (5) to remove sponge rubber remains and dust etc.

2 1

3 4

T1998

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Installation Mechanical installation

2-9

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 water inlet solenoid valve located to the front left, underneath the processor. The hose can be connected to a water tap with " or " male thread (WRG). When connecting to ", the reduction nipple shall not be used. When water connection has been made open the water tap and check that all connections for water inlet and hand shower (if mounted) are tight.

WATER TAP

GASKET NIPPLE 3/4" - 1/2" (WRG) GASKET

SOLENOID VALVE

PLASTIC HOSE

T3225

Mounting of rollers
Inside the top cover is mounted 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 inside the top cover.
Delivered with the processor is a tool for installation of brush rollers. Installation and adjustment of brush rollers are described in Part 3 in the processor service manual.

b
10

T31545

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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. 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 upper input roller in the developer section (6) and the gum distribution roller in the gum section (7). Check leveling in all 4 positions and make final leveling if required.

7 6
5

SETTER OUTPUT HEIGHT 2 mm

R OO FL

T 31508

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Installation Mechanical installation

2-11

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 on 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.
No wash water recirculation.

T31556

The water solenoid valve will let in water when a plate is entered through the input slot.

OPEN

CLOSED

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Installation Mechanical installation

h g d e f
T31537

Service Manual - Plate Processor 85

0949

Installation Mechanical installation

2-13

Installing the cooler unit

Not all models. Accessory equipment.

Do not place the cooler unit underneath the processor.

An external cooler unit can be connected to the developer section. Place the cooler (a) behind the processor. Lead the hoses from the cooler unit through the hole for hoses (b) in the rear panel. Connect the cooler hoses c) and (d) to the in- and outlets to the left underneath the developer tank. Route the cooler cable (e) through the hole (f) in the tank into the fender. Ensure smooth passage for the cable. Fix the cooler cable in the cable clamp (g) and mount the wires in the terminal X16 (h) located next to the electronics cabinet inside the fender on the right side of the processor.
For more information about the cooling unit please consult the cooler unit manual.

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Installation Mechanical installation

3b 3a

2
A
SLANTED EXIT TABLE

STRAIGHT EXIT TABLE

3c
T31518

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Installation Mechanical installation

2-15

Mounting the exit table

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).

Slanted position (A)

Lift the 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 lower holes in the rear panel (3a) and secure them inside using the enclosed locking split pins (3c).

Straight position (B)

Dismount the exit table. Dismount the 4 screws (5) holding the exit

guide (6). 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 (7). Mount the exit table. Lift the 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).

7
LOWER HOLES

T31594

Mounting the feed table

Offline processors only! Mounting of the feed table is described in the manual for the feed table kit.

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Installation Mechanical installation

Mounting fenders
Mount the left and right fenders (1) with the screws (2).

T31566

Placing containers
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 illustration.

T31515-1

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Installation Mechanical installation

2-17

Mounting panels
Mount the left and right stand panels (1) and (2) and secure them by closing the

locks (3).

3
T31539

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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.

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 by continuing with Part 3 in this manual.

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Installation Finishing installation

2-19

Finishing installation
Start-up
Switching the processor on
See illustration below.
Make sure that the containers (4) are sufficiently filled. Turn main switch (1) to ON/I. The Power" indicator (2) is lit. The processor initalizes for about 3 sec. then turns in

to wait mode ("Ready" indicator (3) flashing) until the temperature in the developer section is at the set point, and the water section (not at all model) is filled up. When "Ready" indicator (3) lights up constantly the processor is ready to process the plates.

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 2 minutes. After that the JOG will run for 30 sec. every 10 minutes.

3 2

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Installation Finishing installation

Service Manual - Plate Processor 85

0949

PCU firmware/software installation Installing USB to COM driver

3-1

Part 3: PCU firmware/software installation

Installing USB to COM driver
Locate driver CDM X.XX.XX in

firmware/software folder. Run CDM X.XX.XX.exe. Supported OS:

Windows Server 2008, Windows Server 2008 x64, Windows Vista, Windows Vista x64, Windows Server 2003, Windows Server 2003 x64, Windows XP, Windows XP x64, Windows 2000. Wait for driver installation to complete.

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PCU firmware/software installation Connecting to PCU board

Connecting to PCU board

Open Windows Device Manager: Start -> Settings -> Control Panel, Open Performance and Maintenance,

Open System,

Select Hardware -> Device Manager.

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PCU firmware/software installation Connecting to PCU board

3-3

Switch the processor on and connect

USB cable to PCU board.

Wait for the USB COM port to show

up in Device Manager. If COM port number is between 1 and 8, skip to the next Downloading firmware/software chapter.

Right click on the USB Serial Port

(COMX) and select Properties -> Port Settings -> Advanced.

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PCU firmware/software installation Downloading firmware/software

Change COM Port Number to a

number between 1 and 8. Left click on OK button to c lose all windows.

"

Device Manager does not update COM Port Number in device name before Device Manager is reopened.

Downloading firmware/software
Locate firmware/software. Run pcloadw.exe.

Switch the processor on and connect

USB cable. Select COM port (from Windows Device Manager).

"

Do NOT check Erase EEPROM.

Left click on Start button.

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0949

PCU firmware/software installation Adjusting firmware/software settings

3-5

Wait for programming to comlete. If programming does not start: power the processor off, short circuit JP1 (alpha boards), power the processor on, restart download procedure.

Left click on OK button when

programming succeeds.

Adjusting firmware/software settings

Switch the processor on and connect

USB cable. Open a new HyperTerminal:

Start -> Accessories ->

Communication -> HyperTerminal, Enter an appropriate name and left click on OK button.

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PCU firmware/software installation Adjusting firmware/software settings

Select COM port number found in

Windows Device Manager (see Connecting to PCU board chapter for more information).

Setup Port Settings as shown on the

picture. Left click on OK button.

Press "Enter" key in the blank area to

show menu system.

Follow the on screen guide to change

settings.

"

To setup serial number type "duy" to list serial numbers menus. To hide serial number menus type "logout".

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0949

PCU firmware/software installation Adjusting firmware/software settings

3-7

Example how to change settings: Choose one of the settings to be changed, e. g. speed.

Type "4" and press "Enter".

Type a new value, e. g. "100" and

press "Enter".

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PCU firmware/software installation Adjusting firmware/software settings

Continue with the next settings.

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0949

Functional description General

4-1

Part 4: Functional description

General
See illustration below. The basis processor contains four major sections:
1 2 3 4

T11199

1 2 3 4

Developer Wash Gum Dryer

Developing of the plate and removing of the remaining unexposed emulsion.. Washing off the developer chemicals from the developed plate. Application of a thin layer of gum onto the developed and washed plate to protect it from oxidation, dirt, fingerprints etc. Drying of the plate to ensure immediate handling of the plate.

The processor sections are described in detail on the following pages.

"

Plate sizes must be entered in the "PLATE SIZES" menu in order to optain exact calculation of replenishment.

Controls and indicators

The controls and indicators are described later in this chapter.

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Functional description General

DEVELOPER
S1
INPUT SENSOR

OVERFLOW SPRAY TUBE

M1 TRANSPORT M2
ROLLER MOTOR DEV. BRUSH MOTOR

E1 DEV. HEATING B1 DEV. TANK R1

TEMP. SENSOR

MIN. SENSOR

NOT ALL MODELS

COOLING TUBE

M3
DEV. CIRC. PUMP (IWAKI)

COOLER M4
DEV REPLENISH

REPLENISH

WASTE

T31898

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Functional description General

4-3

TAP WATER, WASH

TAP WATER K8
VALVE FLOW LIMITERS

SPRAY TUBE

DRAIN

CIRCULATION WATER, WASH

TAP WATER REPLENISH

K8
VALVE FLOW LIMITERS

OVERFLOW

SPRAY TUBE WASH TANK MIN. SENSOR

B2

DRAIN VALVE
CIRC. PUMP

M10

DRAIN

T31899

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Functional description General

GUM

APPLICATION TUBE

M23
GUM CIRC. PUMP DRAIN

GUM

T31900

Service Manual - Plate Processor 85

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Functional description General

4-5

DRYER
S2
OUTPUT SENSOR

R2
DRYER TEMP. SENSOR

M9
FAN

HEATING ELEMENT

E2+E3

TRANSPORT
1 3 2 4 5 6 7 8 9 10

T31901

2
1 2 3 4 5 6 7 8 9 10 transport input roller developer spray tube developer brush roller exit roller developer section entrance roller wash brush roller wash exit roller wash application roller gum gum roller exit roller dryer

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Functional description General

Remote surveillance

PC

GNUXB

(optional)

PCU

GNUIB

Plate Setter

PCB foil
T 2583

Service Manual - Plate Processor 85

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Functional description Electronic control

4-7

Electronic control
See illustration opposite. The electronics consists of:

Power control unit (PCU)

The whole electronic system is controlled by the PCU-board. It has two separate communication lines (buses): GNUIB for all internal communication in the processor. GNUXB for external communication between the processor and a PC or modem. The PCU-board holds all the high voltage in- and outputs for the control of heaters, motors etc.

Printed circuit board foil (PCB foil)

The PCB foil is the Control Panel board from which the user operates the processor.

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Functional description Controls and indicators

Controls and indicators

See illustration below.

Function keys
The processor is equipped with the function keys located at the back of right fender.

(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 developer section.

(Red)

5 4 3

1
(Green)

2
(Yellow)

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Functional description Controls and indicators

4-9

Indicators
The indicator panel is located on the right fender facing upwards. The panel holds 3 indiactors:

(3) Power (yellow)

When lit the processor is powered on.

(4) Ready (green)

This indicator has 3 different states indicating various processor conditions:
STATE CONDITION

Off

The processor initializing. The processor is currently processing a plate. The processor is in "Processing Mode". Alarm indicator is lit: The processor in "Alarm State" See description of Alarm indicator for details.

Lit Flashing

The processor is in "Standby Mode" and ready to process. The processor is in "Processing Preparation Mode".

(5) Alarm (red)

This indicator is lit if: The processor is in "Alarm Mode". See "Part 6: Trouble shooting" later in this manual for a list of possible alarms/errors.

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Functional description Controls and indicators

Service Manual - Plate Processor 85

0949

Maintenance General

5-1

Part 5: 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 Processor User Manual.

WARNING!
Please note that where this label appears on the processor, electrical shock hazard still exists when the main switch is turned off.

DANGER
ELECTRICAL SHOCK HAZARD DISCONNECT ALL EXTERNAL POWER SUPPLY BEFORE SERVICING TO BE SERVICED BY AUTHORIZED PERSONNEL ONLY RISQUE DE CHOC LECTRIQUE AVANT TOUTE INTERVENTION, DBRANCHER TOUTES LES SOURCES DE COURANT MAINTENANCE PAR PERSONNEL AUTORIS SEULEMENT

WARNING!
When performing any service, maintenance, calibration, or trouble shooting etc. it may be necessary to override the function of the processors interlock switches. In these cases please be aware, that the processors JOG-function is still active, making the drive system run idle at intervals.

There will be NO advice when the JOG function starts

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Maintenance Safety check

Safety check

"

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:

Processor must stop when the switch is deactivated.

Main switch:

Processor must turn off when set to "0".

Emergency stop:

Processor must turn off when activated.

Control panel Emergency stop Lid switch Main switch

Electronics cabinet Upper side panel

Lower side panel

T2652

Mechanical
Check proper function/location of: Upper side panels, left/right:

Make sure the fenders are properly secured with 2 screws each.
Lower side panels, left/right. Lid, electronics cabinet:

Make sure the lid is secured by screws.

Service Manual - Plate Processor 85

0949

Maintenance Fuses

5-3

Fuses
Fuses for motors are placed on the motors behind the left fender.

T437

The fuse(s) for the main power supply are placed together with the main power switch on the back of the right side fender. A fuse label below the main power switch shows the rating of the fuses.

T2653

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.

0949

Service Manual - Plate Processor 85

5-4

Maintenance Rollers and brush rollers

Rollers and brush rollers

General
Inside the top cover is mounted 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. Delivered with the processor is a tool for installation of brush rollers. Installation and adjustment of brush rollers are described later in this chapter.

b
10

Installation of rollers

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

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0949

Maintenance Cleaning

5-5

Cleaning
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 the position of the outlet nozzle (5). 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).

1
2 3 4

T 31064

0949

Service Manual - Plate Processor 85

5-6

Maintenance Cleaning

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 apart and clean the small valve in warm water.

VALVE INLET NOZZLE OUTLET NOZZLE

"

Extra valves are included with the spare parts kit delivered with the processor.

FL

OW
T438

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 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 illustration below. The valve is fully open from the factory. Normally no adjustments are necessary.

t31558

Service Manual - Plate Processor 85

0949

Maintenance Cleaning

5-7

Adjustment of gears for wash brush

See illustration below.

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.

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). Turn the gear (7) manually to adjust the space gap between the gear (5) and the bearing (6) to fit the feeler gauge (4). Tighten the screws (2) on the brackets (3) for the main drive shaft. Remove the feeler gauge (4). Finally make sure that the adjustment has left a small gap between the gears (5) and (7).

3 3 1 3 3 2

5 6

4 7 5
T31584

0949

Service Manual - Plate Processor 85

5-8

Maintenance Cleaning

3 1

T31710

400 300 200 100

T31711

Service Manual - Plate Processor 85

0949

Maintenance Cleaning

5-9

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: 5 mm 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
Lift up the processor top cover. Activate the interlock switch. Start the Eject Plate function.

Adjustment - method A
See top illustration on page 3-8. While the brush (1) runs use the test plate (2) to test the brush pressure on both brush ends and in the middle. Adjust the brush pressure on the screws (3) (clockwise = tighten) until you feel a slight resistance when pulling the test plate backwards. Make sure that you obtain a uniform pressure on both sides and in the middle. From this point turn the screws (3) half a turn clockwise in each side.

Adjustment - method B
See bottom illustration on page 3-8. Use a strip of film and a spring balance and proceed as follows: Insert a strip of polyester film (10 cm wide, approximately 50 cm long, 0.19 mm thick/4 x 20 x 1/128) between the brush roller and the lower roller (or guide). Activate the manual function button and hold the film strip with the spring balance against the rotation of the brush, pulling the spring balance upwards. Adjust the pressure to a balance reading of 350-400 g (0.77-0.88 lbs) over the entire brush roller width. Repeat the procedure for the all brush rollers. All brushes should be adjusted to the same settings.

0949

Service Manual - Plate Processor 85

5-10

Maintenance Cleaning

Service Manual - Plate Processor 85

0949

Trouble shooting General

6-1

Part 6: 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 2 sections:
A. Problems with the processor B. Problems with processed material

For cleaning and maintenance subjects see the processor user manual and chapter 3 in this manual. 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, or trouble shooting etc. it may be necessary to override the function of the processors interlock switches. In these cases please be aware, that the processors JOG-function is still active, making the drive system run idle at intervals.

0949

Service Manual - Plate Processor 85

6-2

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
NO FUNCTION ACTIVE

PROBABLE CAUSE
Main switch turned off or power cable not connected to main power outlet. Fuse(s) blown. PCB defective. Input sensor(s) defective.

REMEDY
Connect cable to main power outlet and/or turn main switch on. Replace fuse. Replace defective part. Replace defective sensor.

MACHINE WILL NOT START UP MACHINE DOES NOT START WHEN A PLATE IS INSERTED 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 or defective. Electronics defective. Fuse(s) blown. Temperature sensor defective. Heating element defective. Electronics defective. Fuse(s) blown. Blower defective. Electronics defective.

Open water tap. Clean filter. Open valve. Replace valve.

Replace defective electronics. Replace fuse. Replace temperature sensor. Replace heating element. Replace defective electronics. Replace fuse. Replace blower. Replace defective electronics.

DRYER BLOWER WORK, HEATER DOES NOT

DRYER BLOWER DOES NOT WORK

Service Manual - Plate Processor 85

0949

Trouble shooting Problems with processed material

6-3

SYMPTOM
NO GUM ALTHOUGH MACHINE IS IN PROCESS MODE

PROBABLE CAUSE
Gum container empty. Gum hose blocked. Pump valves blocked or defective. Pump defective. Fuse(s) blown. Electronics defective. Gum hose blocked. Pump valves blocked or defective. Fuse(s) blown. Pump defective. Electronics defective. Replenishment hose blocked. Pump valves blocked or defective. Replenish container empty. Replenishment parameters settings not correct. Electronics defective.

REMEDY
Refill container. Clean hose. Clean or replace valve. Replace pump. Replace fuse. Replace defective electronics. Clean hose. Clean or replace valve. Replace fuse. Replace pump. Replace defective electronics. Clean hose. Clean or replace valves. Refill container. Make correct settings. Replace defective electronics. Replace fuse. Replace pump. Clean and/or repair pump. Clean spray bar. See Part 5. Replace fuse. Check sensor and clean/replace whatever is necessary.

GUM PUMP RUNS BUT NO FINISHER (NO ALARMS) DEVELOPER REPLENISHMENT PUMP DOES NOT WORK DEVELOPER REPLENISHMENT PUMP RUNS BUT NO REPLENISHMENT REPLENISHMENT SYSTEM DOES NOT WORK ALTHOUGH THE MACHINE IS IN PROCESS MODE NO DEVELOPER CIRCULATION NO WATER CIRCULATION

Fuse(s) blown. Developer circulation pump defective. Pump defective or clogged. Water spray bar clogged. Fuse blown. Level sensor in wash dirty or defective.

ROLLER DRIVE MOTOR RUNS,BUT NO PLATE TRANSPORT

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
PLATE IS NOT COMPLETELY DRY

PROBABLE CAUSE
Gum section applying too much gum. Dryer section is malfunctioning.

REMEDY
Check gum section. Check dryer section.

0949

Service Manual - Plate Processor 85

6-4

Trouble shooting Problems with processed material

SYMPTOM
PLATE HAS STRIPES LENGTHWISE OR CROSSWISE

PROBABLE CAUSE
Defective or dirty rollers or guides.

REMEDY
Take rollers and/or guides out, inspect and wash them. Rollers with dents or other marks must be changed. Adjust brush(es) according to description on page 5-11. Replace defective brush(es). Change developer. Reduce the transport speed slightly. Increase developer temperature slightly. Check function of circulation pump and spray tubes. Increase replenishment rate slightly. Adjust brush according to description on page 5-11. Increase the transport speed slightly. Reduce developer temperature slightly. Reduce replenishment rate slightly. Open water tap. Check valve and filter.

Brush(es) misadjusted. Brush(es) defective. Developer exhausted. PLATE IS Machine runs too fast. UNDERDEVELOPED (EXPOSURE IS CORRECT AND PLATE NOT TOO OLD) Developer temperature too

low. Developer circulation insufficient. Replenishment insufficient. Brush out of adjustment.

Machine runs too slow. PLATE IS OVERDEVELOPED Developer temperature too (EXPOSURE IS CORRECT high. AND PLATE NOT TOO OLD) Replenishment setting too high. Water tap closed. Water solenoid valve defective or water filter clogged. Spray-tubes clogged or misadjusted. Water circulation pump does not run. Brush misadjusted. Gum container nearly empty. Gum rollers dirty. Gum distributing tube clogged or out of adjustment. Gum pump clogged.

WASHING NOT SUFFICIENT

Clean or adjust whatever is necessary. See page 5-6. Adjust brush according to description on page 5-11. Refill container. Take rollers out and clean them. Take tube out and rinse or readjust. Take pump apart and clean valves. Adjust brush according to description on page 5-11. Reduce brush speed.

PLATE HAS AN UNEVEN GUMMING

PLATE'S TRAILING EDGE IS BENT

Brush pressure too high. Brush speed too high.

Service Manual - Plate Processor 85

0949

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:

Motors and internal bus wiring 24V DC distribution Page 2 of 3: Primary wiring 230V AC, control devices Page 3 of 3: Low voltage wiring Sensors and control devices

0949

Service Manual - Plate Processor 85

A-2

Motors and internal bus wiring

Motors and internal bus wiring

24V DC distribution

Service Manual - Plate Processor 85

0949

Part of Power Control Unit, PCU

DC DC

F27 + 3.3 Vdc (mikrocontroller circuitry) TX TX RX RX GND 100 R 1 6 5 9 3 7 2 8 4

3 2

2.5 AT 4AT + 24 Vdc (DC output supply) Q411

.

P1

F28

X1 + 5 Vdc 0V + 24 Vdc

CN5, 5

F24

U37

24 VDC from CN 5 on PSU 1

CN5, 1

0.6 AT

CN2, 3

Dual Motor Controller

GND

IN

OUT

LM78L05

F26

CN2, 6 P1 TX X36 TX
1 2 3 4 5 6

10AF

CN2, 15 4 8 2 7 3 100 R 1 6 M8,1

390 R 390 R

F25

24 VDC from CN 2 on PSU 2 (interrupted by E-stop and cover switch)

CN2, 18

10AF

RX RX GND

BTN7930

BTN7930

BTN7930

BTN7930 BTN7930

390 R

M8,2

5 9

signal

X5 + 1 4 2 6 3 5

X4

+ 1 4

M2,1

M2,2

M1,1

M1,2

signal

X36,5 2

X36,4 1 X64 2 x T filter 1 X65

J5,2

J5,3

J5,5

J4,2

J4,3 2 1

S7 Opto interrupter 2

J4,5 S6 Opto interrupter Red

M M

J5,4 2 5AT Black M1 Transport Motor

F32 J4,4

F31

4AT

Red

2 X T filter2

2 X T filter1

J5,1 1

Black J4,1

M2

Brush Motor

Not standard

M8 Prewash Brush Motor

A-4

Primary wiring

Primary wiring
230V AC, control devices

Service Manual - Plate Processor 85

0949

Power Control Unit, PCU

6 hot 3

5 return 3

4 hot 2

3 return 2

2 hot 1

Non interrupted

X6
S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 S14K460 Q55 Q45 Q42 Q43 Q46 Q53 Q64 Q66 Q34 Q35 Q54 Q61 S14K460 BTA 16 RV27 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 RV21 RV19 RV20 RV22 RV26 RV31 RV32 RV15 RV16 RV30 ! BTA 16

S14K460

S14K460

S14K460

R46 150k

L1

Q36

Q28

Q44

Q30

S14K460

BTA 16

RV17

BTA 16

RV13

BTA 16

RV18

BTA 16

RV14

Max 1A

Max 1A

Max 1A

X102

X101

X109

X104

X103

X108

X105

X106

L4 0.64 mH 7 4 3 6 5 1 2 8 7 4 3 5 6 1 2 4 2 3 1 6 5 2 4 1 3 8 7 4 3 6 2 5 1 4 2 3 1 8 7 4 3 6 5

X107

Max 1A

Cx Cy Cy 4.7n 100n 4.7n

F6 1AT
1

Non interrupted

1 return 1

F8 1AT

F9 1AT
2

100n

Cx

X16,1

X39,2

X14,2

X14,1

X14,4

X14,3

X27,1

X16,2

X39,1

X15,3

X17,2

X17,1

X46,2

X46,1

X20,3

X20,2

X21,1

X27,2

X46,4

X46,3

X46,6

X46,5

X16,3

X12,2

X12,1

X37,3

Ground screw in Electronics POLYMER VERSION ONLY

POLYMER VERSION ONLY

OPTIONAL

S1 X104,5 X104,1 X104,7 X104,4 X102,6 X46 15 14 13 12 X102,7 X102,4 11 10 9 8 7 6 5 4 3 2 X17 3 2 1 X29,4 X29,3 E10 E11
L3 0.4 mH

X106,4 X106,2

X107,5

X107,2

X105,4

X106,3

X106,1

X107,7

X107,3

X101,3

X101,1

X101,4

X101,2

X105,6

X105,1

X105,5 X105,2

X105,4

X109,5

X101,3

X101,1

X20,1 X101,1

X109,1

16A
L2
R40 R

X14 4 2 3 2 1 3 2 1 2 1 2 1 1 X20 4 X21 3 X39 3 X27 3

X12 3

X15 4

X26 4

X37 4

Blue

X21,2

PE

S13,P3

S13,P1

X29,2
M
Cy 2.2n Cx 68n

X102,1 M6 X46,5 X46,6 X46,4 X46,11 X46,3 X46,2 X46,1 X29 PreWash. Circ. Pump 4 3 2 1 X46,14 X33,2 X33 3 2 X29,1 1 S16 Preheater Chassis
P4 P2 P2

ON/OFF

X26,2

X26,1

X37,1

X15,2

Yl/grn

Black

Brown

750W

L PE N
75 C
M M

IEC 60320 Appliance Inlet

75 C C1 M9
PE N

X16 4 3 M10 2 1
M

M3

M4

M23

Gum Pump
L_const

230V AC 1 W + N + PE or 230V AC 2 W + PE
750W E3 M35 Dryer Heating, E2 : basis E3 : reg. Motor Cooling Fan Connection For Chiller OPTIONAL Motor Capacitor Dryer Blower
L_reg.

Dev. Circ. Pump

Dev. Repl. Pump

250W

E1

Dryer Blower

Wash. Circ. Pump

Dev. Heating

To PCU X114, x and y See page 2

C4

U1
CN1 CN5

176 C
To PCU X1,1 1 To PCU X1,4 2 X49 303 2 221
GND

M12 Preheat blower M11 Motor Capacitor Dryer Blower

1 2 3

X109

+24 VDC 24 VDC SUPPLY, 125W For electronics and valves

1 2 3 4 5 6 7 8

M
Electronic fan

U2
24 VDC SUPPLY, 225W For motors
CN2 +24 VDC

X109 To PCU X1,5 To PCU X1,2

X106

1
+24 VDC CN1
1 2 3

E10 750W

E11 750W

S49
GND

To PCU X1,6 To PCU X1,3

Emergency Switch Front

GND

X109

Prewash 750W Plate travel POLYMER VERSION ONLY 750W Entry E11 E10

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

11

12

S42 Cover Switch Dev Section

X46,1

70 C

750W E2

Cy 2.2n

X33,1

PE

A-6

Low voltage wiring

Low voltage wiring

Sensors and control devices

Service Manual - Plate Processor 85

0949

Power Control Unit, temp and digital input

IN 0

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

PTin+ PTinThermo + ThermoDEVDEV+ FIXFIX+ Spare2Spare2+

24 VDC motor Valve supply select

Val7 source GND Val6 source

C sense+ C sense-

1 1 2 3 4 5 6 1 2 1 2 3 4

10 11 12 13 14 15 16

10

IR out - 0 IR out + 0 IR out - 1 IR out + 1

X204 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9

X113

R1,1

R1,2

R7,1

R7,2

X?,6

X?,7

X?,8

X?,3

S1,1

S1,2

S2,1

S2,2

X114,5

X114,7

X?,1

X114,6

X114,8

X204,1

X204,8

X204,3

X204,5

X118,5

X118,6

X118,7

X118,8

1 1 1 1 H1 H2 S10 S11 R7 10K GND GND GND 3 S10 NO6 NO7 S11 4 6 H1 H3 2 3 4 5 6 7 8

To emergency stop X52 See page 1

S5 GND R2 Rntc 10K

S4

X204,10

X204,7

X?,4

Keyboard with diodes.

GND GND 7 H2 8 H3

NC

NC

2 2 Dev temp sensor Preheat temp sensor (Only Polymer version) Plate Eject 2

Input sensor

Output sensor

Man. Replenish

Ready LED

Power On LED

Power Control Unit, PCU, level input and valve output

0 Vdc Sinus +24Vdc 0 Vdc

0 Vdc

Sinus

+24Vdc

LEV0 VAL7
+ + + + + + + + -

LEV1

VAL0

VAL6

LEV1

LEV2 LEV3 LEV4 LEV5 LEV6 LEV7

VAL0 VAL1 VAL2 VAL3 VAL4 VAL5

+ +

IN 1

IN 0

X116 X10 11 7 12 1 2 3 4 5 6 8 9 10 11 12

X117

X9

X11 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

10

K1,1

K1,2

K1,1

K1,2

H1,1

K1,1

K1,2

K1,1 X11,3 X11,9 X11,10 4b

R3,1

R3,2

H1,1

X11,9

X11,15

X11,16

X11,10

4b

X?
4c

X11,4

Black

1 15k

2
1 Red

15k

B1 2

K8
2

24V B2

H1
Buzzer

K6 2

24V

B16
2

Dev tank min sensor

Wash valve

Wash tank max sensor

PreWash valve

Prewash tank max sensor

Only Polymer Version OPTIONAL

15k 15k

4c

K1,2

PIM in 1 ?? PIM out 1 emit PIM in 1 ?? PIM out 1 coll PIM out 0 emit PIM in 0 ?? PIM out 0 col PIM in 0 ??
10 Error LED Sinus

X36

X119

GND "Vcc" OUT 0 A/D IN 0 OUT 1 A/D IN 1 OUT 2 DIG IN 0 OUT 3 DIG IN 1
X205

X114

X118

LEV0