39 0 10MB
Service Manual
Plate Processor 86/860 Plate Processor 125/126/1250
Service Manual Plate Processor 86/860 Plate Processor 125/126/1250
Edition BI, January 2015 This book has part No 10067524
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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 Selandia Park 1 DK-4100 Ringsted Denmark Phone:+45 57 68 81 81 E-mail: [email protected] Internet: www.glunz-jensen.com
Copyright © 2012 by GLUNZ & JENSEN A/S.
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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:
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Always replace a fuse with one of the same size and rating as the old one.
Symbol
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.
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Caution
The operator must observe and/or act according to the information in order to avoid any mechanical or electrical damage to the equipment.
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Warning
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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.
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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 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 • 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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 User's manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12
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 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Installation hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Installation hours for off-line machine: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Standard installation hours for on-line machine:. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Customer training hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Preparing the installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CTP online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 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 Processor/setter connections (ctp online processors) . . . . . . . . . . . . . . . . . . . . . . . 2-8 Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Adjustment of lid switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Cleaning the processor tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Installation of the hand shower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Configuration of water solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Instalation to tap water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Change of wash configuration via Remote Enabling System . . . . . . . . . . . . . . 2-13 Installation to the water saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 Change of wash configuration via Remote Enabling System . . . . . . . . . . . . . . 2-15 Mounting of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 Installing the developer filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Filling up developer and wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Mounting the delivery table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Installation of level sensors for replenish and waste . . . . . . . . . . . . . . . . . . . . . . 2-20 Mounting the feed table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Mounting the fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21 Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Gum (10) (Blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Repl. (1) (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 1505
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Fill up (Clear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Dev. waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Dev. drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Wash drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Gum return hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Tap water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 Installation of setter interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 Finishing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Software settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Part 3: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Master input/output unit (MIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Power control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Control panel (MMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Setter connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Function keys - standard function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 (1) Eject plate/manual function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 (2) Manual replenisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 (3) Scroll up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 (4) Accept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Function keys - service mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 (2) Pump calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 (5) Power (white), (6) Ready (green) and (7) Alarm (red). . . . . . . . . . . . . . . . . 3-9 Jog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Change of settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Connecting to Remote Enabling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Setting up the service connection between the processor and the Remote Enabling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Static IP address setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Change of processor parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Plate sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Change of wash configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Change of conductivity configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Part 4: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
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Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Motor fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 PCB fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 IMPORTANT!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Cleaning accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Standard recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Special recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Normal cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Normal cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Daily cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Cleaning of the circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Cleaning of valves in the replenish and small circulation pumps. . . . . . . . . . . . . . 4-11 Cleaning of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Developer and gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Wash section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Replacement of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Adjusting the transport rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Tools: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Adjusting the brush pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Processor conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Adjustment - method A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Adjustment - method B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Mounting of r-clips for gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 NEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 ALWAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 Calibration of the replenish pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Calibration of the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Calibration of the developer fill pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
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General information Table of contents
Calibration of the conductivity sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Chain servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 After processing of 400 hours/6,500 m2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 After processing of 2,500 hours/80,000 m2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 How to check for potential chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Measurement point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Measure between a given numbers of pitches . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Control the length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Chain adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Complete view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Main chain (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Scrub chain (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Preventive Maintenance Kit Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Part 5: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Before starting trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 PCU PCB analyzing LED signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Level sensor LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Digital ouput LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 MIO PCB analyzing LED signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 MIO inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Appendix A: Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Primary wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 230 VAC, control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Low voltage wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Sensors and control devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Motors and internal bus wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6 24 VDC distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
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General information Manuals
Manuals A complete set of manuals consists of the following:
Service manuals The manuals listed below are for service technicians only. In addition the service technicians will need the manuals listed opposite as "User Manuals".
Spare Parts Manual, Plate Processor (1) Language: Contents:
English Spare parts
Service Manual, Plate Processor (2) Language: Contents:
1245
English Technical specifications Installation Functional description Maintenance Troubleshooting Electrical diagrams
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General information Manuals
User's manuals User's manuals available for the equipment:
CE Declaration Of Conformity (3) Languages: Contents:
26 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:
5 Operating and cleaning procedures
Quick Intro, Control Panel (6) Languages: Contents:
5 Quick guide to control panel user functions
Maintenance Chart, Plate Processor (7) Languages: Contents:
5 Maintenance instructions
Recycling Passport, Plate Processor (8) Languages: Contents:
5 Material list of the complete product
Keep the manuals with the machine for reference at all times.
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Technical specifications General environmental information
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: < 62 dB Stand-by mode: < 51 dB
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Technical specifications Mechanical specifications
Chemical emissions Ozone: Dust: Styrene:
3
0 mg/m 3 0 mg/m 3 0 mg/m
Heat emissions See "Power consumption" on page 1-5.
Mechanical specifications Performance 86/860 Plate types Plate width min.- max.
125/126/1250
single sided thermal offset plates 240 - 860 mm (9.5 - 33.9")
Plate length min.
240 - 1250 mm (9.5 - 49.2") 325 mm (12.8 ")
Plate thickness min.- max.
0.15 - 0.40 mm (0.008 - 0.016")
Plate speed
50 - 240 cm/min (15.7 - 94.5 "/min)
Brush speed
40 - 125 rpm
Tank capacities
Developer, total ex. pumps etc.
Wash (optional with integrated water circulation) ex. pumps etc.
86/860
125/126/1250
46.0 l (12.2 US gal.)
64.0 l (16.9 US gal.)
14 l (3.7 US gal.)
19.5 l (5.2 US gal.)
Gum
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Technical specifications Mechanical specifications
Temperatures 86/860,125/126/1250 18 - 35 °C (64 - 95 °F)
Developer min. - max. Dryer, process
50 °C (122 °F) non-adjustable
default
Water requirements 86/860,125/126/1250
Pressure
> 1 bar (15 psi)
Water consumption 86/860,125/126/1250
Operation (tap water in wash)
16 l/min (4.2 US gal/min)
Stand-by (tap water in wash)
0.0 l/min (0.0 US gal/min)
Hose connections 86/860,125/126/1250
Water supply
12 mm (¾")
Drain, developer
20 mm (0.79")
Drain, wash
20 mm (0.79")
Weights 86/860
125/126/1250
Weight, crated (± 5%)
400 kg (880 lb)
453 kg (997 lb)
Weight, processor
312 kg (688 lb)
340 kg (749.6 lb)
Exit table Capacity
1505
max. 30 plates NOTE! Consider risk of scratches
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Technical specifications Mechanical specifications
Dimensions Side view 311.4 cm (122.6")
101 - 116 cm (39.8 - 45.7")
82.0 - 97.0 cm (32.3 - 38.2")
79.6 - 94.6 cm (31.3 - 37.2")
Top view
86: 93.4 cm (36.8") 126: 131.6 cm (51.8") 40 cm (15.7")
86: 144.5 cm (56.9") 126: 183.5 cm (72.2")
123.6 cm (48.7")
86: 99.8 cm (39.3") 125/126: 138.8 cm (54.6")
1-4
147.8 cm (58.2")
T31977
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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
Recommended cable type
EUR
Single Phase, 1W + N + PE 230V / 1 x 16 Amps, 50-60 Hz
Min. 3 x 1.5 m2 type H03VV-F
US
Single Phase, 2W + PE 230V / 2 x 20 Amps, 50-60 Hz
Min. 3 x 14 AWG type SJ or SJO
JAP
Single Phase, 2W + PE 200V / 2 x 15 Amps, 50-60 Hz
Min. 3 x 14 AWG 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. 3.6 kWh (12000 BTU/hour) Stand-by: approx. 1.2 kWh (200 BTU/hour)
Noise level See “General environmental information” on page 1-1.
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1-6
Technical specifications Electrical specifications
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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 . • If the 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 installation hours for on-line machine: • Provided the machine is unpacked and will stay in the room and all electrical, water
and drain installations are in place, the estimated installation time, including interface installation and connection to the setter, is 6 – 8 hours. • If the 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.
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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 ( 162.2")
> 50 cm (19.7")
Feed table
> 60 cm (23.6")
86: > 304.5 cm ( 119.9") 125/126: > 344 cm ( 135.4")
2-2
Processor
Exit table (optional)
> 50 cm (19.7")
> 100 cm (39.4")
T32205
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 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 86/860
100 x 40 cm (39.4 x 15.8")
125/126/1250
150 x 40 cm (59.6 x 15.8")
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%.
"
1505
Capacity of the air condition/ventilation system must be adequate for heat emission (see "Power consumption" on page 1-5).
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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 door is…
Then…
> 159 cm (62.6")
No action is required as the crated processor can be transported immediately to the installation site.
125 - 159 cm (49.2 - 62.6")
The Service Technician has to unpack the processor.
< 125 cm (49.2")
The Service Technician has to unpack and strip down the processor.
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Installation Unpacking/preparing the processor
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 Enter the fork lift under the processor from either the input or exit end of the processor. If the forklift is entered under the processor from the side, make sure that the forks are placed under the transport member and not under the processor stand rails.
"
Carefull handling can prevent damage or accidents.
T32206
T32206
After handling remove the transport member by removing the screws, the washers and the nuts.
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2-6
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. • Lift and remove the top cover. • Loosen the screw inside the processor in front and rear side, lift and pull the right
side fender to remove it.
T32000
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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 (b) in the electronics cabinet (a) by the delivered cable (c). • Check the processor connections (see pages 1-5) for the current wiring type.
b a c
T32207
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2-8
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.
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Installation Mechanical installation
Mechanical installation Adjustment of lid switch See illustration below. Adjustment of the lid switch may be needed after levelling 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.
2
1
5
3
4
T32208
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Installation Mechanical installation
Installation of the hand shower
"
Not all models.
To mount the hand shower please follow the description below and the illustration on the following page. • The hose (1) is mounted to the solenoid valve (2) underneath the processor. • Mount the shower head (3) and the washer (4) on the hose (1). • Fix the shower head to the snap locks (5) inside the front panel.
1 2
1 4 3
5
T33049
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Installation Mechanical installation
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 at the rear base panel, underneath the processor. The hose can be connected to a water tap with ½" or ¾" male thread (WRG). When connecting to ¾", the reduction nipple shall not be used.
WATER TAP
GASKET
SOLENOID VALVE
NIPPLE 3/4" - 1/2" (WRG) GASKET
PLASTIC HOSE
When water connection has been made open the water tap and check that all connections for water inlet are tight. T3225
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2-12
Installation Configuration of water solution
Configuration of water solution
"
The processor can be set to the tap water system or to the water saving system from the factory. Installation to the water saving system or to the tap water system is described and illustrated on the following pages.
Installation to the water saving
$
For the water saving system installation is recommended min. 2 bar of the water pressure.
• Turn the processor off and disconnect the main power supply. • Turn off the main water supply at the main tap. • Remove the top covers and the left fender from the processor. • Drain the liquid from the processor. • Remove the rollers (a, b, c).
a b c
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Installation Configuration of water solution
•
2-13
Remove the stopper (d) from the block (e) and install the filter (f) to the block.
e d f
• Mount the drain pipe (g) and the bracket (h) to the tank by using the screw and
install the rollers (a, b, c).
g
a h b
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c
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Installation Configuration of water solution
"
Be aware of the small amount of the chemistry in the hoses and the pump which can leak out when dismounted.
• Disconnect the wires from the pins on the solenoid (i) used for tap water
• • • •
configuration and connect the wires to the pins on the solenoid (j) used for water saving configuration. Dismount the hose (k) from the fitting (l) on the tank by loosing the clamp. Dismount the stopper (m) from the hose (n) and secure the hose (k) with the stopper (m). Connect the hose (n) to the fitting (l) by using the clamp. Connect the pump (o) to the slot X109 on the electric box.
m
l n
o
n
k
k i j
WATER SAVING PINS
TAP WATER PINS
• Reinstall the left fender and the top cover on the processor. • Turn on the water supply. • Connect the processor to the main power supply and turn the processor on.
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Installation Configuration of water solution
2-15
Change of wash configuration via Remote Enabling System • Click 'Change access level' and set to 'Service'. • Enter password 'duy'. • Go to 'Data' -> 'Configuration' -> 'Hardware' -> 'Wash configuration'. • Doubble click on 'Tap water' and set it to 'Recirc + valve' . • Click 'Ok'. • Click 'Restart'. • After the restart of the processor go to 'Data' -> 'Settings' -> 'Preferences' -> 'Level
set up' -> 'Fill up mode' and set it to 'Automatic'. And do the same for 'Top up mode' and set it to 'Automatic'. • Click 'Ok'.
"
Calibrate the solenoid valve is necessary. See procedure on page 4-19 in the Service manual.
Instalation to tap water • Turn the processor off and disconnect the main power supply. • Turn off the main water supply at the main tap. • Remove the top cover and the left fender from the processor. • Drain the liquid from the processor. • Remove the rollers (a, b, c).
a b c
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Installation Configuration of water solution
• Remove the filter (f) from the block (e) and mount the stopper (d) to the block.
e d f
• Remove the drain pipe (g) and the bracket (h) from the tank by loosening the screw.
g
h
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Installation Configuration of water solution
#
2-17
Be aware of the small amount of the chemistry in the hoses and the pump which can leak out when dismounted.
• Disconnect the wires from the pins on the solenoid (j) used for the water saving
• • • •
configuration and connect the wires to the pins on the solenoid (i) used for the tap water configuration. Dismount the hose (n) from the fitting (l) on the tank by loosing the clamp. Dismount the stopper (m) from the hose (k) and secure the hose (n) with the stopper (m). Connect the hose (k) to the fitting (l) by using the clamp. Disconnect the pump (o) from the slot X109 on the electric box.
m
l n
o
n
k
k i j
WATER SAVING PINS
#
TAP WATER PINS
Always disconnect the pump from the electric box when is not in use to avoid the damage.
• Fill the processor with the liquid. • Reinstall the left fender and the top cover on the processor. • Turn on the water supply. • Connect the processor to the main power supply and turn the processor on.
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Installation Configuration of water solution
Change of wash configuration via Remote Enabling System • Click 'Change access level' and set to 'Service'. • Enter password 'duy'. • Go to 'Data' -> 'Configuration' -> 'Hardware' -> 'Wash configuration'. • Doubble click on 'Recirc + valve' and set it to 'Tap water'. • Click 'Ok'. • Click 'Restart.
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 Roller location: U = Upper L = Lower Roller pair number Section: DV = Developer W = Wash G = Gum DR = Dryer
a
b
a
T32209
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Installation Configuration of water solution
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 e.g. 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 levelling in all 4 positions and make final leveling if required. 7
6
4
7
6
5
1
FL O
O
R
SETTER OUTPUT HEIGHT ÷ 2 mm
3
2
T32210
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2-20
Installation Configuration of water solution
Installing the developer filter element The developer filter element must be installed in the filter vessel at the leftt tank side. • Close the valve (1). • Loosen the filter vessel (2) by means of the filter key (3) and unscrew the vessel (counterclockwise). • Install the filter element (4) inside the filter vessel. • Mount the filter vessel and make sure that O-ring (5) fits properly into the groove in filter vessel. Tighten with filter key (clockwise). • Make sure that the drain valve (6) is closed (counterclockwise). • Open the valve (1).
180°
1 CL
O
PE
4
O
SE
N
D
CL
O
3
SE
D
2
5
6
T32009
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Installation Configuration of water solution
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.
"
T31556
Remember to calibrate the solenoid valve. See description on page 4-19.
OPEN
No wash water recirculation.
CLOSED
The water solenoid valve will let in water when a plate is entered through the input slot.
T31981
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.
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2-22
Installation Configuration of water solution
Installation of level sensors for replenish and waste Enclosed in the installation kit are 3 sets of level sensors for developer replenishment and gum replenishment containers. • Locate the cables for level sensors (1). The cables are marked with name tags for each sensor. • Connect the enclosed sensor cables and mount sensors as shown on the illustrations: – "Dev repl min. cont. B10" to developer replenishment container (2). – "Developer fill up min. cont. B11" to developer replenishment container (2). – "Gum min. cont. B9" to gum replenishment container (3).
1
2
3 a
c
b
a
b
c
T33050
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Installation Configuration of water solution
2-23
Mounting the feed table Offline processors only! • Mount the screws (1), into the front panel, do not tighten yet. • Mount the screw (2) with lock stay (3) into the front panel, and tighten the screw (2). • Hang the feed table on the two screws (1), do not tighten yet. • Mount the two screws (4) and tighten them. Make sure the lock fits into the counterpart (5). • Check that the distance between the surface of the feed table and the edge of the entrance slot in the front panel is approximately 1.5 mm (as shown on picture below). • Tighten the two screws (1).
1.5 mm
3 2
1
4
5
4 T32211
Mounting the fenders • Mount the left and right fenders with the screws as shown below.
T32001
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Installation Configuration of water solution
Hose connections The illustration at the next page shows the hose configuration. Make the following hose connections underneath the tank:
"
All drain hoses must have a positive fall from the processor to the waste containers and drain.
Q
T31366
2-24
R
"
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.
$
Particularly when preparing the drain connection, ensure that copper or brass is not used in the draining system since the chemicals involved might corrode it. Plastic or rubber is therefore recommended. Check with your chemicals supplier for details.
"
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.
Fill up (Clear) Connect to developer replenishment container.
Dev. waste Connect to waste container.
Dev. drain Connect to waste container.
Wash drain Connect to waste container.
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Installation Configuration of water solution
2-25
Gum return hose Connect to gum container.
"
When inserting the gum return hose into the gum container, make sure that the hose end is never below the gum surface (see illustration below).
Tap water Make connection from water tap to solenoid valve underneath the processor.
Tap water
Gum return hose
Dev. drain
Gum (10) Fill up
Repl. (1)
Wash drain Dev. waste
T32354
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 shows recommended power supply cables for processors delivered without cable.
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Installation Configuration of water solution
$
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.
T32213
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.
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Installation Finishing installation
2-27
Finishing installation Software settings The processor is configured from the factory. The default parameters 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
120 rpm
120 rpm
120 rpm
120 rpm
Developer set temperature
24 °C
24 °C
24 °C
24 °C
Developer dwell time
29 s
29 s
29 s
29 s
No
No
No
No
Developer brush speed
Parallel plates
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.
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Functional description General
Part 3: Functional description General The basis processor contains four major sections:
1
2
3
4
T11264
1
Developer Developing of the plate and removing of the remaining unexposed emulsion.
2
Wash
Washing off the developer chemicals from the developed plate.
3
Gum
Application of a thin layer of gum onto the developed and washed plate to 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.
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3-1
3-2
Functional description General
DEVELOPER S1 INPUT SENSOR
OVERFLOW
M1 TRANSPORT M2
ROLLER MOTOR DEV. BRUSH MOTOR
M
E1 DEV. HEATING B1 DEV. TANK
M
R1
MIN. SENSOR
S28 COND.
TEMP. SENSOR
SENSOR
M19 DEV AUTOFILL. PUMP
M4
M3
DEV REPLENISH
DEV. CIRC. PUMP (IWAKI)
DEVELOPER FILTER
B11 DEV FILL UP CONT. MIN. SENSOR
COOLER
OPTIONAL REPLENISH NOT ALL MODELS
B10 DEV REPL. CONT. MIN. SENSOR
WASTE
OPTIONAL
T31992
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Functional description General
WASH, TAP WATER TAP WATER K8 VALVE FLOW LIMITERS
SPRAY TUBE
SPRAY TUBE
DRAIN
WASH, CIRCULATION WATER
TAP WATER REPLENISH
K8 VALVE FLOW LIMITERS
OVERFLOW
SPRAY TUBE
WASH TANK MIN. SENSOR
B2
SPRAY TUBE
DRAIN VALVE CIRC. PUMP
M10
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DRAIN
T31993
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3-3
3-4
Functional description General
GUM
APPLICATION TUBE
M23 GUM CIRC. PUMP
DRAIN
B9 GUM CONT. MIN. SENSOR
GUM OPTIONAL
NOT ALL MODELS
DRYER S2 OUTPUT SENSOR
R2 TEMP. SENSOR
M
HEATING ELEMENT
E2+E3
T31994
M
M51
M53
FAN
FAN
HEATING ELEMENT
E4+E5
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Functional description General
TRANSPORT
DV 2U Roller location: U = Upper L = Lower Roller pair number Section: DV = Developer W = Wash G = Gum DR = Dryer
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3-6
Functional description General
REMOTE ENABLING (Optional)
ETHERNET
MMI
USB
X50 MASTER I/O BOARD
MIO
INTERFACE
SoM
GNUIB (RS485)
SLAVE I/O BOARD
PCU
SETTER
(Online installations only)
T32249
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Functional description 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): • GNUIB for all internal communication in the processor (RS485). • 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 (see illustration below).
T32355
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3-7
3-8
Functional description Controls and indicators
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.
7
6
5
3
1
4
2 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.
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Functional description Controls and indicators
Indicators The control panel holds 3 indicators:
(5) Power (white), (6) Ready (green) and (7) Alarm (red).
WHITE
GREEN
RED
CONDITION
OFF > 1 minute
OFF
OFF
For software older than xxx-20111201 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 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 Z z Z z Z z Z". Error. See display for status.
ON
Warming up. Display shows ":-I".
FLASHING 5 sec loop
OFF
ON
ON
OFF
Ready to process plates. Display shows ":-)".
ON
OFF
ON
Alarm requiring user intervention.
Processing plates. Display shows ":-)".
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 ½ minute. After that the jog will run for ½ minute every 10 minutes.
Change of settings Change of settings is possible only via the Remote Enabling System.
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3-9
3-10
Functional description Controls and indicators
Connecting to Remote Enabling System Making settings of this processor requires the Remote Enabling System 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 PC's harddisk. • To 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 • If a LAN (Local Area Network) cable is
connected to the processor, or the PC is connected to wireless LAN, make sure to disconnect the cable/connection now. • Connect the Ethernet cable delivered with the processor between the PC and the processor (see illustration).
Network cable
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
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
to scroll to the Service/Info menu and press enter . 1) • Press to scroll to the LAN IP address (marked with ) and press enter 2) • You will now see a 'service' IP address 169.254.11.xx in the 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 System 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 System installation (permanent LAN IP address) at the customer's site.
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Functional description Controls and indicators
3-11
• Make a note of the 'service' IP address. It is needed for connecting to the Remote • • •
• •
Enabling System. 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 'OK'. When 'OK' the processor tab (4) will appear in the upper left corner of the Remote Client window.
"
For more information about the Remote Enabling System please see the general installation manual enclosed with the Remote Enabling System 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). • Enter Password 'duy'. • Select 'Config' (6).
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Functional description Controls and indicators
• Select 'Network'.
• Select the static IP addresses and change the IP address field to the IP address
informed by the IT administrator. • Click 'OK' and confirm 'Restart' by pressing 'OK'.
• When the Remote Enabling System is ready, please verify, on the processors control
panel, (by scrolling to the IP address marked with ) that the IP address now listed is identical to the one added in 'Static IP address' in the Remote Enabling System.
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Functional description Controls and indicators
3-13
Change of processor parameters • Press the processor tab (4). • Select 'Data -> Settings -> Programs'. • The processor parameters list will be shown in the 'Settings' view and new settings
can be made.
• Double click on the parameter.
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Functional description Controls and indicators
• Change the value of the parameter. • Press 'OK'.
Plate sizes
"
Plate sizes must be entered in order to obtain exact calculation of replenishment.
• Select 'Data' -> 'Settings' -> 'Plate sizes'. • Define new, or select already used plate sizes.
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Functional description Controls and indicators
3-15
Change of wash configuration • Click 'Change access level' and set to 'Service'. • Enter Password 'duy'. • Go to 'Data' -> 'Configuration' -> 'Hardware' -> 'Wash configuration'. • Double click on 'Tap water' and set it to 'Recirc + valve'. • Click 'OK'.
• Click 'Restart'.
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Functional description Controls and indicators
Change of conductivity configuration • Click 'Change access level' and set to 'Service'. • Enter password 'duy'. • Go to 'Data ' -> 'Configuration' -> 'Hardware' -> 'Developer configuration'. • Double click on ''Conductivity' and set it to 'ReadOut current'. • Click 'OK'.
• Click 'Restart'.
Service Manual - Plate processor 86/860, 125/126/1250
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Functional description Controls and indicators
3-17
Configuration file
"
Save a copy of the configuration file locally, and on the USB stick once the installation is finished.
• Set access level to 'Service'. • Go to 'Tools' -> 'Remote SW Tools'. • Click 'Backup data'.
• Select the folder where the file will be saved and click 'OK'.
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Functional description Controls and indicators
Service Manual - Plate processor 86/860, 125/126/1250
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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 Processor User's Manual.
"
Download of software for upgrade or repair purpose is available from the manufacturer's website: www.glunz-jensen.com.
WARNING!
DANGER
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 ÉLECTRIQUE AVANT TOUTE INTERVENTION, DÉBRANCHER TOUTES LES SOURCES DE COURANT MAINTENANCE PAR PERSONNEL AUTORISÉ 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.
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4-1
4-2
Maintenance Safety check
Safety check
#
The safety check described below 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.
Emergency stop
Control panel
Emergency stop
Main switch
Electronics cabinet
Upper side panel
T32214
Mechanical • Check 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.
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Maintenance Fuses
Fuses Motor fuses F17 and F18 are located in cables leading to connectors X4 and X5. Other fuses for the various 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
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.
F17
Transport motor M1
5AT, 6.3 x 32 mm S/B 5659
F18
Brush motor M2
4AT, 6.3 x 32mm 6896
Fuse
Fuse for
Type / part No.
F1 & F2 & F3
Main power supply
12AT, 6.3 x 32 mm 5527
PCB fuses
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4-3
4-4
Maintenance Rollers and brush rollers
Rollers and brush rollers General The 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/roller is marked with a small number (b). Install the rollers by referring to the roller numbers on the label. DV 2U Roller location: U = Upper L = Lower Roller pair number Section: DV = Developer W = Wash G = Gum DR = Dryer
a
b
a
T32209
Installation of rollers
"
A minimum of two persons are required for this operation.
3
• 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. • Insert the rollers into the clutches (5), then lower the rollers into the grooves and then mount the adjustments (2), and close the locks (1).
4
1 5 2 T32361
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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 or abrasive materials when cleaning any part of the processor.
Apron, rubber gloves and eye goggles. For personal protection Lint-free cloth, sponge and soft brush. For cleaning of rollers, guides, tank walls, and all surfaces, especially the exit table and the feed table (if fitted). Long-handled bottle brush and thin wire (i.e. Paper clip). For cleaning the inside and the holes of the spray tubes.
Cleaning agents
#
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°C (95-104°F). For normal cleaning purposes and to rinse after using other cleaning agents. Citric acid 10%/Nitric acid 5% For major cleaning purposes. Commercially available biocide/strong alkalic liquid For cleaning off heavy algae-, fungal- or bacterial growth in the wash section.
Special recommendations As some chemicals may require special cleaning agents, contact your chemicals supplier for recommendations about cleaning agents for your processor.
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4-5
4-6
Maintenance Cleaning
Cleaning of developer heating element
$
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).
T32302
Service Manual - Plate processor 86/860, 125/126/1250
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Maintenance Cleaning
Removing rollers from clutch case CLOSE OPEN
1
2
3
4
T31626
Removing drive clutch from clutch bearings
1
2
3
T31627
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4-7
4-8
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. • Wash the tank bottom and walls with water using a 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. • 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). • 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.
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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 (b). • Release the roller lock (c) and clean the upper gum roller (d) with a moist cloth. • 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 (c). • Mount back the top cover.
a c
d
c b
e T32389
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Service Manual - Plate processor 86/860, 125/126/1250
4-9
4-10
Maintenance 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).
1 2 3 4
5
T31064
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Maintenance Adjustment of spray tubes
Cleaning of valves in the replenish and small circulation pumps 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
VALVE VALVE
T436
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 illustration below. The valve is fully open from the factory. Normally no adjustments are necessary.
t31558
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4-11
4-12
Maintenance Replacement of bearings
Replacement of bearings See the illustration below. • Pull out 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.
1
2
1 3 T32011
Service Manual - Plate processor 86/860, 125/126/1250
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Maintenance Adjusting the transport rollers
Adjusting the transport rollers Tools: – 10 mm 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.
1
2
3
+
T 31642
1245
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4-13
4-14
Maintenance Adjusting the brush pressure
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: as specified on page 2-20.
Preparations • Lift up the processor top cover. • Remove the upper roller (1) in the developer section before adjusting. • Activate the interlock switch. • Start
(3).
Adjustment - method A See top illustration opposite. • While the brush (4) runs 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. • Adjust the brush pressure on the screws (2) (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 (2) 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 polyester film (7) and a spring balance (6) 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 (6) 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.
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Maintenance Adjusting the brush pressure
Adjustment - method A
2
Adjustment - method B
6 400 300 200 100
7 T31942
8
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4-15
4-16
Maintenance Mounting of r-clips for gears
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 illustration.
Q
R Service Manual - Plate processor 86/860, 125/126/1250
T32010
1245
Maintenance Calibration of the replenish pump
Calibration 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.
2 5C 2 0 S
Service/Info
>
Service mode
?
! Service mode
!
T32390
P1 : - )
• Place the suction tube from the replenish pump into a measuring container with
developer. • Start up the Remote Enabling client. • Click 'Change access level'. • Set Access Level to 'Service' and enter Password 'duy'.
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Service Manual - Plate processor 86/860, 125/126/1250
4-17
4-18
Maintenance Calibration of the replenish pump
• Click on 'Devices' -> 'Developer devices'. • Double click on 'Replenisher pump'. • Start the pump to remove air from the tube and let the pump run till no air is in the
tube. • Stop the pump.
• Fill-up the container so it contains 2 litres of developer. • Let the pump run for 1 min. exactly.
PUMP
X Y
T 31943
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Maintenance Calibration of the solenoid valve
• Go to 'Data' -> 'Configuration' -> 'Calibrate' -> 'Replenish pump'. • Set the measured value and press Ok.
Calibration of the solenoid valve Calibration of the solenoid valve is done via the Remote Enabling System. See page 3-10.
The processor must be in service mode, and access level must be set to 'Service' as described on page 4-17. • Dismount the hose leading from solenoid valve to wash spray fitting, and place it into the measuring container. • Go to 'Devices' -> 'Wash devices'. • Double click on 'Water valve' and let it run for one minute. • Measure the volume of water pumped into the container. • Go to 'Data' -> 'Configuration' -> 'Calibrate' -> 'Water valve capacity'. • Set the measured value.
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Service Manual - Plate processor 86/860, 125/126/1250
4-19
4-20
Maintenance Calibration of the developer fill pump
Calibration of the developer fill pump • Start up the Remote Enabling client. • Click 'Change access level'. • Set Access Level to 'Service' and enter Password 'duy'.
"
If the developer fill pump is mounted to the processor as an option, is necessarry to configure the fill pump as shown below.
• Go to 'Data' -> 'Configuration' -> 'Hardware' -> 'Developer configuration'. • Double click on 'Fill pump' and set it to 'Yes'. • Click 'Ok' and restart the processor.
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Maintenance Calibration of the developer fill pump
4-21
Calibrating of the pump is done via the Remote Enabling System. See page 3-10. • Activate the service mode in the processor menu. 2 5C 2 0 S
Service/Info
>
Service mode
?
! Service mode
!
T32390
P1 : - )
• Place the suction tube from the developer fill pump into a measuring container with
developer. • Click on 'Devices' -> 'Developer devices'. • Double click on 'Fill pump' and set it to 'On'. • Click 'Ok'.
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4-22
Maintenance Calibration of the developer fill pump
• Start the pump to remove air from the tube and let the pump run till no air is in the • • • • •
tube. Stop the pump. Fill-up the container with the developer. Let the pump run for 1 min. exactly. Go to 'Data' -> 'Configuration' -> 'Calibrate' -> 'Fill pump capacity'. Set the measured value and press 'Ok'.
Service Manual - Plate processor 86/860, 125/126/1250
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Maintenance Calibration of the conductivity sensor
Calibration of the conductivity sensor Calibration of the solenoid valve is done via the Remote Enabling System. See page 3-10.
The proccesor must be in service mode, and access level must be set to 'Service' as described on page 4-17. • Place an external calibrated conductivity meter in the developer section filled up with a liquid and measure the conductivity of the liquid. • Compare the measured value with the value measured by the processor conductivity sensor via the Remote Enabling System. Note the deviation between these values. • Go to 'Data' -> 'Configuration' -> 'Conductivity' -> 'Conductivity reading adjustment'. • Double click on 'Value' of 'Conductivity reading adjustment' and type the value equal to the deviation between the two measured values (e.g. if the value measured by the conductivity meter is 40 mS and the value measured by the processor conductivity sensor is 38 mS then the 'Value' of 'Conductivity reading adjustment' should be set to '2'. The range for 'Conductivity reading adjustment' parameter is ± 20 mS.
"
1427
Conductivity measured by the processor can be temperature compensated if chemistry supplier has a recommended 'Temperature coefficient'.
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4-24
Maintenance Chain servicing
Chain servicing
"
Regular chain servicing is important if maximum life is to be achieved.
Find data regarding processed total amount of the processing hours via the Remote Enabling System: • Go to 'Data' -> 'Statistics' -> 'Counters' -> 'Plate counters'.
After processing of 400 hours/6,500 m2 ... whatever comes first • Check the chain tension and adjust if necessary. See chain adjustment procedure on
page 4-28.
After processing of 2,500 hours/80,000 m2 ... 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 following 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.
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Maintenance Chain servicing
How to check for potential chain wear 2
The below guidelines should be followed after processing 2,500 hours/80,000 m of plates. Measure the length of the chain between a given number of pitches (see latter illustrations).
Measurement point
Measure between a given numbers of pitches
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4-25
4-26
Maintenance Chain servicing
Control the length • Measure e.g. 5 pitches. First rivet in first pitch to first rivet in fifth pitch. • Multiply the measured length to equal 20 pitches and compare the result with the
lengths listed below. Replace the chain and gears if worn out.
$
Length of 20 pitches should not exceed the length for a worn out chain as specified below.
$
Be aware that in case either the chain or the gears are worn out, both chain and gears have to be replaced.
$
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.
C
C
C
E
C
A
E
C
D
C
C
C
D
B
A
C
D A
20 pitches New = 378 mm Used = 381 mm
C
C
C
E
C
A
A
E
C
D B
D D A 12 pitches New = 225 mm Used = 227 mm
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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:
T31682
"
Some processors are manufactured with bearing with a lubricator nipple (a). There will be no need for grease/oil, as bearing has been lubricated from manufacturer of the bearing and it will last longer than the life time of your processor.
a
T565
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Service Manual - Plate processor 86/860, 125/126/1250
4-27
4-28
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.
1
2
T31999
Main chain (1) • Loosen the sprocket (a) on the drive plate
backside. Loosen the lock nut. • Adjust the chain tension on the adjustment screw (b). • Fasten the lock nut and the sprocket.
a b
T32002
Scrub chain (2) • Adjust the chain tensioner (c) until the
notch is aligned with thread M5 (d). The chain tension must be between 10° and 22.5°. • Mount the lock screw and fasten the chain tensioner.
c d T32003
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Maintenance Preventive Maintenance Kit Program
Preventive Maintenance Kit Program To ensure a continuous high quality and maximize productivity and processor up-time, it is recommended to carry out preventive maintenance at regular intervals. To facilitate this a Preventive Maintenance Program has been developed, consisting of a number of relevant service parts to be replaced at specific service intervals. It is recommended that the following Preventive Maintenance Kits are implemented, at the mentioned intervals, at which point the cycle will start over. • Minor Preventive Maintenance at 500 production hours or every year what comes
first. • Medium Preventive Maintenance at 1000 production hours or every year what comes first. • Minor Preventive Maintenance at 1500 production hours or every year what comes first. • Major Preventive Maintenance at 2000 production hours or every year what comes first.
1427
"
Please refer to the Spare Parts manual for order numbers for particular kits.
"
Read more about our Preventive Maintenance Kits on www.glunz-jensen.com and see the content of the Preventive Maintenance Kits - or contact us at [email protected].
Service Manual - Plate processor 86/860, 125/126/1250
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4-30
Maintenance Preventive Maintenance Kit Program
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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. LED signals on PCU PCB D. LED signals on MIO PCB
For cleaning and maintenance subjects see the processor user manual and chapter 5 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 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.
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5-1
5-2
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
PROBABLE CAUSE
REMEDY
NO FUNCTION ACTIVE
• 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 or defective. • Electronics defective.
• Open water tap. • Replace valve.
DRYER BLOWER WORKS, HEATER DOES NOT
• • • •
• • • •
DRYER BLOWER DOES NOT WORK
• Fuse(s) blown. • Blower defective. • Electronics defective.
Fuse(s) blown. Temperature sensor defective. Heating element defective. Electronics defective.
Service Manual - Plate processor 86/860, 125/126/1250
• Clean filter. • Check sensor and clean/replace whatever is necessary. • Replace defective electronics. Replace fuse(s). Replace temperature sensor. Replace heating element. Replace defective electronics.
• Replace fuse(s). • Replace blower. • Replace defective electronics.
1245
Trouble shooting Problems with processed material
SYMPTOM
PROBABLE CAUSE
REMEDY
NO GUM ALTHOUGH MACHINE IS IN “PROCESS” MODE
• Gum container empty. • Gum hose blocked. • Pump valves blocked or defective. • Pump defective. • Fuse(s) blown. • Electronics defective.
• Refill container. • Clean hose. • Clean or replace valve.
GUM PUMP RUNS BUT NO GUM (NO ALARMS)
• Gum hose blocked. • Pump valves blocked or defective.
• Clean hose. • Clean or replace valve.
DEVELOPER REPLENISHMENT PUMP DOES NOT WORK
• Fuse(s) blown. • Pump defective. • Electronics defective.
• Replace fuse(s). • Replace pump. • Replace defective electronics.
DEVELOPER REPLENISHMENT PUMP RUNS BUT NO REPLENISHMENT
• Replenishment hose blocked. • Pump valves blocked or defective. • Replenish container empty.
• Clean hose. • Clean or replace valves.
REPLENISHMENT SYSTEM DOES NOT WORK ALTHOUGH THE MACHINE IS IN ”PROCESS” MODE
• Replenishment parameters settings not correct. • Electronics defective.
• Make correct settings.
NO DEVELOPER CIRCULATION
• Fuse(s) blown. • Developer circulation pump defective.
• Replace fuse(s). • Replace pump.
NO WATER CIRCULATION
• • • •
• • • •
ROLLER DRIVE MOTOR RUNS,BUT NO PLATE TRANSPORT
• Drive gears and/or worms defective.
Pump defective or clogged. Water spray bar clogged. Fuse blown. Level sensor in wash dirty or defective.
• Replace pump. • Replace fuse(s). • Replace defective electronics.
• Refill container.
• Replace defective electronics.
Clean and/or repair pump. Clean spray bar. See Part 4. Replace fuse. Check sensor and clean/replace whatever is necessary.
• Check all gears and worms gears on rollers and make sure they move freely. Replace any defective part.
Problems with processed material
1245
SYMPTOM
PROBABLE CAUSE
REMEDY
PLATE IS NOT COMPLETELY DRY
• Gum section applying too much gum. • Dryer section is malfunctioning.
• Check gum section. • Check dryer section.
Service Manual - Plate processor 86/860, 125/126/1250
5-3
5-4
Trouble shooting Problems with processed material
SYMPTOM
PROBABLE CAUSE
REMEDY
PLATE HAS STRIPES LENGTHWISE OR CROSSWISE
• Defective or dirty rollers or guides.
• 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 4-14. • Replace defective brush(es).
• 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.
WASHING NOT SUFFICIENT
PLATE HAS AN UNEVEN GUMMING
• Increase the transport speed slightly. • Reduce developer temperature slightly. • Reduce replenishment rate slightly. Calibrate replenish pump according to description on page 4-14.
• Water tap closed. • Water solenoid valve defective or water filter clogged. • Spray-tubes clogged or misadjusted. • Water circulation pump does not run. • Brush misadjusted.
• Open water tap. • Check valve and filter.
• Gum container nearly empty. • Gum rollers dirty.
• Refill container.
• Gum distributing tube clogged or out of adjustment. • Gum pump clogged.
PLATE'S TRAILING EDGE IS BENT
• Change developer. • Reduce the transport speed 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 4-17. • Adjust brush according to description on page 4-14.
• Brush pressure too high. • Brush speed too high.
Service Manual - Plate processor 86/860, 125/126/1250
• Clean or adjust whatever is necessary. • See page 4-10. • Adjust brush according to description on page4-14 .
• 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 4-14. • Reduce brush speed.
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Trouble shooting PCU PCB analyzing LED signals
PCU PCB analyzing LED signals GREEN LED D88
RED LED D3
YELLOW LED D2
GREEN LED D1
CONDITION
OFF
-
-
OFF
The CPU PBC power supply missing.
ON
OFF
FLASHING 1.5 sec pause
ON
Waiting for SoM/MIO to power up. If flashing continues for more than 6 seconds after power up, please check the RS485 cable connection and follow up on the status stated in this table.
ON
OFF
OFF
ON
Malfunctioning PCU PBU.
ON
OFF
ON
ON
The PCU PBU is ready to receive messages from the MIO/SoM.
ON
OFF
ON
ON
The PCU PBU is receiving messages from the MIO/SoM.
ON
ON
OFF
ON
Malfunctioning PCU PBU.
ON
ON
ON
ON
Possible hardware error detected but trying to continue normal operation.
T32012
• LEDs D5 - D12 (green) – show the status of level sensor inputs 0 - 7 • LEDs DI1 - DI8 (green) – show the status of digital inputs • LEDs DO1 - DO8 (green) – show the status of digital outputs
1505
LED STATUS
INPUT/OUTPUT/SENSOR STATUS
ON
OK (in level)
FLASHING
Disconnected
OFF
Not OK (not in level) or not in use
Service Manual - Plate processor 86/860, 125/126/1250
5-5
5-6
Trouble shooting PCU PCB 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
T32015
LED
CONNECTOR
COMPONENT IN USE
DO1
X9, 7 and 8 (sink)
Wash valve
Service Manual - Plate processor 86/860, 125/126/1250
1505
Trouble shooting MIO PCB analyzing LED signals
MIO PCB analyzing LED signals
GREEN LED D16 OFF
RED LED D17
CONDITION
The CPU PCB power supply missing or malfunction SoM/MIO. OFF > 1 minute • Remove all cables from the electronics cabinet (except power and emergency switch) and try again. • Check the SoM PCB board connection. • If still not good, replace the MIO/SoM/LDM PCB board.
ON
Maybe malfunctioning SoM PCB. ON > 1 minute • Remove all cables from the electronics cabinet (except power, emergency switch and the RS485 cable [P1¬®P1]) and try again. • Check the SoM PCB 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 processor's electronics cabinet and power off and on. Wait at least 3 minutes. Then check (via PC) that the "platform" or the "platform.txt" file is renamed to "platform.old" file. If no file is renamed, replace the MIO/SoM/LDM PCBboard.
1245
ON
TOGGLING
OFF
ON
For software newer than xxx-20111201 Power up sequence: The sequence lasts for approximately 1 minute. The green LED goes off/on approximately 5 times in an irregular pattern. For software newer than xxx-20111201 Software started: Please see display for status.
Service Manual - Plate processor 86/860, 125/126/1250
5-7
5-8
Trouble shooting MIO PCB 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
S2 output sensor
J10, 15 and 16
Output sensor
Service Manual - Plate processor 86/860, 125/126/1250
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Appendix A: Electrical diagrams
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
1245
Service Manual - Plate processor 86/860, 125/126/1250
A-1
A-2
Primary wiring
Primary wiring 230 VAC, control devices
Service Manual - Plate processor 86/860, 125/126/1250
1505
16A
4
2
3
2
4
1
4
M
1
5
1 2 3
CN?
1
4
GND
+24 VDC
GND
+24 VDC
CN?
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
2
Q44
Dev. Water Repl. Pump
M
1
2
2
M13
X29 3
6
24 VDC SUPPLY, 225W For motors
U2
Dev. Repl. Pump
2
S14K460
OPTIONAL
3
Dev. Circ. Pump
7
M4
M
1
X106,4 X106,2
2
X102
X15 3
8
X102,5
M3
X12 3
IEC 60320 Appliance Inlet
ON/OFF
S1
Ground screw in Electronics
10057309
Emergency Switch Front
S14
1
3
230V AC 1 W + N + PE or 230V AC 2 W + PE
L PE N
X109
X52
100n
Cx
L4 0.64 mH
X27,1
Cx Cy Cy 4.7n 100n 4.7n
X27,1
X101
X14,2
10057738
10057740
RV18
S14K460
L5
X34,3 X20,3
BTA 24
X14,1
RV13
3
1
Q30
BTA 24
RV14
2
8
1
4
5
Q55
BTA 24
1
X42 1
2
10061547
Gum Pump
S8
1
3
4
4
2 1
6
8
To PCU X1,6
To PCU X1,3
To PCU X1,5
To PCU X1,2
To PCU X1,4
7
X20 4
4
Q45
BTA 24
620W E3
75 °C
X104 To PCU X1,1
Dryer Heating, E2 : basis E3 : reg.
3
10063826
5
620W E2
75 °C
10058856
1AT
F6
S14K460
X14
2
RV27
OPTIONAL
6
2
3
M23
X37 3
7
Cover Switch
10061549
Dev. Heating
E1
63 °C
X26 3
X31,3
Q28
X33,1
S14K460
X31,2
X106,3
X109
X21,1
X106,1
BTA 24
X20,2
1000W
RV17
X27,2
Max 1A
X27,1
Q36
X104,6
BTA 24
X104,1
L1
X102,1
3
RV21
5
X34,2
R46 150k
6
Q42
BTA 24
S14K460
Dryer Blower
M
M51
1
2
3
1
2
RV19 S14K460
4
Q43
BTA 24
2
1
2
S14K460
3
1
Q46
BTA 24
620W E4
75 °C
X34
10057218
RV20
RV22
4
1
2
5
Dryer Heating, E4 : basis E5 : reg.
3
6
Q53
BTA 24
4
620W E5
75 °C
2
RV26
1
S14K460
1
Emergency switch
S14
10057309
X43 2
X42 1
3
2
4
3
4
X42 1
2
3
Connections for emergency switches on processors with double emergency switch (OPTIONAL)
Motor Capacitor Dryer Blower
C1
X21 3
X14,3
1 return 1
X107,7
X6
X101,4
S14K460
X107,5
X34,1
2 hot 1
X101,2
X103
X13,2 X20,1 X101,1
3 return 2
X13,1
S14K460
X101,2
Max 1A
12AF
4
X31 4
3
M53
4
2
1
6
Q66
BTA 24
2
5
RV32
2
M34
X39 3
1
M
1
4
Q34
BTA 24
2
1
Cover Switch Double cover
S3
10063826
X43 2
X42 1
3
2
4
3
5
4
6
5
1
3
Q35
BTA 24
2
1
8
7
Q54
BTA 24
4
2
2
3
4
6
Cover Switch Double cover
S8
10063826
5
Page:
1 Of: 3
Approval:
Constructor: MLS
6
1
1
1AT
F8
2
1
2
RV30
OPTIONAL
Wash. Circ. Pump
M
1 2
M10
X27 3
1AT
F7
S14K460
4
6
F7 2AT
3
Mains for stacker
7
8
5
7
1
4
2
unauthorized person without our specific permission.
and must not be used or handed over to any
This drawing belongs to Glunz & Jensen A/S
ELECTRONIC AND MECHANICAL ENGINEERING
X10
X109
8
3
Cx 68n
Cy 2.2n
1
Doc. No.:
O OrCAD
Rev.:
X109
2
10058007
Number:
5
10063345
Cy 2.2n
R
R40
PE L3 0.4 mH
10053844
6
L2
OPTIONAL: Power supply for Stacker
OPTIONAL
5
Q61
BTA 24
Dev. Autofill Pump
M19
X13
3
3
3
RV29
10061536 (short vers.)/ 10076507 (long vers.)
Plug for Chiller
3
1
RV16
Date: Tuesday, December 16, 2014
X42
6
S14K460
X16
RV15
Connections for cover switch(es) for processor with double top cover (OPTIONAL)
Motor Cooling Fan
230 VAC Control Devices
Function:
3
RV31 S14K460
Motor Capacitor Dryer Blower
C2
7
Primary Wiring
Title:
S14*
Emergency switch
10057309
10075674
Dryer Blower
M
1
2
3
X105
X33 3
8
Q64
BTA 24
X39,2
Non interrupted
X16,3 X31,1 X101,1
Non interrupted
X16,1
4 hot 2
X107,4
X34,4
X107,1
X16,2
F1
X12,2
5 return 3
X12,1
S14K460
X39,1 X105,6
X106
X105,1
12AF
X101,4
X26,2
X105,4 X105,5
S14K460
X107
F2
Yl/grn
X104,6
X108
X104,1
X14,4 X21,2
Blue
X101,3 Black
X101,1 Brown
X33,2
Blue
X101,3 Black
X101,1 Brown
X26,1 X105,2
Power Control Unit, PCU
Yl/grn
X37,2
Max 1A
X37,1 10072807
6 hot 3
X15,2
Max 1A
X15,1
12AF
X109,5
S14K460
X103,4 X103,2
X109,1
F3
N N
L
L
PE
L
N
A-4
Low voltage wiring
Low voltage wiring Sensors and control devices
Service Manual - Plate processor 86/860, 125/126/1250
1505
R1,2
J10,1
10K
R1
2
7
8
1
10K
Dryer temp sensor
2
J10,6
R2
NC
S2
Output sensor
2
1
S1,2
S1,1
1
X116
IN 1
2
R1,1
1
X117
IN 0
2
1
X9
2
3
4
-
+
LEV1
Sinus
15k
S2,2
NC
1
Dev tank min sensor
9
2
24V
Wash valve
K8
1
S1
Input sensor
2
1
J10,14
10
11
B2
12
VAL6 VAL7
10057195
8
7
6
VAL0
+24Vdc
5
B1 2
LEV0
B1,1
X9,5
0 Vdc
+
B1,2
X9,6
-
K8,1
2
1
0 Vdc
1
J11 4
5
1
X10 2
7
8
9
3
4
5
10 11 12 13 14
7
6
5
6
7
8
9
1
J12
10
2
3
4
2
1
OPTIONAL
10061551
2
1
11
10
9
8
12
14
13
Sensors And Control Devices
Function:
Low Voltage Wiring
5
7
9
Page: 2
Approval:
8
20
+24Vdc
See Setter manual for actual pin connections, or contact your Service Suplier.
Plate Setter
Optional
P3
Processor Interface Module, PIM
3
2
2
3
4
5
Of: 3
6
9
M24
M
10
2
12
10077463
11
Biocide Pump (Optional)
2
1
X21 1
Optional
8
13
This drawing belongs to Glunz & Jensen A/S and must not be used or handed over to any unauthorized person without our specific permission.
5
4
5
15
16
Rev.:
Doc. No.:
OrCAD
10058007 O
Number:
14
LEV0
Sinus
Conductivity Sensor
0 Vdc
S28
ELECTRONIC AND MECHANICAL ENGINEERING
7
4
3
2
Optional
P2
VAL0 VAL1 VAL2 VAL3 VAL4 VAL5
10 11 12
Tuesday, December 16, 2014
1
X11
8
Constructor: MLS
Date:
Tank Min. Sensor : Gum - B9
2
1
6
Serial Peripheral Interface Bus, SPI (for external use)
Cont. Min. Sensor: Cont. Max. Sensor: Cont. Min. Sensor: Dev. fill-up - B11, Dev Waste - B15 Water - B22
2
1
Title:
4
3
Cont. Min. Sensor: Dev repl. - B10,
2
1
OPTIONAL
Wash tank max sensor
6
2
LEV1 LEV2 LEV3 LEV4 LEV5 LEV6 LEV7
Sinus
3
10058855
2
1
X10,14
J17
1
10 11 12 13 14 15 16
J10,5
Rntc
9
S2,1
J10,15
K8,2
Green
6
R2,2
Preheat temp sensor (optional)
50K
R6
R6,1
Rntc
R6,2
J10,3
1
4
J10,13
Power Control Unit, PCU, level input and valve output
Dev temp sensor
2
Rntc
1
J10,2
10041307
5
R2,1
J10,4
3
X10,3
2
+
J10,16
X9,7
+
1
X9,8
+
Yellow Green
J10
X10,4 15k
-
X10,9 15k
-
B2,1 X10,10
B2,2
-
B15,1 X10,12 15k
+
B15,2
-
Red Yellow
Master In - Out, MIO
X10,6
B22,1
X10,11
+
B22,2 X10,5 15k
-
B10,1
+
B10,2
+
B9,1
-
B9,2
-
B11,1 X10,8
B11,2 X10,7 15k
X10,13 15k
2
2
1 5
Blue
10035580 Red +
3 X21,2 X11,10
X21,1 X11,9
Blue -
A-6
Motors and internal bus wiring
Motors and internal bus wiring 24 VDC distribution
Service Manual - Plate processor 86/860, 125/126/1250
1505
M2
24 VDC from CN 2 on PSU 2 (interrupted by E-stop and cover switch)
CN2, 18
CN2, 15
CN2, 6
CN2, 3
1
1
5
5
2
2
M
Brush motor, Dev, M2 Encoder S31
X
3
3
6
6
X5,2
7
7
8
+
+
4
8
8
IN
U?
OUT
F18 4AT
X5
+ 1 4
10AF
M1
2
Dual Motor Controller
10069154
4
3
6
2
5
0.6 AT
BTN7930
1
M2,5
CN5, 1
M2,1
1
1
BTN7930
6
390 R
+
F18
GND
3
M2,7
1
3
5
5
5
2
2
Transport motor, M1 Encoder S30
X
3
3
6
6
X4
BTN7930
F17 5AT
10AF
LM78L05
signal
4
7
7
6
4
8
10069154
4
2
+ 1 4
8
+ 24 Vdc
0V
+ 5 Vdc
M1,5
X1
M2,2
DC
M1,1
X4,2
BTN7930
390 R
DC
M1,7
10057224
5
3
.
2
+ 24 Vdc (DC output supply)
X12 + 1 4
X36
+ 3.3 Vdc (mikrocontroller circuitry)
1
2
2
6
3
3
4
5
5
6
7
9 10
2
6
3
5
GND
10062011
1
Man Machine Interface, MMI TOUCH DISPLAY
X13 + 1 4
8
BTN7930
GND
2
100 R
RX
RX
TX
TX
100 R
RX
RX
TX
TX
#9
9
5
6
1
3
7
2
8
4
3
2
1
J2,2
24 Vdc distribution
Function:
Motors and Internal Bus Wiring
Title:
One-line display
10062070
#5
P1
#6
9
#3
3 #1
#7
7
5
#2
2
6
#8
8
1
#4
4
P1
Processor is equipped with EITHER touch display OR one-line display
Q?
4AT
2.5 AT
3
F19
F20
M1,2
signal
M1,6
BTN7930
IN 6 IN 7
Part of Power Control Unit, PCU
P2
X1
X2
X3
Display driver plug-in PCB
J4
Error LED RED
H2
Page: 3
Approval: Of: 3
Constructor: MLS
5
Ready LED GREEN
Date: Tuesday, December 16, 2014
H1
8
Keyboard with diodes.
J3
J16
Part of Master In- and Out, MIO See page 2 of 3 for connection to input and temperature sensors
98516
GND
CN5, 5
X5,1
Black
GND
24 VDC from CN 5 on PSU 1
X5,4
White
X5,5
White
X5,3
Red
Vcc
Black
10057540 X2,3
IN SIGNAL E-STOP 1
M2,6
Black
X2,1
1
GND 2
+12VDC DISP.,2
+12VDC 2
10057223
X4,4
White
X4,5
White
J2,4 GND
X4,3
Red
Vcc
Black
GND
J2,1 S12
DISP.,1
3
GND
4
GND
150R
S13
1
+12VDC
2
+12VDC
3 GND
J20
1 J21,3
10062307 (optional)
4
Power On LED WHITE
Enter
S12
3
This drawing belongs to Glunz & Jensen A/S and must not be used or handed over to any unauthorized person without our specific permission.
Rev.:
Doc. No.:
OrCAD
10058007 O
Number:
Man. Replenish
S13
2
Plate Eject
S11
7
10061537
Arrow up
S10
6
8
7
6
5
4
3
2
1
ELECTRONIC AND MECHANICAL ENGINEERING
H3
GND
#2
GND
4 150R
2
#3
S13 150R
J2 GND
#1 1 +12VDC
3
3 DISPLAY (SERIAL)
#4 4 S12
J2,9
J21,1
2 GND
4 J21,2
#5 5 IN 1 8 J20,2
J2,13
9 J20,1 H3
J2,8
#6 6 OUT RED
10 J2,14
GND
H2
J2,12
#8 8 S10
J2,10
J20,8
OUT (EXTRA) 7
#7 7 IN 2 GND
GND
J20,4
J2,16 H1
S11
J2,11
#9 9 OUT GREEN IN 3 11 12 J20,3
IN 4 13 J20,5
OUT WHITE
14 J20,6
GND 15
GND 16 J20,8 GND
X4,1
M
A-8
Service Manual - Plate processor 86/860, 125/126/1250
1245