Plate Processor 86-860 PDF [PDF]

Zitiervorschau

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

0-2

#

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

General information The processor

Part 0: General information Reservations • This manual was written and illustrated using the best possible information

available at the time of publication. • Any differences between this manual and the equipment reflect improvements introduced after the publication of the manual. • Changes, technical inaccuracies and typographic errors will be corrected in subsequent editions. • As a part of our policy of continuous improvement, we reserve the right to alter design and specifications without further notice.

Notes, cautions, and warnings ! Throughout the manual notes, cautions, and warnings are written in bold like the example below:

$

Always replace a fuse with one of the same size and rating as the old one.

Symbol

Meaning

Explanation

Note

The operator should observe and/or act according to the information in order to obtain the best possible function of the equipment.

$

Caution

The operator must observe and/or act according to the information in order to avoid any mechanical or electrical damage to the equipment.

#

Warning

"

The operator must observe and/or act according to the information in order to avoid any personnal injury.

Other manuals Please see description of "Manuals available for the plate processor" later in this chapter.

The processor Approvals • Approvals will appear from the labels attached to the name plate or the frame part

of the processor.

1245

Service Manual - Plate processor 86/860, 125/126/1250

0-3

0-4

General information The processor

Unintended use of the equipment Glunz & Jensen A/S do not take any responsibility for any damage or accidents caused by unintended use of the equipment: • As the equipment is certified by accredited test laboratory (UL International Demko A/S) it is absolutely prohibited to make any modifications, electrical nor mechanical, of the equipment. If however this prohibition is disregarded, Glunz & Jensen's warranty will no longer apply and the certification labels for UL, C-UL, and CE certification of the equipment shall be removed as the certification will no longer apply to the equipment.

Intended use of the equipment • Development of photographic materials as specified in “Technical specifications” in

Part 1 in this manual.

Installation • Never install the processor in explosive environments. • It is the responsibility of the owner and operator/s of this processor that the

installation is made in accordance with local regulations, and by engineers authorized to carry out plumbing and electrical installations. • Installation, service and repair must be performed only by service technicians who are trained in servicing the equipment. The installation procedure is described 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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

General information The processor

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

local supplier.

1245

Service Manual - Plate processor 86/860, 125/126/1250

0-5

0-6

General information Table of contents

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

Service Manual - Plate processor 86/860, 125/126/1250

1245

General information Table of contents

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

Service Manual - Plate processor 86/860, 125/126/1250

0-7

0-8

General information Table of contents

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

General information Table of contents

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

0-9

0-10

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

Service Manual - Plate processor 86/860, 125/126/1250

0-11

0-12

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.

Service Manual - Plate processor 86/860, 125/126/1250

1411

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

1245

Service Manual - Plate processor 86/860, 125/126/1250

1-1

1-2

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

Service Manual - Plate processor 86/860, 125/126/1250

N/A

1505

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

Service Manual - Plate processor 86/860, 125/126/1250

1-3

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

1-5

1-6

Technical specifications Electrical specifications

Service Manual - Plate processor 86/860, 125/126/1250

1245

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

2-1

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.

Service Manual - Plate processor 86/860, 125/126/1250

1505

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).

Service Manual - Plate processor 86/860, 125/126/1250

2-3

2-4

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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.

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-5

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-7

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-9

2-10

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

Service Manual - Plate processor 86/860, 125/126/1250

1411

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

1411

Service Manual - Plate processor 86/860, 125/126/1250

2-11

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

1505

c

Service Manual - Plate processor 86/860, 125/126/1250

2-14

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.

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-16

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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.

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-18

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-19

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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.

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-21

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

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.

Service Manual - Plate processor 86/860, 125/126/1250

1505

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.

1505

Service Manual - Plate processor 86/860, 125/126/1250

2-26

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.

Service Manual - Plate processor 86/860, 125/126/1250

1505

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.

1505

Service Manual - Plate processor 86/860, 125/126/1250

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

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

Service Manual - Plate processor 86/860, 125/126/1250

1411

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

1245

DRAIN

T31993

Service Manual - Plate processor 86/860, 125/126/1250

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

Service Manual - Plate processor 86/860, 125/126/1250

1411

Functional description General

TRANSPORT

DV 2U Roller location: U = Upper L = Lower Roller pair number Section: DV = Developer W = Wash G = Gum DR = Dryer

1245

Service Manual - Plate processor 86/860, 125/126/1250

3-5

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

Service Manual - Plate processor 86/860, 125/126/1250

1245

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

1505

Service Manual - Plate processor 86/860, 125/126/1250

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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).

1245

Service Manual - Plate processor 86/860, 125/126/1250

3-12

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

3-14

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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'.

1245

Service Manual - Plate processor 86/860, 125/126/1250

3-16

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

1322

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'.

1245

Service Manual - Plate processor 86/860, 125/126/1250

3-18

Functional description Controls and indicators

Service Manual - Plate processor 86/860, 125/126/1250

1245

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

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.

Service Manual - Plate processor 86/860, 125/126/1250

1505

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

1245

Service Manual - Plate processor 86/860, 125/126/1250

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

Service Manual - Plate processor 86/860, 125/126/1250

1505

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

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

1505

Maintenance Cleaning

Removing rollers from clutch case CLOSE OPEN

1

2

3

4

T31626

Removing drive clutch from clutch bearings

1

2

3

T31627

1245

Service Manual - Plate processor 86/860, 125/126/1250

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

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

1245

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

Service Manual - Plate processor 86/860, 125/126/1250

1245

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

1411

Service Manual - Plate processor 86/860, 125/126/1250

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

1245

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

Service Manual - Plate processor 86/860, 125/126/1250

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.

Service Manual - Plate processor 86/860, 125/126/1250

1245

Maintenance Adjusting the brush pressure

Adjustment - method A

2

Adjustment - method B

6 400 300 200 100

7 T31942

8

1245

Service Manual - Plate processor 86/860, 125/126/1250

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'.

1245

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

Service Manual - Plate processor 86/860, 125/126/1250

1245

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.

1245

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.

Service Manual - Plate processor 86/860, 125/126/1250

1427

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'.

1427

Service Manual - Plate processor 86/860, 125/126/1250

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

1427

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'.

Service Manual - Plate processor 86/860, 125/126/1250

4-23

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.

Service Manual - Plate processor 86/860, 125/126/1250

1427

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

1427

Service Manual - Plate processor 86/860, 125/126/1250

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

Service Manual - Plate processor 86/860, 125/126/1250

1427

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

1427

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

Service Manual - Plate processor 86/860, 125/126/1250

1427

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

4-29

4-30

Maintenance Preventive Maintenance Kit Program

Service Manual - Plate processor 86/860, 125/126/1250

1427

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.

1245

Service Manual - Plate processor 86/860, 125/126/1250

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.

1245

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

1245

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