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Service manual Plate Processors 85-125 Supreme

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3. aseud ZU c LUD c ur dd M AOE J amp inaN Inoull A seseug Appendix B Electrical diagrams High Voltage Wiring 230V AC Control Devices HPU Service Manual Plate Processors 85 125 0906 qvo wossiuued 9ypeds sno nou uosied pezyovjneun S z ue e o pepueu Jo pesn eq jou snw pue 1 SY a orjak g seone o41uO1 OVA US d DNIHS3NION3 TV2INVH23W ONE JINOHLIJIJ ones 691520017 dh i n iis NJSNA4C 8 ZNATE ae REENERT dag Buni oBeljoA un KejaH DEO I AO 1004 JOO 91425 Jojjoedeg LO O FEN FIO ye ye Jamo g 1e uq 19e9H Ja LSIN sa ye va 009 Jemojg Jo W PA m JOJO qnuog Joyoedeo T gt 9 n m EN zo a la 5 AS H Je D 2 a 5 Z B m H D PE I I EN S V EN FN A pa XN GA TA TA AAA ll lli RR EROI iP tt Li cle vy L lt ol Le E P ZN 29 o EEN el 93 S REE l M GO GC L ba ba fio T D N a O lt m m IS NS En D ra Ro eq rein
4. SJUEUEA SUELIEA 991 8 OSL S9L 8 OSL uo Aug 921 uo 1614 WD Jewo g JAH Jejeop JAMO es 93 n va MOOS H ue4 19MO g Ia N d 91U0N98 3 9110 USEM 9110 Aer Jolloedeo T 9 Su ZIN PN 9 Ver IE GO JO liti N N N Q o n 8 o D en Enn C eae Lu Iu A X n FA AAA Ill ERRE ID II ilze ry bleley z LEVE Te LEE eee BIN ZIN YIN L ok EN x ls 93 A JA ZA JA A JA ih k E Ser PE BE EE EEN po GES EE o 5 Ss 5 m5 In jc N no Pr sch Co SJUBIJEA S9L 9 081 uo Aug MO00L 0001 pore e mia 19e8H Aeg dund dund Ile dund dund eu Ae Og 104 HONY d u jeje Id q A9g Io unc BEI i EE Tio Iny neg day JejeM Ka 8N 9N Lat ke Si le 8 6LIN CIM gt 6 W W W W E ELE nn n LEN EN ES V T EN AS A KOC E A r gi EEE OEEO HUTT ood II EET UP I r zlelri i frleleler lzle l
5. NIVO NIV OL YANIVLNOD YANIVLNOD INJMWHSINJIdJA uno 434013130 Nouvinowi EE 331002 ERES TVSH3AIND 1I3dO T3A3q NOVA q y MO1443A0 NOILO31100 MOJ AON3DIINI a NOLLVn23I23 Wno NOILLVINDUII NJdOTJAJA A g da O B WIL s uar D ZS HJdOTJAJA Y JATVA 10ULNO9 X X XX X MOT pr P ET AlddNS 43 1 VM gt jonuo9 eds SNIVW sJeq lt LON JATVA aaivs3do pp pp lt EN TEO WNS HSVM MJIdOTJAJA Service Manual Plate Processors 85 125 0906 CD 125 Processor Service Manual Plate Processors 85 125 0906 GZL JOSS920Jd NIV3G H311IVM NIVIN OL MO 1323AO AOSN39 H43JW3 d3 1002 TVSAJAINN Belg YANIVLNOD INAMHSINJIdJA dINNd NOILLVINIUI9 NOUA NOILO3TIOO YOA d3dO 13 A3d aM li O Sau INN e MN SPOLLL H3NIVINOO uno NOLLV1n 23233 WNS vor KlddnS YALVM gt SNIVIN gt 3ATVA Qa1V adoO 7 _ SS dddoO 13A3G GIONA 10S Aug WAS X O XX N Aeids enpiaipui sieq Aids 31ON HSVM NOILVINIUI9 d3dO 13 A3d JATVA 10ULNO9
6. 3 21 Changing roller 3 22 Roller bearing 6 5 125 3 23 Part 4 Trouble shootihg 4 1 EE e E x ERES oo 6 4 1 Before starting trouble shooting 4 2 Problems with the 0 4 2 Problems with processed material ee ee ee 4 4 Part 5 Spare parts 5 1 GENERE e s se canta e E uktuy EE I b 1 5 1 Ordering spare 5 b 1 Special spare 5 b 1 CDS Wale u see va ata nbs puka EE S pm m eee eed a b 1 PASS uad sus oe So Ed oe ARRETRARE 5 3 SIAN WEE 5 5 Feed MaDe Lili Cet bee EG RE EERE E oes Ew ee eee ee eee ee 5 DEVE ID s 46 ea sab edine RI xoc REOR ORO w w bee Owed 5 9 Drive plate CD 125 x suene bees aci ta des des Eon EOS UO en 5 11 Chain driv plat 5 13 0748 Service Manual Plate Processors 85 125 Drive plate double scrub Sbi RR RR IR RR 5 15 Chain drive plate double scrub 85 5 17 Group Titer GeV A606 s e mame he a E elia 5 19 firu lge DE Lei DEE 5 21 l le e EEN b 25 lt 5 29 Group dev kit cd twin scrub 5 31 Group dev Kit
7. ye 1 3 Water requirements EEN 1 3 Mae cOnSUMDUON e e e s s Ee qh i tei 1 3 WR elen 1 3 Dra sas n eee ga id ie lieta 1 3 DIMENSIONS a ue door e e kar SH i ond 4 P EXE e k NOG G Gnd Q Rome d 1 4 ig 1 4 Electrical specificationS _ rem e da 1 5 Installation requirements for power supply 1 5 FOWEFCONSUMPLHON 1 5 0748 Service Manual Plate Processors 85 125 ca Table of contents Noise lev l EEN 1 5 Part 2 Functional desecription 2 1 Cc e e EE EE NEE eee te oe eee EEEE EE a 2 1 l IOCOSSOF SBCHOLIS xus as asas pa du eb e RR A dw ea k X SUS Row zoba Rex d S e s 2 1 6 GO suyu uswa ao sa ms ai bua UTITUR 2 1 Beer Ee a EE 2 2 CONTI SURE CIO ENNEN 2 2 EEN EE EE EE EE EE SNE SNE 2 2 Level control temperature 2 2 Replenishment anti oxidation system 2 2 Wash SeCllOlle 2 3 2 3 erus ee italiane 2 3 EE 2 3 Biere le NEE 2 4 EE EIERE b Ee vai 2 4 2 11 Master Input Output Unit 2 11 High Power Unit HPU ze esa se ee ae Sa e sia a d Sx eSETESSS4 2 11 Motor Filter Unit MFU 2 11 Touch Scr
8. Procedure described for b is then repeated in order to ensure accurate base point Adjust the final scrub roller pressure as follows Plush cover Adjust roller down to just before touch point roller and then turn the screws 14 turn clockwise Please do never exceed of a turn clockwise as this may potentially cause plate jam in the WASH section Bristle brush The scrub roller pressure is then finally defined by roller adjusting each of the four adjusting screws of a turn clockwise Please do never exceed 1 of a turn clockwise as this may potentially cause plate jam in WASH section Roller reassembling Replace the roller assemblies in the tank Once the rollers are replaced and no further adjustments are necessary repeat the Preparation for Processing section of this manual to check the correct transport of the plate through the processor before use The overall height of the drive gum rollers and scrub roller is determined by the slot depth in the tank side walls and is therefore not adjustable 0906 Service Manual Plate Processors 85 125 Cleaning and Maintenance Maintenance 3 14 Chain maintenance Regular chain maintenance is important if maximum life is to be achieved The following maintenance schedule is suggested After processing 400 hours 6 500 m Whatever comes first e Check chain adjustment and rectify if necessary After processing 2 500 hours 80 000 m What
9. lt CT dWfid ldad Service Manual Plate Processors 85 125 0906 REMOTE ETHERNET Optional USB o lt lt MASTER I O BOARD Online installations only SETTER GNUIB RS485 SLAVE I O BOARD GNUIB RS485 SLAVE I O BOARD Some models only Service Manual Plate Processors 85 125 T31649 0906 ES Electronic control Electronic control See illustration opposite The electrical control system consists of Master Input Output Unit MIO The electrical control system is controlled by the MIO board via the SOM System on Module There are two separate communication lines buses e GNUIB for all internal communication in the processor RS485 e ETHERNET for Remote Enabling System The MIO board is equipped with a platesetter interface for communication between the processor and platesetter High Power Unit HPU The HPU board holds all the high voltage in and outputs for the control of heaters motors etc Motor Filter Unit MFU The MFU board is a slave controlling speed and current flow of one DC motor only Often placed very close to the motor itself All commands and power supply for the board are received via the GNUIB RS485 cable whereas power supply for motor control is recieved via a separate cable Touch Scre
10. 45764 21041091 10031354 10038499 10038501 10030464 10030238 10039870 10037729 21859053 10031346 10040558 21080353 10040560 10040092 21113212 10021826 35598 0180202 10051708 21113708 21113165 10040089 125 10024856 35362 21108780 21041091 10031354 10038496 10038497 10032426 10032427 10039870 10037729 21839033 10031346 10040558 21080333 10040560 10039978 21113172 10021826 35598 0180202 10051708 21113708 21113149 10040052 Spare parts Panels Specification COVER TOP COMPLETE W SPRING HANDLE SPRING GAS 200N SPRING GAS 500N D D19 ACTUATOR SWITCH SAFETY SEE APPENDIX A SENSOR OPTO 60MM CABLE COMPLETE PANEL SIDE FRAME RIGHT PANEL SIDE FRAME LEFT COVER PLUMB RH COVER DRIVE LH DISPLAY COMPLETE BLACK TAPE 1 5 VELCRO LOOP LONG SEE APPENDIX A TUBE SPACING LONG BRACKET SENSOR REAR SWITCH EMERGENCY STOP DISC YELLOW EMERGENCY STOP D70 CABLE EMERGENCY STOP PANEL FRONT FINGER GUARD COVER SWITCH LID COMPLETE CIRCLIP D14 A2 DIN 471 GUIDE SILICONE D25 INCL BUSHING TUBE SPACING SUPPORT ROLLER SHAFT ROLLER ASSY INFEED COMPLETE PANEL REAR Service Manual Plate Processors 85 125 N me x O Q x O Q Un T8575 STAND 0906 Service Manual Plate Processors 85 125 Pos 10 ji 12 1
11. 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 There will be NO advice when the JOG function starts 0906 Service Manual Plate Processors 85 125 Trouble shooting Before starting trouble shooting Before starting trouble shooting IMPORTANT Plates and chemicals are very sensitive materials and correct storage is vital to obtain a satisfactory production result Incorrect storage may very well result in unsatisfactory processing quality etc Contact your local supplier for information about storage requirements for plates and chemicals Before making adjustments of the equipment make sure that incorrect storage of plates and chemicals can be excluded Problems with the processor SYMPTOM PROBABLE CAUSE REMEDY NO FUNCTION ACTIVE e Mains switch turned off or power cable not connected to main power outlet Fuse s blown e Connect cable to main power outlet and or turn main switch on Replace fuse PROCESSOR CANNOT INITIALIZE e Configuration error If main power has been cut off temporari
12. D15 54x2 62 EPDM CLAMP HOSE D16 8 18 4 SNP12 HOSE BRAIDED 1 BLUE HOSE 1 2 REINFORCED PER M HOSE BRAIDED 1 2 BLUE TUBE REPLENISH BOTTLE 1 2 DIA TUBE SPRAY NOZZLE GUM FLOWREGULATOR GUM O RING D12 29X3 53 HOSE D10 D14 PVC RED PER METER HOSE D10 D14 PVC BLUE PER METER CLAMP HOSE D11 18MM Service Manual Plate Processors 85 125 Spare parts Pump circulation 5 23 Spare parts T8581 TANK BASE Service Manual Plate Processors 85 125 0906 Pos 10 ji 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 21153150 21040073 21060178 21253216 10014671 21112247 15510 6080 19025918 353595 10040806 88820 21060191 21106975 29302 87520 35386 10037727 44968 43724 10023498 10023497 10023496 21793104 10031354 125 21116265 5124 21050028 21655209 21155206 21154132 21040073 21060178 21253216 10014671 21112247 15510 6080 10025918 35355 10040806 88820 21060191 21106975 25302 8 520 35386 10037727 44968 43724 10023498 10023497 10023496 21793104 10031354 Tank base Specification PLATE GUIDE COMPLETE SCREW M5X6 HE SO CP FINAL DRIVE COLLAR 1 2 BLOCK SPRAYBAR END SUPPORT BLOCK TUBE CHILLER CABLE GLANDS M20 8 13MM BSP HEX PLUG 3 4 MANIFOLD DISTRIBUTION BLOCK FITTING ELBOW 3 4 RG BSP 1 2 HOSE FITTING HOSETAIL 1 2 CLAMP HOSE D11 18 MM HOSE 1 2 REINFORCED PER
13. WEDGE ROLLER NOT ALL MODELS 34 21793301 ROLLER DEVELOPER D60 35 21112957 SCRUB COVER 36 10023254 SCRUB COVER D60 37 21793220 BLOCK ARM ROLLER SCRUB 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 0906 Service Manual Plate Processors 85 125 N me pus O Q x O Q Un GROUP DEV KIT DOUBLE SCRUB 0906 Service Manual Plate Processors 85 125 Pos 10 11 12 13 14 15 16 17 18 19 20 2l 22 23 24 29 26 27 28 29 30 0906 85 10025720 10025998 21792220 21113447 5124 21792263 21153115 21005120 10030126 21153206 15038 6191 10030974 10041444 21109996 10041443 21850403 10022104 21109258 10017387 10023915 10024519 Spare parts Group dev kit double scrub Group dev kit double scrub Specification LID DEVELOPER ROLLER DEV EXIT LAY ON BLOCK BEARING ROLLER GEAR 15T 30 PCD STAINLESS STEEL SCREW M5X6 HE SO CP SUPPORT STRIP DEVELOPER MESH PRESSURE PLATE SUPPORT NP DEV ROLLER ASSY MESH DEVELOPER LONG SUPPORT BLOCK NUT M5 KN BK PL BUSHING D5 13X6 SLAVE BEARING BLOCK DRILLED GEARBOX BUSH LONG 85 TURCITE BLOCK SLAVE SINGLE ADJUST GEARBOX BUSH SHORT 85 TURCITE SHAFT SHORT GEARBOX CIRCLIP D12X1 3 A2 DIN6799 BLOCK GEARBOX ADJUSTMENT PIN TUBULAR D6X45 DIN 1481 SHAFT GEARBOX LONG SCRUB COVER D35 S
14. 6191 21150403 21982594 21982595 21450218 10022045 10022104 21050997 21050993 21050992 21073397 21545304 21545303 10041447 10026001 10031301 21112908 21050220 21153206 Spare parts Group dev kit cd twin scrub Group dev kit cd twin scrub Specification LID DEVELOPER ROLLER DEVELOPER 40 TWIN SCRUB GEAR 23T 25 MM BORE DELRIN BUSH LONG GEARBOX TURCITE BEARING BLOCK O RING 13 3x2 4 EPDM GEAR 18T SS 45 PCD SCREW M5X10 BUSH SHORT GEARBOX TURCITE SHAFT LONG GEARBOX PIN TUBULAR D6X45 DIN 1481 BUSHING D5 13X6 SHAFT GEARBOX SHORT BUSH RING TURCITE BUSH FLANGE TURCITE GEAR BOX RETAINER SHORT SHAFT GEAR DRIVE CIRCLIP D12X1 3 A2 DIN6799 GEAR 26T ROLLER GEAR 41T BUSH FLANGE 52 LONG GRUB SCREW M5x16 HE SO CP DIN916 ROLLER DRIVE LOWER ROLLER DRIVE UPPER TURCITE BUSH SCRUB amp RUBBER ROLLERS GEAR 2 5M 19 TEETH SS WITH GRUB SCREW GUIDE DEV REAR GUIDE FRONT DEV RE ENTRY CAM SUPPORT BLOCK Service Manual Plate Processors 85 125 5 31 N re pus O Q x O Q Un T8584 GROUP DEV KIT CD TWIN SCRUB 0906 Service Manual Plate Processors 85 125 Spare parts Group dev kit cd twin scrub 5 33 Group dev kit cd twin scrub Pos 125 Specification 31 21072912 NO 8X 1 1 2 S TAP PAN HD SCREW S S 32 21585301 ROLLER DEV EXIT LAY ON COMPLETE NOT ALL MODELS 33 21982567 BLOCK
15. 96 0 or 253 8 cm 99 9 326 8 cm 128 7 or 500 0 cm 152 3 Length L2 30 0 cm 11 8 or 40 0 cm 15 7 40 0 cm 15 7 or 100 0 cm 39 4 Length L3 1 uni 1 mE Length L4 p TRU no p Height H2 Si Di eg Height is adjustable up to approx 6 cm 2 4 upwards from measurements listed above Some processors have foot extentions Heights will in those cases increase accordingly Weights Processor type 85 125 Weight empty 324 kg 610 kg 714 Ibs 1345 Ibs Service Manual Plate Processors 85 125 0906 Electrical specifications 0906 Installation requirements for power supply Technical specifications Electrical specifications Supply Fuse Recom cable type 85 125 1W N PE 230V AC Min 3 x 1 5 mm e 1x20 Amps 50 60 Hz type HO7 RNF 1W N PE 230V AC Min 3 x 4 mm e zs 1x30 Amps 50 60 Hz type H07 RNF 3W N PE 400V AC Min 5 x 1 5 mm2 e 3x16 Amps 50 60 Hz type HO7 RNF 3W N PE 400V AC Min 5 x 1 5 mm e 3x16 Amps 50 60 Hz type H07 RNF 2W PE 230V AC Min 3 x 12 AWG e 2x20 Amps 50 60 Hz type SJO 2W 4 PE 230V AC Min 3 x 10 AWG e TE 2x30 Amps 50 60 Hz type SJO 3W PE 230V AC Min 4 x 14 AWG e 3x15 Amps 50 60 Hz type SJO 3W PE 230V AC Min 4 x 12 AWG e 3x20 Amps 50 60 Hz type SJO All Voltage toler
16. F SPE 5741890 HOSE BRAIDED 3 4 RED VALVE 3 4BSP FM PP FITTING HOSETAIL 3 4 BSP x 3 4 MODIFIED BRACKET FILTER DRAIN VALVE AC3C CLAMP HOSE D13 27 Spare parts Group filter dev ac 5c 5 19 Service Manual Plate Processors 85 125 Spare parts 1 20 53 40 T8580 PUMP CIRCULATION Service Manual Plate Processors 85 125 0906 Pos 10 ji 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 22085504 10046848 10026036 10031094 21060040 22085087 10022908 10031426 10032143 21060057 22085528 21060678 21060690 21060685 6062 22085544 21109550 21060670 10032370 21107092 10032366 6332 6323 10026012 21240223 21060674 10034866 125 22085504 10046848 10026036 10031094 21060040 22085087 10022908 10031426 10032418 21060057 22085528 21060678 21060690 21060685 6062 22085544 21109550 21060670 10032370 21107092 10032366 6332 6323 10026012 21154228 21060674 10034866 Pump circulation Specification FTG HOSETAIL 3 4 BSP X 25 PP VALVE BALL 2 WAY 3 4 90 ANGLE BRACKET PUMPS AND TAPS W LABEL PUMP OSC GUM COMPLETE ADAPTOR HOSE PP 3 4 X3 4 FITTING ELBOW 1 2 BSPx1 2 HOSE PUMP AD 550 WITH PLUG CAP SEAL MH57 M12 DRAIN MANIFOLD ADAPTOR HOSE 3 4 90 DEG FITTING ELBOW 90 3 4 BSPx25 HOSE HOSE BRAIDED 1 RED FITTING TEE HOSE
17. METER STACKPIPE DRAIN O RING D5 0X2 5 EPDM SWITCH FLOAT 15KOHM COMPLETE STOPPER TANK D12 PLUG HEX 1 2 BSP HEATER TANK COMPLETE O RING 19X4 46 6051 SENSOR LEVEL 90 DEGREE COMPLETE O RING D16 3X2 4 FPM NUT M12 HE A FITTING BUSHING 2 RG D6 SENSOR TEMP NTC 90MM CABLE SENSOR CONDUCTIVITY DIGITAL WASHER NITRILE SENSOR NUT 3 4 BSP PLASTIC BRACKET TANK BASE SENSOR OPTO 60MM CABLE Service Manual Plate Processors 85 125 Spare parts Tank base Spare parts T8581 TANK BASE Service Manual Plate Processors 85 125 0906 Spare parts Tank base 5 27 Tank base Pos 85 125 Specification 31 10024911 10024911 BRACKET SENSOR MOUNTING 32 10041028 PLATE DRIVE SUPPORT 33 10043228 10043228 PIN DOWEL D6h8 X 60 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 0906 Service Manual Plate Processors 85 125 Spare parts T8582 GROUP ROLLER Service Manual Plate Processors 85 125 0906 Pos 10 11 12 13 14 15 16 17 18 19 20 2 22 23 24 25 26 27 28 29 0906 85 39598 21114912 21839023 10042645 21114911 10037188 10046059 21050125 10017387 10017500 10026001 10018253 10018095 10019170 21105503 10018251 10018089 10018252 10035958 21050783 10037392 10019179 10037393 10044377 125 39596 21114922 21793020 100426
18. NO advice when the JOG function starts 0906 Service Manual Plate Processors 85 125 Cleaning and Maintenance Safety check Safety check nm Below described safety check should be performed at least once a year Electrical e Check proper function of Lidswitch The processor must stop when the switch is deactivated The COVER OPEN message must appear in the control panel display Main switch The processor must turn off when set to 0 off Emergency stop The processor must turn off when activated GECI F10 The processor must turn off when activating the yellow button Emergency stop side panel N lt F wiring box P dia ie E DI Sg 8 DES Electronics Cabinet e P J Lower side panel lt Mechanical Check proper function location of Upper side panels left right Make sure the fenders are properly secured with 2 screws each Lower side panels left right Covers electronics cabinets Make sure covers are secured by screws Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance 3 3 Safety check Fuses Fuses F20 for brush motor M4 is placed on the motor behind the left fender Fuse F19 for drive motor M1 is placed on the DIN rail see fig in the electronics cabinet Other fuses for the various functions are located on the fuse PCB in the electronics cabinet
19. Poly Cyclohexylenedimethylene Terephthalate Mercury Cadmium Lead as additive to plastic parts The processor complies with the RoHS directive 2002 95 EC Plastic parts Significant plastic parts are marked according to ISO 11469 Batteries No batteries in this equipment End of life Estimated product life 10 years Spare parts and service period 7 years after last sales Recycling The processor should be disposed at a 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 64 dB Stand by mode lt 64dB 0906 Service Manual Plate Processors 85 125 Technical specifications Mechanical specifications 1 2 Chemical emissions Ozone 0 mg m3 Dust 0 mg m3 Styrene 0 mg m3 Heat emission See Power consumption at page 1 7 Mechanical specifications Performance Plate types Single sided thermal offset plates Plate width min max 200 850 mm 7 9 33 5 200 1250 mm 7 9 49 2 Plate length min max 285 1100 mm 11 2 43 3 350 1500 mm 13 8 43 3 Plate thickness min max 0 15 0 50 mm Plate speed 40 150 cm min 15 7 5
20. SCREW M6X20 17 10037749 SPACER CLUTCH DRIVE 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 Service Manual Plate Processors 85 125 Spare parts 21 LITI 20 3 8 k A B C 8 18 19 Rf 17 8 D E F 18 19 ib 3 8 G H T8577 DRIVE PLATE DOUBLE SCRUB Service Manual Plate Processors 85 125 0906 Pos 10 11 12 13 14 15 16 17 18 19 20 2l 22 23 24 29 26 27 28 29 30 0906 85 10032142 22602316 10023774 10024015 10024014 10023772 10032146 21050120 21101816 10021642 10016630 21050094 21050091 10016631 10021661 21050089 10025418 10025802 10025415 10025416 Spare parts Drive plate double scrub 85 Drive plate double scrub 85 Specification CHAIN FINAL DRIVE 57 PITCHES LINK CHAIN No 26 3 8 x7 32 SIMPLEX CHAIN MAIN 275 PITCHES CHAIN MAIN SCRUB 73 PITCHES CHAIN MOTOR MAIN 73 PITCHES CHAIN DOUBLE SCRUB 119 PITCHES SCRUB SHAFT ASSY 17Z BEARING 22 SFT 3 4 SPROCKET 21T DUPLEX CONCENTRIC IDLER MAIN DRIVE 19Z DRIVE SHAFT ASSY 19Z DRIVE SHAFT ASSY 19Z SCR
21. of contents EEN Table of contents Part O General information 0 2 Ti Ti DA EE EE 0 2 Products covered Rr rans 0 2 Other mania ui suum We eae eos Kam LERICI 0 2 RECH 0 3 Notes Cautions and Warningsl 0 3 IAO DOCES ATL 0 3 ADDIDUSIS EEEE EEE E EE E ee E are 0 3 Intended use of the eguipment 0 3 MoAA PNE ae ususqa k an EEN 0 4 Technical al 3 xao dex s qa lah eee Ra e s k Q O KOS Q w 4543343253 0 4 Suae see me ate as ee ao a eae RONA K ee HES d 38 SE d eee ee 0 4 End ol lifetime disposal EEN 0 4 Service assistance 0 4 MANUAIS EEN 0 10 Service un 0 10 User manuals rrr 0 11 Part 1 Technical specifications 1 1 General environmental 1 1 The processor does not contain 1 1 Butler le EE 1 1 1 1 PVC OM We 1 1 a CC 1 1 ie eee ee eee 1 1 Noise emission LL 1 1 Chemical emissions 1 2 je a atterra ae ae e d a a ese yee A 1 2 Mechanical specifications 1 2 POLO inte HEEN 1 2 TANK p ier EEN 1 2 TEI PENN CS TERTCCRER RELE KA E AVENE eee bee
22. onto the plate The gum section pump and container are connected in a closed system The gum returns to the section into the container and keeps recycling The gum circulation system is equipped with a bypass valve for adjustment of the circulation flow Adjustment of the gum circulation bypass valve is described in Part 3 Cleaning and maintenance Gum distribution roller The gum distribution roller ensures a uniform distribution of gum The roller must be lifted to upper position and cleaned at each shut down and again lowered to process position at each start up See Part 3 Cleaning and maintenance 0906 Service Manual Plate Processors 85 125 Functional description Dryer section Dryer section Detailed plumbing configuration schematics are shown later in this chapter In the dryer section the plate is dried and so further handling of the plate is possible immediately after it exits the processor A fan blows hot air through a pair of air tubes and dries the plate on both sides Transport system The plate is transported through the processor by a series of rollers and roller guides The rollers are driven by a drive motor and a sprocket chain drive system The plate is transported through the processor by a series of rollers and guides The rollers are driven by a drive motor and a worm gear drive system The rollers at the developer section entrance always run dry to ensure a homogeneous development The guide an
23. setting of a uniform gap of 0 5 mm 0 020 between the rollers is essential to set the correct pressure This gap should be checked with a feeler CERES sss sani gauge which should touch both rollers used in all applications without rotating them T31628 Drive rollers pressure To set the pressure for the drive rollers do the following 85 models Tighten each adjusting screw 1 turn Tighten the drive rollers in the gum section 114 turns 125 165 models Tighten each adjusting screw 1 1 4 turns Tighten the drive rollers in the gum section 1 turns Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance Maintenance 3 13 Scrub roller in wash section Pressure adjustment screw For adjustment of scrub roller follow the procedure below e Press eg on the control panel and press Eject plate Then press Forward Define the touch point the point where the scrub roller is just touching the lower support roller The touch point is defined as follows T31672 a All four adjustment screws see figure need to be loosened anti clockwise so that the scrub roller is NOT causing the support roller to rotate b Each adjusting screw is then adjusted clockwise until the Support Roller starts to rotate Once the support roller has started to rotate the adjusting screw must be adjusted anti clockwise until the support roller just stops rotating This procedure is repeated for all four adjusting screws
24. 25MM BARB FITTING TEE HOSE 25MM BARB CLAMP HOSE D18 38 HOSE WIRE REINF PVC 10ID VALVE SOLENOID TWIN SDT 180 24V DC HOSE BRAIDED 1 2 RED DRAIN MANIFOLD COMPLETE PUMP BELLOWS DEV M8 GRI EPDM COMPLETE VALVE BALL 3 WAY 1 1 2 BSP COMPLETE CLAMP HOSE DO9 16 CLAMP HOSE D13 2790 BRACKET VALVE PIPE DRAIN 355 LG 14 HOSE BRAIDED 3 4 RED HOSE SILICONE D10 D17 Service Manual Plate Processors 85 125 Spare parts Pump circulation 5 21 Spare parts 1 20 53 40 T8580 PUMP CIRCULATION Service Manual Plate Processors 85 125 0906 Pos 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 0906 85 10018312 5971 10040880 10017014 20158 21060239 6019 21060176 21060128 45592 15862 21060679 6080 21060671 21060176 10041041 10036016 21059084 6341 6342 15510 125 10018312 5371 10040880 10017014 26138 21060239 6019 21060176 21060128 45392 15862 21060679 6080 21060671 21060176 10041042 10036016 21059084 6341 6342 15510 Pump circulation Specification FTTTING WASTE WASH COMPLETE CABLE TIE 150X3 5 T30R SINGLE CHECK VALVE 1 2 HOSE SUCTION SENSOR 2 PIN HOSE SPIRAL D25 30 HOSE Y 3 4 CLAMP HOSE D8 22 TUBE REPLENISH BOTTLE 1 2 DIA HOSE ADAPTOR FEMALE 3 4 BSP TO 13 O RING
25. 3 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 21050957 35933 35122 2 1050996 15078 15435 21050207 21060339 10025109 10025768 21050039 0011361 10017951 15427 21114285 125 21050957 35933 35122 21050996 15078 15435 21050207 21060339 10022931 10022927 21050039 0011361 10017951 15427 21114285 Specification CASTOR SWIVEL WASHER D13 24X2 5 A4 NUT M12 HE A FOOT STANDARD 135 HIGH 16MM THREAD WASHER D17 30X3 4 NUT M16 HE 4 CLIP SPRING POLY COAT BRASS HOSE TAIL 3 4 BSPx1 2 PANEL REAR BASE PANEL FRONT BASE SPRAY GUN NOZZLE FITTING VALVE BALL 1 2 MA FE MANIFOLD MAINS WATER COMPLETE NUT M12 HE TH 4 JACKING BLOCK 110 MM DIA X 80 MM HIGH Spare parts Stand NOT ALL MODELS Service Manual Plate Processors 85 125 Spare parts T8576 FEED TABLE Service Manual Plate Processors 85 125 0906 Pos 10 11 12 13 14 15 16 17 18 19 20 Di 22 23 24 25 26 27 28 29 0906 85 21114758 21113399 21050972 21110018 22934224 21070166 125 21114763 211195957 21050972 21110018 22934224 21800144 21070166 Spare parts Feed table Feed table Specification TABLE INPUT LARGE 1000 MM TABLE INPUT 400 MM TABLE INPUT 300MM CLIP 1 4 RETAINING GEAR BUFFER SKIFFY 049 0800 11407 LID STOP STAY TABLE INPUT SCREW M5X6 HE SO CH DI
26. 45 10037189 10046059 21050125 10017387 10019189 21050172 10019286 21722302 10018180 21103630 10019284 21250301 10019285 10035952 21050783 10037392 10019179 54316 10037893 10018180 Group roller Specification CIRCLIP D14 A2 DIN 471 SHAFT IDLER LONG SHAFT IDLER SHORT ROLLER GUIDE NYLON D25 SHAFT IDLER SHORT IDLER DRIVE BAR NYLON COMPLETE BEARING ROLLER D54 FINAL DRIVE WHEEL 3 4 RUBBER PIN TUBULAR D6X45 DIN 1481 FINAL DRIVE BAR COMPLETE GEAR 2 5M 19 TEETH SS WITH GRUBSCREW GEAR DRIVE 78 PCD M3 26 TEETH ROLLER GUM W PIN UPPER COMPLETE ROLLER DRIVE LOWER BLOCK BEARING QUICK RELEASE COMPLETE ROLLER SPREADER GUM ROLLER DRIVE W PIN UPPER COMPLETE ROLLER DRIVE LOWER ROLLER BRISTLE W PIN COMPLETE ROLLER SLICK LOWER SPRING 1 2 X3 4 0 064 BEARING TURCITE A D20 35 D25 33 BLOCK BEARING BRUSH QUICK COMPLETE SPRING D12 6 1 2 L 42 BEARING TURCITE A D20 15 D25 BLOCK BEARING QUICK RELEASE COMPLETE Service Manual Plate Processors 85 125 Spare parts Group roller N re x O Q x O Q Un T8584 GROUP DEV KIT CD TWIN SCRUB 0906 Service Manual Plate Processors 85 125 Pos 10 ji 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 125 10025705 21793302 21050064 10044445 10025397 35434 21050123 15074 10041446 10022037 10017387
27. 5 T31846 0906 Service Manual Plate Processors 85 125 3 16 Cleaning and Maintenance Maintenance Chain adjustment procedure Follow the procedure below when chain adjustment is needed 1 Total view Processor 85 Refer to the steps described later and indicated in the drawing below otep 3 Step 6 Step 4 Step 5 Total view Processor 125 150 165 Refer to the steps described later and indicated in the drawing below Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance Maintenance 3 17 2 Main motor and chain motor e Dismount the cover a Loosen the screws holding the motor b e Adjust motors sideways position on eccentric c in order to adjust chain slack Slack should be 8 mm e Tighten screws b and mount the cover a 3 Final chain Loosen the big sprocket d from the back side of the drive plate e Adjust the sprocket sideways in the slot in order to adjust the chain slack Slack should be 8 mm Fasten sprocket T31683 4 4 Main chain Loosen sprocket e on drive plate backside Loosen lock nut e Adjust chain tension on adjustment screw f Chain tension must be between 10 and 15 measured on tension scale on lower chain tensioner g e Fasten lock nut and fasten sprocket T31683 5 0906 Service Manual Plate Processors 85 12
28. 5 Cleaning and Maintenance Maintenance 5 Scrub chain e Adjust the chain tensioner h until the notch is aligned with thread M5 i Chain tension must be between 10 and 22 5 e Mount the lock screw and fasten the chain tensioner Position of scrub chain tensioner may vary from one processor model to h uiid another but tensioning method is the same 6 Motors and drive plate e Motors must be aligned with the drive plate when the chains have been tightened Align the motors with the drive plate by turning the screws j until motors are aligned with drive plate Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance i 3 19 Maintenance How to check for potential chain wear The below guides line should be followed after processing 2 500 hours 80 000 m of plates Measure the length of the chain between the given number see latter illustrations of pitches Measurement point Measure between two given numbers of pitches 0905 Service Manual Plate Processors 85 125 E Cleaning and Maintenance i Maintenance Control the length e Control the length of the chain to measure the extension of the chain e This needs to be done each year or after 80 000 plates e Measure the chain extension between the given numbers of pitches See the recommendation under each drawing later in this chapter If the chain is over the given maximum length between the giv
29. 6 3 8 7 32 SIMPLEX CHAIN MAIN CD 369 PITCHES CHAIN MOTOR SCRUB 73 PITCHES CHAIN MOTOR MAIN 93 PITCHES CHAIN SINGLE TWIN SCRUB 123 PITCHES SPROCKET 11T BEARING 22 SFT 3 4 SPROCKET 21T DUPLEX CONCENTRIC IDLER MAIN DRIVE 19Z DRIVE SHAFT ASSY 19Z DRIVE SHAFT ASSY 19Z SCRUB SHAFT ASSY 19Z SCRUB SHAFT ASSY 19Z IDLER SCRUB DRIVE 19Z SPROCKET 19Z O6B 1 M8 BORE SHAFT LOCK CLUTCH BRACKET LOCK CLUTCH CHAIN TENSIONER SE11 SCRUBCHAIN COMPLETE CHAIN TENSIONER SE11 DRIVECHAIN COMPLETE Service Manual Plate Processors 85 125 5 11 Spare parts 5 12 T8578 CHAIN DRIVE PLATE CD Service Manual Plate Processors 85 125 0906 Spare parts Chain drive plate CD 125 5 13 Chain drive plate CD 125 Pos 125 Specification 1 35113 SCREW M8X16 HE SO CP 4 2 35114 SCREW M8X20 HE SO CP 4 3 21113578 SPROCKET 23Z 06B 1 15 MM BORE 4 10024646 MOTOR PARVALUX PM6D LIS 9 RPM 5 10021315 SPROCKET CHAIN TENSIONER KS06 1 15 10 6 10025415 TENSIONER CHAIN SE11 SCRUB COMPLETE 7 10025416 TENSIONER CHAIN SE11 DRIVE COMPLETE 8 10022306 SPROCKET 36TX3 8 P 15 MM BORE W KEY 9 10024291 CLUTCH CASE SCRUB 10 10026003 SPRING COMPRESSION DI23X1 75X40 4 11 10022224 CLUTCH CASE DRIVE 12 10024649 MOTOR SD13 LIS WIRED 13 10038304 BLOCK CHAIN TENSIONER 14 1516 NUT M8 HE THIN 4 15 5111X086000 SET SCREW M8 X 60 DIN 933 16 5234
30. 9 1 min 70 230 cm min 27 6 90 6 min Brush speed at 50 Hz at 60 Hz Tank capacities 80 rpm revolutions per min 96 rpm 85 125 Developer total ex filter pumps etc 20 5 71 01 7 5 US gal 18 8 US gal Gum Sal 6 0 ex filter pumps etc 0 9 US gal 1 6 US gal Service Manual Plate Processors 85 125 0906 Technical specifications Mechanical specifications Temperatures 85 125 Developer 18 35 C Min Max 64 4 95 F Dryer process Fixed Water reguirements 85 125 Pressure Min max 2 6 bar 29 87 psi Water consumption 85 125 Operation 8 l min 12 l min if no wash recirc 2 1 US gal min 3 2 US gal min Stand by if no wash recirc 0 0 l min 0 0 US gal min Hose connections 85 125 Water supply 10 mm inside diameter 0 39 Drain connections 85 125 Dev 20 mm 0 79 Wash 20 mm 0 79 Gum 20 mm 0 79 0906 Service Manual Plate Processors 85 125 LA Technical specifications Mechanical specifications Dimensions L1 A L2 L3 T L1 gt w a T H2 Processor type 85 125 152 5 6m 195 0 cm Mo 60 0 76 8 Length L1 243 8 cm
31. A Ga Josues l1 letzt 1501121 1510121 lt lt DDR l l 121 gs SS eS 9S r eu IH gt cele ela ciale oam ae jele E de EE ES EE arri P TUNE poor MESS X gt IN N S x JE x x S zs zs 151121 KA d Ei E 151021 EA E kd R ln Z o 5 Z JR n Z R n Z o a c 9s amp 95 ESS Zoe lt Selle 9 ere zes lo lo lo lo n o o oio x gt DI 6 o le 8 ele o la BOR NON N 2 2 a ers 5 ees zes gt Jo A na L alk is a NE la O EZS ees F dd l 1 1 1 l o Ww Beil bei Sei ES y 0289 Teu Torte v ou dE to T PERE TITS pep eir Lr OIN aTupn aosseooaq UTEN Appendix B Electrical diagrams Motors and Internal Bus Wiring 8 24 and 35 VAC Distribution Service Manual Plate Processors 85 125 0906 6 9 Y S o avo10 uoissiuued 2 mojlno
32. C 5P Service Manual Plate Processors 85 125 0906 Pos 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 0906 85 10031098 10035422 21114286 22050199 22070447 10048114 21060040 21112093 57727 353695 21792259 21110139 10017804 10035355 21110489 22085147 15847 21060186 10031290 21060422 5313 10030528 21060150 21060674 21792146 0323 Group filter dev ac 5c 125 21109444 10035423 21060057 22086216 22070447 10048114 21060040 21112093 SX 727 39385 21792259 21110139 10017804 10035355 21110489 22085147 15847 21060186 10031290 21060422 5313 10030528 21060150 21060674 22086380 21114286 21792146 6323 Specification AC 5C PUMP WIRED ASSY ENCAP IMPELLER CONNECTOR FILTER PUMP FITTING HOSETAIL 3 4 BSP x 3 4 MODIFIED HOSE ADAPTOR 3 4 90 DEG FTG ADAPTOR 3 4 X 3 4 M FITTING REDUCER 1 BSP M X3 4 BSP M HOSE CHEM EPDM 3 4 IN BALL VALVE 3 4 BSP 3WAY MODIFIED ADAPTOR HOSE PP 3 4 X3 4 FIT ELBOW 3 4 BSP M F LOMM THREAD FILTER INSERT 9 7 8 150 MIC REUSE O RING D19 3X2 4 FPM TUBE INNER FILTER 10 LABEL FILTER TOP LID FILTER COMPLETE FILTER HOUSING 10 O RING 77MMX3MM VITON SHORE 70 FITTING ELBOW 1 2 BSP 3 4 HOSE CLAMP HOSE D12 0 13 7 FITTING PLUG 1 4 BSP PP VALVE 3 4 BSP FITTING FITTING HOSETAIL 1 4 BSP x LOMM CLAMP HOSE D13 7 15 3 PL SNP8 HOSE SILICONE D10 D14 VALVE FP 226 8B 8B
33. Control Panel 0906 Service Manual Plate Processors 85 125 Functional description Developer section Developer section Detailed plumbing configuration schematics are shown later in this chapter In the developer section the plate is developed Configuration Roller configuration will vary depending on processor model See also the description of Transport later in this chapter and schematics with configurations for flow and drains Circulation A circulation pump recirculates the developer in the section The solution passes through a filter to clean it from impurities and make the solution last longer Level control temperature The developer bath is equipped with a min level detector circuit and to keep the temperature in range a heater a thermostat and for some models an external chiller unit The chiller unit is a closed system in which water is cooled and circulated through the developer bath Replenishment anti oxidation system The replenishment system automatically adds fresh developer to the developer section to compensate for chemicals expended during processing and for lost activity caused by plate development The processor measures the plate size to determine the correct amount of replenisher for each plate Plate sizes must be entered in the PLATE SIZES menu in order to obtain exact calculation of replenishment The time replenish system adds fresh developer or replenish concentrate to the de
34. EA Kl kd E Lele zj 11121 DE dP c c S8 lt Ir e IS lt lt za lt 8 3 ZE S 68 5 2 js gg 6 a N N wo ow N OI O co x ZE S S S N 5 S S JS a S S 2 9 w N N N N w E w E w w l r 1 9L fe Pl Tel L TH Tok T6 8 iz 79 r JE Te PL Ter et T OL 16 8 Z 9 v Te z E et ThE OL 6 v E 9 e 8 Z Z or er rt 4 4 4 n i 3 1 tf 4 f E Li t F r ET I E S JEN Lx KS KS KE 7 Gs OH OH S x D OH Y 7 1 a KS Sor iv N iva Dif nij saree en qatun UBTH 205095 208095 Josu s 208095 Josu s Josues Josues USe aH ndno indu ndno indu duo 1941 duiei A3g v r Z Z pay SJOSUBS eolldo aal pay eolldo ale N SA T T T T Fa Josues ndu Josues jndu Josues NANO Josues dno E amp I I r O 6 Jeidng eoves mo N N N N Joeluoo JO uid r qQ N9 S r 4 ONS PE A r QNO A gs dose E 37 Ce dd ME ME ze enjoe JOJ jenueuu 19119S ees l a gt e d E S C s E 95 eS 9S vS eu Ly EI o O o OD O o O o O O O O O O O O rs es 9S ss m koji L Y L Y e L 19 9S old TES D A Aa ZA TARA O atata CN E C HM Kw K
35. INGE SOUTHCO 96 50 510 50 BUSHING 258 68 D45 50X1 6 TERMINAL LOCK WAGO249 116 TERMINAL BLIND FUSEHOLDER WAGO 281 311 FUSE 4A 5x20 TERMINAL FUSEHOLDER WAGO 281 611 TRANSFORMER 9 5V 4A 24V 3 5A 36X108MM TRANSFORMER PCB HPU V SPAREPART PCB SYSTEM ON MODULE SOM FUSE 2A 6 3X32 MM S B FUSE 4A 6 3X32 MM FUSE 15A SC15 COVER PANEL FUSE PCB FUSE F SINGLE HPU W VARISTOR PCB GNUC II MIO PCB FILTER 2XTRANSFORMER 4A PTC RESISTOR FUSE 5X20MM 3 15AT FUSE 5X20MM 0 63AT RELAY MOTOR OVERLOAD 0 63 1A CAPACITOR 5uF440V AC LOCKING PIN Service Manual Plate Processors 85 125 5 41 5 42 Spare parts ENCLOSURE ELECTRICS T8586 Service Manual Plate Processors 85 125 0906 Spare parts Electrical 5 43 Electrical Pos 85 125 Specification 31 26364 26364 PLUG FEMALE 4 POL 32 74048 74048 GROMMET 5 4 33 10011284 10011284 FUSE 1AT 5 08 MM VDE 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 0906 Service Manual Plate Processors 85 125 5 44 Spare parts Service Manual Plate Processors 85 125 0906 Pos 0906 85 10025190 10025281 10025721 10021834 10014821 10014793 88377 10017196 10009030 10015166 10015205 10011057 98515 Spare parts Cables not illus
36. N912 Service Manual Plate Processors 85 125 Spare parts T8589 DELIVERY TABLE Service Manual Plate Processors 85 125 0906 Pos 10 li 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 21107631 10021577 21107633 21107632 21020129 125 Spare parts Delivery table Delivery table Specification TABLE TOP DELIVERY FOAM STRIP 15x6 TABLE DELIVERY STOP LEG TABLE DELIVERY SILICONE RED 1 5MM X 50MM ROLL Service Manual Plate Processors 85 125 Spare parts 5 10 zx T8577 DRIVE PLATE CD Service Manual Plate Processors 85 125 0906 Pos 10 11 12 13 14 15 16 17 18 19 20 2l 22 23 24 29 26 27 28 29 30 0906 Spare parts Drive plate CD 125 Drive plate CD 125 125 21108632 22602316 10022028 10021666 10021662 10032141 10017451 21050120 21101816 10021642 10016630 21050094 21050091 10016631 10021661 21050089 10025418 10025802 10025415 10025416 Specification FINAL DRIVE CHAIN 125 150 53 PITCHES LINK CHAIN No 2
37. Service Manual Plate Processors 65 125 Supreme GLUNZ amp JENSEN Service manual Plate Processors 85 125 Supreme Edition CA February 2009 This book has part No 51518 General information This manual Part O General information This manual Products covered This manual is valid for Plate Processor 85 from serial no 94273 0001 Plate Processor 125 from serial no 94274 0015 The serial number is specified on the processor name plate located on the rear end of the tank on the left side A This manual is for Service Technicians only The directions given must not be followed by unauthorized personnel Always read the Safety Instruction Manual part No 21741 before installing the equipment This manual is published by GLUNZ JENSEN A S Haslevvej 13 DK 4100 Ringsted Denmark Phone 45 57 68 81 81 E mail gjhg glunz jensen com Internet www glunz jensen com Other manuals Please see description of Manuals available for the plate processor later in this chapter Copyright 2009 by GLUNZ amp JENSEN A S Service Manual Plate Processors 85 125 0906 Reservations General Information EEN 0 3 The processor W e This manual was written and illustrated using the best possible information available at the time of publication e Any differences between this manual and the equipment reflect improvements introduced after the publication of t
38. TE DRYER TUBE TOP COMPLETE DRYER TUBE BOTTOM COMPLETE GROMMET D6 9X1 5 SENSOR TEMP THERMISTOR PLASTIC DUCT DRYER HEATER ELEMENT COMPLETTE FAN RIGHT DRYER FAN LEFT DRYER GUARDS FINGER COVER DUCT DRYER HANDLE BLACK BLACK TAPE 30MM VELCRO LOOP Service Manual Plate Processors 85 125 Spare parts Dryer 5 39 E Spare parts ENCLOSURE ELECTRICS T8586 Service Manual Plate Processors 85 125 0906 Pos 10 ji 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 16414 54563 36501 36500 10019245 10015202 10017988 10030625 45926 45865 10007152 10007158 0158 10007154 10035257 10015147 10035096 10039871 6716 6896 26508 53794 36563 10019350 10030889 10011111 10040265 10040488 10017780 10021365 125 16414 54563 36501 36500 10019245 10015202 10017988 10030625 45926 45865 10007152 10007158 0158 10007154 10033257 10015147 10035096 10039871 6716 6896 26508 53794 36563 10019350 10030889 10011111 10040265 10040488 10017780 10021365 Spare parts Electrical Electrical Specification SWITCH 1941 16 66 5X66 5 CAPACITOR 2MF CA 250 COMPLETE GLAND CABLE ST M 32x1 5 LOCKNUT FOR CABLE GLAND M32x1 5 GUARD METAL FAN FG 12 120X120 BLOWER COMPLETE SHIELD GFCI RELAY COMPLETE H
39. UB SHAFT ASSY 19Z SCRUB SHAFT ASSY 19Z IDLER SCRUB DRIVE 19Z SPROCKET 19Z O6B 1 M8 BORE SHAFT LOCK CLUTCH BRACKET LOCK CLUTCH CHAIN TENSIONER SE11 SCRUBCHAIN COMPLETE CHAIN TENSIONER SE11 DRIVECHAIN COMPLETE Service Manual Plate Processors 85 125 5 15 Spare parts 5 16 T8578 CHAIN DRIVE PLATE DOUBLE SCRUB Service Manual Plate Processors 85 125 0906 Pos 10 11 12 13 14 Spare parts Chain drive plate double scrub 85 5 17 Chain drive plate double scrub 85 85 35115 35114 10022306 10024646 10021315 10025415 10025416 21113578 10024291 10026003 10022224 10024649 10038304 1516 15 5111X086000 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 5234 10037749 Specification SCREW M8X16 HE SO CP 4 SCREW M8X20 HE SO CP 4 SPROCKET 36TX3 8 P 15 MM BORE W KEY MOTOR PARVALUX PM6D LIS 9 RPM SPROCKET CHAIN TENSIONER KS06 1 15 10 TENSIONER CHAIN SEIT SCRUB COMPLETE TENSIONER CHAIN SEIT DRIVE COMPLETE SPROCKET 23Z 06B 1 15 MM BORE CLUTCH CASE SCRUB SPRING COMPRESSION DI23X1 75X40 4 CLUTCH CASE DRIVE MOTOR SD13 LIS WIRED BLOCK CHAIN TENSIONER NUT M8 HE THIN 4 439 SET SCREW M8 X 60 DIN 933 SCREW M6X20 SPACER CLUTCH DRIVE Service Manual Plate Processors 85 125 518 Spare parts T8579 GROUP FILTER DEV A
40. ance e e 10 10 Power cord must be in accordance with local regulations A Please be aware of double pole neutral fusing See also specifications of actual power consumption below Power consumption Max power consumption at 85 125 230 400 V AC operation 3400 Watt 11600 BTU hour e EUR d 230 400 V AC operation 5700 Watt 19400 BTU hour e Stand by 500 Watt 1710 BTU hour e e Noise level See General environmental information on page 1 1 Service Manual Plate Processors 85 125 Technical specifications Electrical specifications Service Manual Plate Processors 85 125 0906 Functional description 2 1 General Part 2 Functional description General Processor sections The basis processor contains four major sections T11025 Fig Processor for short plates with front drive 1 Developer Developing of the plate and removing of the remaining unexposed exposed emulsion 2 Wash Washing off the developer chemicals from the developed plate Application of a thin layer of gum onto the developed and washed plate to 3 Gum de 1 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 Control panel Processor functions settings and alarms are controlled from the control panel The control panel functions are described in the
41. d rollers ensure that the plate is transported correctly through the developer solution and underneath the brush roller and the guide underneath the brush roller leads the plate to the rollers at the developer tank exit In the wash section the residual emulsion is washed off the plate by means of a brush roller and spray bars The wash section entrance rollers prevent that the wash water runs back into the developer section Water is squeezed off the plate by the wash section exit rollers The gum section contains one roller pair and a smaller roller situated close to the upper roller The gum solution from the application tube forms a small bath between these two rollers and a thin layer of gum is applied to the plate The extra gum returns to the main replenisher container and recirculates In the dryer section the plate is dried which makes it ready for immediate handling afterwards The exit roller pair takes the plate when dry and leads it out of the processor The processor will be equipped with one of the two transport systems illustrated Opposite Service Manual Plate Processors 85 125 0906 SP 85 DEVELOPER WASH GUM DRY CD 125 DEVELOPER WASH GUM DRY 0906 Service Manual Plate Processors 85 125 SP 85 Processor Service Manual Plate Processors 85 125 0906 CVOLLI G9 JOSS920Jd
42. double SCUD ue ace se af ebd ue Cak W gra XC t dee de X EUR ORE RES 5 35 Group tube spray water 5 37 5 39 5 41 Cables not illustrated 5 45 Appendix A Additional spareparts A 1 Appendix B Electrical diagrams B 1 Main Power Distribution B 2 Fuse panel and 5 B 2 High Voltage Wiring RR RR RR RR res B 4 230V AC Control Devices HPU B 4 LOW Voltage WINNE as chon v dox ews dS EC Q ws W E NOR ew EA pu RUE E N B 6 sensors and Control 5 B 6 Motors and Internal Bus B 8 8 24 and 35 VAC Distribution B 8 Service Manual Plate Processors 85 125 0906 0906 Service Manual Plate Processors 85 125 General Information Manuals Manuals Manuals available for the plate processor T31525 Service manuals Service manuals available for the plate processor The manuals listed below are for service technicians only In addition the service technicians will need the manuals listed opposite as User s Manuals Processor Installation Manual 1 Language English Contents Installatio
43. e bearing item 2 part number Press the tubular pin item 1 back again and be sure that the pin is centred in shaft and the slot must be point opposite the shaft end 7 Mount the complete roller bearings again at each roller pair See bullet no 4 regarding the gum rolle r bearing Valid only for 85 model 8 Adjust the transport roller pressure according to the instruction in the service manual See page 3 15 P On zc e 9 Mount the new milled bearing item 10 part c number at the segment roller in drier section lt see bullet no 5 and 6 regarding the tubular pin 10 J item 9 e 10 Fill up the processor again and start up the processor e 11 Adjust the plush scrub roller according to the service manual See page 3 16 Service Manual Plate Processors 85 125 0905 Trouble shooting General Part 4 Trouble shooting General If the processor does not work properly refer to the following pages to find the paragraph that comes closest to your problem The trouble shooting guide is divided into 2 sections a Problems with the processor b Problems with processed material For information about alarm messages see the Control Panel manual For cleaning and maintenance subjects see the processor user manual Use the Test functions parameters on the control panel to test individual components See the Software Service Information manual The electrical diagrams are located in Appendix A
44. e pump apart and clean both of the small valves in warm water N PISA D T436 Cleaning of the circulation pumps If the circulation pump ceases to function properly clean the pump tollowing this description Cut off the power to the unit by removing the top cover Empty the tank section e Dismount the hoses from the pump Be careful not to spill the chemicals on the floor e Note the position of the outlet nozzle 5 e Dismount the pump Dismount the cover 4 and pull out the impeller 3 and the impeller housing 1 e Clean the inside of the cover the impeller and the impeller housing in warm water e 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 T 31064 Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance 3 9 Maintenance Maintenance Changing developer filter The developer filter unit is located ep m underneath the top cover in the right side of the e Lift up the top cover e Unscrew the filter cover 1 counterclockwise and slowly lift it off The filter element 2 will hang on to the 1 2 cover e Mount a new filter element underneath the cover and lower it slowly into the vessel to avoid splashing e Make sure that the O ring 3 is fi
45. ed Water spray bar clogged Fuse blown Level sensor in wash dirty or defective e Clean and or repair pump Replace filters Clean spray bar See Part 3 Replace fuse Check sensor and clean replace whatever is necessary ROLLER DRIVE MOTOR RUNS BUT NO PLATE TRANSPORT Drive gears and or worms defective Check all gears and worms gears on rollers and make sure they move freely Replace any defective part Problems with processed material SYMPTOM PROBABLE CAUSE REMEDY PLATE IS NOT e Dryer temperature is set e Set dryer temperature a COMPLETELY too low little higher DRY e Gum section applying to e Check gum section much gum Dryer section is malfunctioning Check dryer section PLATE HAS STRIPES LENGTH WISE OR CROSSWISE Defective or dirty rollers or guides Wash spray tubes clogged Take rollers and or guides out inspect and wash them Rollers with dents or other marks must be changed Clean the spray tubes See Part 3 WASHING NOT SUFFICIENT Spray tube clogged Brush not turning Brush pressure not sufficient Water circulation pump does not run Rollers dirty in wash section See earlier in this chapter Clean spray tube Check the brush and fix the problem Adjust brush pressure See Cleaning of the pumps in Part 4 Clean rollers PLATE HAS AN UNEVEN GUM e Gum container nearly empty Gum rollers d
46. een Control Panel ee II 2 11 Part 3 Cleaning and Maintenance 3 1 EE Ee EE c Ee ee rm 3 1 IN OO e CA E Ee ena usa E spa sk ua RE EE V E 3 2 Wed e 3 2 IO In EE 3 2 EISE ee RE E b s e s Q e D S n 3 3 Si a sew PX REC EEN 3 4 Cleaning 3 4 Cleaning dgelTlS x35 aa nd Eom o dedos Cpu Q b a RR OR E NOS OE Q ka EE ded 3 4 Standard lt 5 3 4 Special lt 3 4 Hand 3 5 Container contents ns 3 5 Removing rollers from block bearihlgs 3 5 Removing rollers from clutch bearings 3 6 bes leiere e usw ac ua yku wow a Po Ren or a REL ae WOW a w W h Re OE UH RUE 3 6 Malor CIO J e pee ee marie aa A e s e D W S S be ee kos ko s s le Mult k 3 6 Wash SOC e O aliis 3 6 Malor e EE 3 6 EK WEE Ju ZS me l pb uiw bus e kung E E Ee S SUS e E 3 ul DEE 3 Cleaning of valves in the replenish lt 3 8 Cleaning of the circulation pumps 3 8 Maintenance 3 9 Service Manual Plate Processors 85 125 0748 Table of contents 0 7 C
47. en Control Panel A graphical user interface colour display The processor is operated on the touch screen display Control panel service information is described in the Software Manual 0906 Service Manual Plate Processors 85 125 2 12 Electronic control Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance General Part 3 Cleaning and Maintenance General This chapter holds the special service information such as adjusting procedures cleaning of pumps etc For software related service information please refer to the separate Software Service Information manual For user related maintenance and cleaning procedures refer to the Plate Processor User Manual WARNING Please note that where this label appears on the processor electrical shock hazard still exists when main switch is turned off ELECTRICAL SHOCK HAZARD DISCONNECT ALL EXTERNAL POWER SUPPLY BEFORE SERVICING TO BE SERVICED BY AUTHORIZED PERSONNEL ONLY RISQUE DE CHOC LECTRIQUE AVANT TOUTE INTERVENTION DEBRANCHER TOUTES LES SOURCES DE COURANT MAINTENANCE PAR PERSONNEL AUTORISE SEULEMENT WARNING When performing any service maintenance calibration or trouble shooting etc it may be necessary to override the function of the processor s interlock switches In these cases please be aware that the processor s JOG function is still active making the drive system run idle at intervals There will be
48. en numbers of pitches it is time for chancing Please be aware that in case either the chain or the gears are worn out both chain and gears have to be replaced Chain Kit Scrub drives 85 Chain Kit Scrub drives 125 26 pitches 26 pitches pauca Used gt 252 mm gt lt pb Service Manual Plate Processors 85 125 0905 Cleaning and Maintenance Maintenance Chain Kit Roller drives 85 O 59 pitches New 562 mm Used lt gt 570 mm Chain Kit Roller drives 125 43 pitches New 409 mm Used gt 415 mm 0905 Service Manual Plate Processors 85 125 Cleaning and Maintenance 3 22 U Maintenance Chain Kit Roller Scrub motor 85 22 pitches New lt 210 mm E Used lt gt 213 mm x AA pF Aa 0269 39 99 q 26 pitches New 248 mm Used gt 252 mm Chain Kit Roller Scrub motor 125 22 pitches New 210 mm Used gt 213 mm 26 pitches New 248 mm Used gt 252 mm Changing roller bearing e All the roller bearings need to be changed after 2 500 production hours or 80 000 m2 plate what ever coming first To secure the roller drive stability it is necessary to change the complete b
49. eparts Service Manual Plate Processors 85 125 0906 Appendix B Electrical diagrams B 1 Appendix B Electrical diagrams This chapter includes all electrical diagrams for the processor The diagrams cover Main Power Distribution Fuse panel and Interlocks e High Voltage Wiring 230V AC Control Devices HPU Low Voltage Wiring Sensors and Control Devices Motors and Internal Bus Wiring 8 24 and 35 VAC Distribution 0906 Service Manual Plate Processors 85 125 Appendix B Electrical diagrams Main Power Distribution Fuse panel and Interlocks Service Manual Plate Processors 85 125 0906 8
50. ervice Manual Plate Processors 85 125 5 35 Spare parts T8583 GROUP TUBE SPRAY WATER GUM Service Manual Plate Processors 85 125 0906 Pos 10 ji 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 10035138 21107930 21107931 10024865 10020204 5127 21801115 10036016 21059084 125 10035280 21107930 21107931 21050028 21107870 5127 21801115 21107871 5124 10036016 21059084 Specification TUBE GUM Spare parts Group tube spray water gum Group tube spray water gum VALVE BALL 1 2 BSP MALE PLUS ONE NUT O RING 13 I D X 3 WALL EPDM TUBE WATER SINGLE FINAL DRIVE COLLAR 1 2 TUBE SPRAY WATER DOUBLE COMPLETE SCREW GRUB 5 X 16 MM BLOCK SPRAY BAR END TUBE SPRAY WATER COMPLETE SCREW M5X6 HE SO CP FLOWREGULATOR GUM O RING D12 29X3 53 Service Manual Plate Processors 85 125 5 37 T8585 GROUP DRYER 0906 Service Manual Plate Processors 85 125 Pos 10 ji 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 85 10025859 21839009 10040234 6295 26385 21835086 10017818 10017895 35396 10023607 6293 10040356 125 10025858 10024952 10025864 6295 26385 21835086 10017818 10017894 10017595 35396 10024370 0293 10040357 Dryer Specification COVER GUARD AIRTUBE COMPLE
51. ever comes first e Carry out above check e Check for wear on side plates of the chain link e Check for chain elongation e Check cleanliness of components Remove any accumulations of dirt or foreign materials e Check for shaft and sprockets alignment e Check for wear on sprockets e Check the conditions of the lubricant Lubrication Chain drive should be protected against dirt and moisture and be lubricated with good quality non detergent petroleum based oil A periodic change of oil is desirable Heavy oils and greases are generally too stiff to enter the chain working surfaces and should NOT be used A multi grade SAE 20 50 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 Service Manual Plate Processors 85 125 0845 Cleaning and Maintenance Maintenance 3 15 Idler sleeve bearings maintenance Once a year or for every 1 000 hours the idler sleeve bearings have to be lubricated as show on the illustation below Recommeded oil type Mineral Oil to ISO VG SAF30 Normally self lubricating bearings are considered maintenance free however we recommend a drop of mineral oil to be applied to each bearing on an annual basis T3184
52. hanging developer filter Lee 3 9 Adjustment of spray 3 9 Adjustment ol eurn HOW uas dur uc durs dece ua Yo aed EE E RUE bee xm OR E kadi 3 10 Changing the brushollerdoth es 3 11 setting rollers and brush rollets 3 12 IS GI en O Miel CETT ur eo ee kee eee eee he JE 0 ee i 3 12 Drive kse gi o 3 12 BOTE u u u eee w 3 12 Adjusting gap between the rollefts 3 12 Drive rollers 3 12 scrub roller in wash section 3 13 Roller reassembling 3 13 Chain 3 14 After processing 400 bours ip DO0mg a 3 14 After processing 2 500 hours 80 000 m2 3 14 LUDNICA spartito eta 3 14 Idler sleeve bearings maintenance 3 15 Chain adjustment procedure es 3 16 How to check for potential chainwear 3 19 Measurement point 3 19 Measure between two given numbers of pitches 3 19 COMMON He lengi ME 3 20 Chain Kit Scrub drives 85 CDI KIE CUD Bel EE 3 20 Chain Kit Roller drives 85 3 21 Chain Kit Roller drives 125
53. he manual e Changes technical inaccuracies and typographic errors will be corrected in subsequent editions e Asa part of our policy of continuous improvement we reserve the right to alter design and specifications without further notice Notes Cautions and Warnings Throughout the manual notes cautions and warnings are written in bold like the example below Always replace a fuse with one of the same size and rating as the old one Symbol Meaning Explanation nm Note The operator should observe and or act according to the information in order to obtain the best possible function of the equipment Caution The operator must observe and or act according to the information in order to avoid any mechanical or electrical damage to the equipment A Warning The operator must observe and or act according to the information in order to avoid any personnel injury The processor Approvals e Approvals will appear from the labels attached to the name plate or the frame part of the processor Intended use of the equipment e Development of photographic materials as specified in Technical specifications in Part 1 in this manual 0906 Service Manual Plate Processors 85 125 General Information The processor Installation e Never install the processor in explosive environments Itis the responsibility of the owner and operator s of this processor that the instal
54. irty Gum distributing roller not in place Gum pump clogged Refill container Take rollers out and clean them Correct the placement of the roller Take pump apart and clean valves Service Manual Plate Processors 85 125 0906 Spare parts 5 1 General Part 5 Spare parts General Spare parts kit A small kit consisting of the most needed spare parts is delivered with the processor For further need of spare parts please refer to the spare part lists in this chapter with iso metric drawings descriptions and part numbers Ordering spare parts When ordering spare parts Please state carefully the spare part number the specification and the number of items wanted Special spare parts Some of the spare parts covers panels etc are available in different colors In these cases please refer to Appendix A Additional spare parts for the correct numbers for your specific processor PCB s and software IMPORTANT All spare part PCB s with software proms will be delivered without software installed Contact the processor supplier for information about software 0906 Service Manual Plate Processors 85 125 N me x O Q x O Q Un T8574 PANELS 0906 Service Manual Plate Processors 85 125 Pos 10 11 12 13 14 15 16 17 18 19 20 2 22 23 24 25 26 27 28 29 0906 85 10026005 35362
55. la U Uizi ipi 1 1 0 6 8IN 9 9 ca LA SUN CEN SEL e Kl SARS MEL Ble SRL 5 BL ka foo I Fr o 1 TA Ka Fa N ka tm IT Ino foo 1 len o 1 o e o m m m m lt LA ZE RERAN ko o EN D o PO Co PO KA n LLI ES jauedasn4 LLX wo 9 L LX uunjai Jou or v Uma EL LX Joy ZL LX FLEX 100 3TUQ USTH punog Appendix B Electrical diagrams Low Voltage Wiring Sensors and Control Devices Service Manual Plate Processors 85 125 0906 S
56. lation is made in accordance with local regulations and by engineers authorized to carry out plumbing and electrical installations e Installation service and repair must be performed only by service technicians who are trained in servicing the equipment The installation procedure is described in the separate Installation manual The manufacturer cannot be held responsible for any damage caused by incorrect installation of this processor Technical data Observe technical data from the processor name plate and from Part 1 in this manual Chemicals Itis 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 e 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 e PCB s and other electric equipment must be sent to a suitable waste deposit Service assistance e If help is needed to correct any problem with the equipment please contact your local supplier Service Manual Plate Processors 85 125 0906 Table
57. ly the processor switches to off mode green led flashes Defective PCB Cables not properly connected Reload software Replace PCB Check cables and make proper connections MACHINE WILL NOT START UP MMU PCB defective Replace defective part MACHINE DOES NOT START WHEN A PLATE IS INSERTED e Input sensor s defective Replace defective sensor NO WASH WATER ALTHOUGH MACHINE IS IN PROCESS MODE Water tap closed e Water solenoid valve defective Water solenoid valve filter clogged Processor with filter Filter valve closed Processor with level sensor Level sensor in wash dirty or defective Electronics defective Open water tap Replace valve Clean filter Open valve Check sensors and clean replace whatever is necessary Replace defective electronics Service Manual Plate Processors 85 125 0906 Trouble shooting Problems with the processor DRYER BLOWER WORK HEATER DOES NOT Fuse s blown Temperature sensor defective Heating element defective Electronics defective Replace fuse Replace temperature sensor Replace heating element Replace defective electronics DRYER BLOWER DOES NOT WORK Fuse s blown Blower defective Electronics defective Replace fuse Replace blower Replace defective electronics NO GUM ALTHOUGH MACHINE IS IN Gum container empty Gum hose blocked Refill container Clea
58. n hose PROCESS e Pump valves blocked or e Clean or replace valve MODE defective Replace pump e Pump defective Replace fuse Fuse s blown e Replace defective e Electronics defective electronics GUM PUMP RUNS Gum hose blocked e Clean hose BUT NO FINISHER e Pump valves blocked or e Clean or replace valve NO ALARMS defective DEVELOPER Fuse s blown Replace fuse REPLENISHMENT e Pump defective e Replace pump PUMP DOES NOT e Electronics defective e Replace defective WORK electronics DEVELOPER e Replenishment hose e Clean hose REPLENISHMENT blocked PUMP RUNS BUT NO e Pump valves blocked or e Clean or replace valves REPLENISHMENT e Replenish container empty Refill container REPLENISHMENT e Replenishment parameters Make correct settings SYSTEM settings not correct DOES NOT WORK e Electronics defective e Replace defective ALTHOUGH electronics THE MACHINE IS IN PROCESS MODE NO DEVELOPER e Replenish container empty Fill replenish container CIRCULATION Fuse s blown e Replace fuse Processors with filter Filter clogged Processors with filter Filter valve closed Developer circulation pump defective Replace filter insert Open valve Replace pump Service Manual Plate Processors 85 125 Trouble shooting Problems with processed material NO WATER CIRCULATION Pump defective or clogged Water filter clogg
59. n of the processor Processor Service Manual 2 Language English Contents Technical Specifications Functional Description Service Information Service Maintenance Trouble Shooting Spare Parts Electrical Diagrams Software Service Information 3 Language English Contents Menu structure service menus Control Panel Service Information Calibration Procedures Service Manual Plate Processors 85 125 0906 General Information Manuals 0 11 User manuals User manuals available for the plate processor CE Declaration Of Conformity 4 Language Various Contents Survey of the directives to which the products conform Safety Instruction Manual 5 Language Various Contents General Safety Information User s Manual Processor 6 Language 4 Contents Operating and cleaning procedures User s Guide Control Panel 7 Language 4 Contents Functional description Menu structure user available Operation and programming Alarm list Quick Intro 8 Language 4 Contents Quick intro to Control Panel user functions Keep the manuals with the machine for reference at all times 0906 Service Manual Plate Processors 85 125 Service Manual Plate Processors 85 125 0906 General See Hart 1 Technical specifications General environmental information The processor does not contain Ozone depleting substances according to Montreal protocol Asbestos e Polychlorinated biphenyl or
60. on of tank cleaner if needed Wash section Major cleaning Follow procedure described for cleaning in the User s Manual but use a 10 citric acid solution instead of water Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance 3 7 Cleaning Gum section Daily cleaning The gum applicator roller ensures a uniform distribution of gum on the gum roller The applicator 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 e Press the stand by key to shut down the processor e Lift up the top cover e Lift the gum applicator roller a out and clean it e Clean the upper gum roller b with a moist cloth e Place the gum applicator roller in upper position ready to next start up Close the top cover Start up e Lift up the top cover Lower the gum applicator roller a to process position d Close the top cover Press the stand by key on the control panel to switch the processor to stand by mode Ul WES FS L K lo Si UA 731631 0906 Service Manual Plate 85 125 Cleaning and Maintenance Cleaning Cleaning of valves in the replenish pumps If a replenishment pump ceases to function properly run it with some warm water in VALVE order to clear the pump of chemicals 4 VALVE 6 If this does not help take th
61. ottom part of the bearing and not just the inner bearing part Service Manual Plate Processors 85 125 0905 Cleaning and Maintenance Maintenance Roller bearing kit 85 125 Item Specification Quantity 1 MILLED BEARING ROLLER D54 2 2 BEARING TURCITE L 50 MM TOS T 3 BEARING TURCITE L 45 MM 2 4 BEARING TURCITE A D20 15 D25 17 models 85 only Kit picture Roller bearing kit 85 125 e 1 Drain the processor from chemistry and water TAA e 2 Take all the transport rollers plush scrub roller MUT i and segment roller out of the processor See a illustration opposite d Z D 0905 Service Manual Plate Processors 85 125 Cleaning and Maintenance Maintenance 3 24 3 Remove the complete roller bearings and disassemble the bearings as it is shown in the illustration opposite Mount the new bottom part of the bearing in where the new Turcite bearing is mounted together with the old top part of the bearing 4 The bottom part of the roller bearing at the roller pair in the gum section is 5 mm shorter that the rest of the bearings Be sure that they are mounted in the right position again Valid only for 85 model 5 Remove the tubular pin item 1 in the illustration from the top roller and then remove DI the turcite bearing item 2 Use a 6 mm mandrel to drive out the pin 2 34 e 6 Mount the new turcit
62. 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 Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance 3 5 Cleaning shower A hand shower is located on the rear left hand side of the base frame Use the hand shower for cleaning purposes Only use the hand shower when all power has been disconnected from the processor Ensure that the hand shower tap is closed when the hand shower is not in use 131621 Container contents When one or more containers have been exchanged it is very important that the correct hoses are connected to them e Check that the replenish containers are sufficiently filled Refill or replace if necessary e Empty replace waste containers e Replace gum if it is dirty too thin or too thick Removing rollers from block bearings T31626 0906 Service Manual Plate Processors 85 125 Cleaning and Maintenance Cleaning 3 6 Removing rollers from clutch bearings 131627 Developer section Major cleaning Follow the procedure described for cleaning in the User s Manual but use a soluti
63. rvice Manual Plate Processors 85 125 0906
64. see fig behind the left side panel A fuse label on the inside of the lid shows the position and rate of the fuses When changing a fuse first switch off all power to the machine Always ensure that the new fuse is of the correct rating according to the label 0906 Service Manual Plate Processors 85 125 Cleaning and Maintenance Cleaning Cleaning Cleaning and maintenance procedures to be carried out on a regular basis are described in the User s Manual for plate processors 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 A Never use cleaning agents containing chlorinated solvents or 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
65. ther roller edge and hold it tight while fastening with a strip Mount the pin and bearing 1 Reinstall the brush roller T31102 Service Manual Plate Processors 85 125 3 11 Cleaning and Maintenance Maintenance 3 12 Setting rollers and brush rollers Installation of rollers Make sure to align the gears the upper and lower rollers The gear on the lower rollers has a plate guide that must fit into the gear of the upper rollers Drive scrub chain The drive scrub chain should be lightly lubricated with SAE 20 50 Oil and the tension checked and reset if required every 6 12 months All of the bearings are sealed and require no maintenance Roller pressure If the pressure between each pair of rollers is excessive then an undue load is applied to the drive motor and the rollers will bow This will result in the middle of the plates becoming wet and a possible drive motor failure If the pressure is too slack the plates will slip on their way through the processor and the plates will be wet all over Both situations will allow residues to carry over between tank sections resulting in an uneven wash Adjusting gap between the rollers e Ensure the machine is switched off e Lift the top cover Pressure 0 5 mm feeler gauge adjustment important to chec e Remove the roller and upon screws both ends of rollers reassembling as pairs lay it flat on the top N edges of the tank The initial
66. trated Cables not illustrated 125 10025085 100239064 10025721 10016678 10014821 10014793 88377 10017196 10009030 10015166 10015205 10011057 10012827 Specification WIRING HARNESS Q SUPREME GNUC II CABLE EMERGENCY STOP COVER SW CABLE MOTOR WIRING HARNESS HIGH VOLTAGE CABLE SHORT CUT EMERGENCY STOP CABLE MAIN SWITCH FUSE PANEL HFI CABLE HPU TRAFO CABLE FUSE PANEL TO HPU CABLE FUSEPANEL FILTER PCB CABLE BLOWER CABLE GROUND CABLE MAINS IEC 60320 RECEPTACLE CABLE GNUIB MMU HCU Service Manual Plate Processors 85 125 E Spare parts Service Manual Plate Processors 85 125 0906 Appendix A Additional spareparts A 1 Appendix A Additional spareparts Some of the spareparts shown on the ISO metric drawings in Part 5 have no sparepart number and specification The sparepart numbers and specification for those parts are listed below The page and position numbers refer to the page and position numbers used in Part 5 Please also refer to the ISO metric drawings in Part 5 When ordering spareparts please state carefully the sparepart number the specification and the number of items wanted before you send your order Pos 85 125 Specification Page 5 3 Panels 9 10033731 10033744 COVER SIDE RIGHT UPPER W LOGO 13 10033730 10033745 COVER SIDE LEFT UPPER W LOGO 0906 Service Manual Plate Processors 85 125 Appendix A Additional spar
67. tted properly in the filter vessel groove 4 then tighten the cover 1 clockwise Reset the filter area Enter the E3 gt Manual task and select the DEV filter replaced dialog Pressing Confirm replace will reset filter area counter uu 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 t31623 0906 Service Manual Plate Processors 85 125 Cleaning and Maintenance Maintenance Adjustment of gum flow The gum distribution bar is adjusted from the factory If further adjustment is needed loosen the nut a and then turn the block b downward for adding less gum to the gum roller or upwards for adding more gum ewe 25 gt 3 3 S 2 s 7 gt T31625 Service Manual Plate Processors 85 125 0906 Cleaning and Maintenance Maintenance Changing the brush roller cloth The brush roller cloth can be replaced in case of heavy fouling or wear 0906 Take out the brush roller 1 remove the pin and the bearing 2 remove the strip holding the cloth 3 pull off the cloth and apply the new cloth use talcum 4 wrap it round the roller edge and fasten it with a strip Stretch the cloth to obtain a smooth fit along the roller wrap it round the o
68. ulim uosjed S JO r bed u pi es pi tie UOHNUISIG OVA GE pue pg 8 erem DNIHIINIONI 1V2INVHO3W GNV DINOULIITI 73 uopnasuo9 UI n i ep NASNAr Li ZNITI 1002 So Kepsinu leq Du SUE m nd S JOJOW 140dSsue1 5 IN N S Ha S HS ES T SA SN T TI Po DIA 1 LIS ININ eoepaju UEN be T T T T LV 614 6 1 405 LLX C c c c DI PP A A N Ww O x gt x x TI no a E m x N jo A N O 2 si G jo oDed aas NO pue J OJ UOO feng Ajddns N N 6170 x ezra cora x o o 7 0PX 999 9 w SVO a 2 w AA d A Sr q A EP z Je T m 8 7 i 8 1M9 d 09 HO ii boss siosu s pue VSVO wo STO o A B T indui 0 uogoeuuoo 10 oBed ees 91 for Ler 02vd i 7 0 E OIN JO SHE LOPX ed N jp o je j J gt NINO c OVX VIIIITILI 6 CS G EX Xt Ho E dk JE F GG N On jo A c m ei 9 Lg 4 E D CH L HX Li CH 8 Vit oBed uo L X 8 OVX WOIH OVA SE 8 9 uid OVA S 9 uid OVA vc 9 OVA 8 Get uid Lr Appendix B Electrical diagrams B 10 Se
69. veloper section to compensate for lost activity caused by oxidation and evaporation The replenish amounts can be set individually for stand by mode heated bath and off mode unheated bath The replenishment system also features an off replenishment function which adds an amount of developer into the developer bath when the processor is turned on after being turned off for a long period The replenishment anti oxidation developer is added to the section by means of a pump Service Manual Plate Processors 85 125 0906 Functional description _ 2 3 Wash section Wash section Detailed plumbing configuration schematics are shown later in this chapter In the wash section the developer solution is washed off the developed plate When the plates passes through the section water is applied onto both sides of the plate through 3 spray tubes 2 above and 1 underneath the plate Gum Detailed plumbing configuration schematics are shown later in this chapter In the gum section a thin layer of gum is applied to the developed and washed plate to protect it from oxydation dirt fingerprints etc Later when the plate is fixed in the printing machine the layer will be rinsed off If the plate has been corrected or if it has to be used again on a later occasion it should be rewashed and regummed optional feature for some processors Circulation The gum solution is pumped from the gum container into a distributing tube and
70. xog Bull 4 uondo peu peu e ES peg H MOSA MOIIBA UD KI Sou e 8seJ A UHMSOUIJOU U 1iNg uMo4g umoJg SR Rtl eI OL AU MEIT 7 8 ie N D n enig enig VLE OL el em Sec ASE 3 Oe OFF Ig N uH N Ln IZ mm E NOOZ umole obuebio Bue1O JO dnaJeju JNEJ PUNOJH If NdHOL 1 m Joe NOEZ Dou ax ZL Adve Bue1O SES eg dd y oBed uo umoys Le SE 19994 SEMOS INONIH i yum yymsouay ul 1ling 00g dd N M AOOP IeNN N Seseug 991U L Q 9 Lr OL I A0 MOER ec zur mm n Jt me GL OL e LP NOG AO00z uMwo4g 002 LLP TH OL MOEZ oec YOU MS UIEN xog pial LL nova ore E LvX 41914 AOUUOJSUBIL 994 i s i 29 4 UMOIg peu RE gt ue9J6 MO 9 A m ET 5 MOIISA i ang Le e gene N UMOJg SI JONOLIS 104 Jejdnoo eoueiddy Ed s ST enig Ger Igueq aen Jojdnijeju yne4 punosH BueBio obuelO Jd xoelg Pele LZS Hd N AL JO 3d NA Z pus uny U911MS xog Dat z up Dog 952 Case peu peu Buin UBIH UO zf O UDIEIN La L Sas 1 zn z seyd MOIISA MOJA i z peu oseug UMOJA UMOJg f 2 v MONA 2 95604 gunieg ang enig re 9 f uwoig 1 EE c oDuelO 3Bue10 enig OLA Omer SC xod yos Jojdnueju jnej punoo 5 T Ss

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