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Service Manual Plate Processors 85-125 Supreme Service manual Plate Processors 85-125 Supreme T11041 Edition CA, February 2009 This book has part No. 51518 0-2 General information This manual Part 0: 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. # 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: [email protected] 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 & JENSEN A/S. Service Manual - Plate Processors 85-125 0906 General Information The processor 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 personnel injury. The processor Approvals • Approvals will appear from the labels attached to the name plate or the frame part of the processor. Intended use of the equipment • Development of photographic materials as specified in “Technical specifications” in Part 1 in this manual. 0906 Service Manual, Plate Processors 85-125 0-3 0-4 General Information The processor Installation • Never install the processor in explosive environments. • It is the responsibility of the owner and operator/s of this processor that the installation is made in accordance with local regulations, and by engineers authorized to carry out plumbing and electrical installations. • Installation, service and repair must be performed only by service technicians who are trained in servicing the equipment. The installation procedure is described in the separate “Installation manual”. • The manufacturer cannot be held responsible for any damage caused by incorrect installation of this processor. Technical data • Observe technical data from the processor name plate and from Part 1 in this manual. Chemicals • It is the responsibility of the owner of this equipment that data is available concerning possible health risk from the chemicals used with the equipment. "End of lifetime" disposal The equipment is designed for easy disassembling. All disposal of parts from the machine must be made according to local regulations with special regards to following parts: • For recycling purposes significant components are marked with material specification according to the ISO 11469 standard. • PVC, tank etc., must be sent to a waste deposit with recycling in view. Alternatively the PVC can be incinerated at a suitable incinerating plant. • PCB's and other electric equipment must be sent to a suitable waste deposit. Service assistance • If help is needed to correct any problem with the equipment, please contact your local supplier. Service Manual - Plate Processors 85-125 0906 Table of contents Table of contents Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 This manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 Products covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Notes, Cautions, and Warnings ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Intended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 "End of lifetime" disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Service assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10 User manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 Part 1: Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 The processor does not contain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Plastic parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 End of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Chemical emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Heat emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Drain connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Installation requirements for power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 0748 Service Manual, Plate Processors 85-125 0-5 0-6 Table of contents Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Part 2: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Processor sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Level control/temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Replenishment/anti-oxidation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Gum distribution roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Master Input/Output Unit (MIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 High Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Motor Filter Unit (MFU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Touch Screen Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Part 3: Cleaning and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cleaning accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Standard recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Special recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Hand shower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Container contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Removing rollers from block bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Removing rollers from clutch bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Daily cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Cleaning of valves in the replenish pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Cleaning of the circulation pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Service Manual - Plate Processors 85-125 0748 Table of contents Changing developer filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Adjustment of gum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Changing the brush roller cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Setting rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Drive/scrub chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Roller pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Adjusting gap between the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Drive rollers pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Scrub roller in wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Roller reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 Chain maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 After processing 400 hours/6,500 m2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 After processing 2,500 hours/80,000 m2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Lubrication:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Idler sleeve bearings maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Chain adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 How to check for potential chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Measurement point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Measure between two given numbers of pitches . . . . . . . . . . . . . . . . . . . . . . 3-19 Control the length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Chain Kit Scrub drives 85 Chain Kit Scrub drives 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Chain Kit Roller drives 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Chain Kit Roller drives 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 Changing roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Roller bearing kit 85 - 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Part 4: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Before starting trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Part 5: Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Spare parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Special spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 PCB's and software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Feed, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Delivery, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Drive plate (CD 125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Chain drive plate (CD 125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 0748 Service Manual, Plate Processors 85-125 0-7 0-8 Drive plate (double scrub 85). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Chain drive plate (double scrub 85) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Group filter dev ac-5c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Pump / circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Tank base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Group roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Group dev kit cd twin scrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Group dev kit double scrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Group tube spray water gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 High Voltage Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 230V AC, Control Devices, HPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Low Voltage Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 Sensors and Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6 Motors and Internal Bus Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 8, 24 and 35 VAC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8 Service Manual - Plate Processors 85-125 0906 0-9 0906 Service Manual, Plate Processors 85-125 0-10 General Information Manuals Manuals Manuals available for the plate processor: 1 3 2 ual Man ware Man rvice Soft Se Instal 6 6 ual s Man User’ 4 5 ual ual Man lation Safe 7 User’ s Gui ruct ty Inst ions 8 1/2 . 51436D o de ick Intr Qu Power on (Example ) ep y/Sle Read Sleep Read (pow er save Screen ) save X min. y (Example ) 1 sec. (Example ) Over view 1 2 3 (Example) 4 5 6 7 8 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: Installation 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 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 0-11 0-12 Service Manual - Plate Processors 85-125 0906 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. 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: 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: Stand-by mode: 0906 64 dB < 64 dB Service Manual, Plate Processors 85-125 1-1 1-2 Technical specifications Mechanical specifications Chemical emissions Ozone: Dust: Styrene: 0 mg/m3 0 mg/m3 0 mg/m3 Heat emission See "Power consumption" at page 1-7. Mechanical specifications Performance 85 125 Single sided thermal offset plates Plate types 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") 0.15-0.50 mm (0.006-0.02”) Plate thickness min.- max. Plate speed 40-150 cm/min (15.7-59.1“/min) Brush speed at 50 Hz at 60 Hz 70-230 cm/min (27.6-90.6 “/min) 80 rpm (revolutions per min.) 96 rpm Tank capacities Developer, total ex. filter, pumps etc. Gum ex. filter, pumps etc. Service Manual - Plate Processors 85-125 85 125 28.5 l (7.5 US gal.) 71.0 l (18.8 US gal.) 3.5 l (0.9 US gal.) 6.0 l (1.6 US gal.) 0906 Technical specifications Mechanical specifications Temperatures 85 125 18 - 35 °C (64.4 - 95 °F) Developer Min. - Max. Fixed Dryer, process Water requirements 85 125 Pressure 2 - 6 bar (29 - 87 psi) Min. - max. Water consumption Operation (if no wash recirc.) 85 125 8 l/min (2.1 US gal/min) 12 l/min (3.2 US gal/min) 0.0 l/min (0.0 US gal/min) Stand-by (if no wash recirc.) Hose connections 85 125 10 mm (0.39") Water supply inside diameter Drain connections 85 0906 125 Dev 20 mm (0.79") Wash 20 mm (0.79") Gum 20 mm (0.79") Service Manual, Plate Processors 85-125 1-3 1-4 Technical specifications Mechanical specifications Dimensions L1 L2 L4 L3 W H1 H2 T31619 Processor type 85 125 152.5 cm (60.0") 195.0 cm (76.8") Length (L1) 243.8 cm (96.0"), or 253.8 cm (99.9") 326.8 cm (128.7"), or 386.8 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) 107.0 cm (42.1") 141.0 cm (55.5") Length (L4) 106.8 cm (42.0") 145.8 cm (57.4") Height (H1) * 108.5 cm* (42.7")* 114.5 cm* (45.1")* Height (H2) * 79.8 cm* (31.4")* 80.6 cm* (31.7)* Width (W) *) 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 (714 lbs) 610 kg (1345 lbs) Service Manual - Plate Processors 85-125 0906 Technical specifications Electrical specifications Electrical specifications Installation requirements for power supply Supply/Fuse Recom. cable type 85 1W + N + PE, 230V AC, 1x20 Amps, 50/60 Hz Min. 3 x 1.5 mm2, type H07 RNF • 1W + N + PE, 230V AC, 1x30 Amps, 50/60 Hz Min. 3 x 4 mm2, type H07 RNF 3W + N + PE, 400V AC, 3x16 Amps, 50/60 Hz Min. 5 x 1.5 mm2, type H07 RNF 3W + N + PE, 400V AC, 3x16 Amps, 50/60 Hz Min. 5 x 1.5 mm2, type H07 RNF 2W + PE, 230V AC, 2x20 Amps, 50/60 Hz Min. 3 x 12 AWG, type SJO 2W + PE, 230V AC, 2x30 Amps, 50/60 Hz Min. 3 x 10 AWG, type SJO 3W + PE, 230V AC, 3x15 Amps, 50/60 Hz Min. 4 x 14 AWG, type SJO 3W + PE, 230V AC, 3x20 Amps, 50/60 Hz Min. 4 x 12 AWG, type SJO 125 • EUR • • • • US All Voltage tolerance +10%/-10% • • • • Max power consumption at … 85 125 230/400 V AC operation: 3400 Watt / 11600 BTU/hour • *) Power cord must be in accordance with local regulations. # Please be aware of double pole/neutral fusing. See also specifications of actual power consumption below. Power consumption EUR/ 230/400 V AC operation: 5700 Watt / 19400 BTU/hour US Stand-by: 500 Watt / 1710 BTU/hour • • • Noise level See "General environmental information" on page 1-1. 0906 Service Manual, Plate Processors 85-125 1-5 1-6 Technical specifications Electrical specifications Service Manual - Plate Processors 85-125 0906 Functional description General Part 2: Functional description General Processor sections The basis processor contains four major sections: 1 2 3 4 T11025 Fig.: Processor for short plates with front drive Developing of the plate and removing of the remaining unexposed/exposed emulsion. 1 Developer 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. Control panel Processor functions, settings and alarms are controlled from the control panel. The control panel functions are described in the Control Panel. 0906 Service Manual, Plate Processors 85-125 2-1 2-2 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 developer 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 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 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 2-3 2-4 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 and 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 2-5 SP 85 DEVELOPER WASH GUM DRY T11046 CD 125 DEVELOPER WASH GUM DRY T11047 0906 Service Manual, Plate Processors 85-125 2-6 SP 85 Processor Service Manual - Plate Processors 85-125 0906 0906 DEVELOPER CIRCULATION PUMP FOR COLLECTION FROM DEVELOPER CIRCULATION PUMP DEVELOPER REPLENISHMENT CONTAINER REPL. PUMP DEVELOPER FILTER FLOW CONTROL VALVE UNIVERSAL COOLER DEV FILL PUMP GUM TO MAIN WATER DRAIN EMERGENCY OVERFLOW NOTE: All spray bars have individual spray control WASH Processor 85 DEVELOPER DRY T11042 MAINS WATER SUPPLY GUM CONTAINER GUM RECIRCULATION PUMP SOLENOID OPERATED VALVE 2-7 Service Manual, Plate Processors 85-125 2-8 CD 125 Processor Service Manual - Plate Processors 85-125 0906 0906 DEVELOPER CIRCULATION PUMP FOR COLLECTION FROM DEVELOPER CIRCULATION PUMP DEVELOPER REPLENISHMENT CONTAINER REPL. PUMP DEVELOPER FILTER FLOW CONTROL VALVE UNIVERSAL COOLER DEV FILL PUMP GUM TO MAIN WATER DRAIN EMERGENCY OVERFLOW NOTE: All spray bars have individual spray control WASH Processor 125 DEVELOPER DRY T11045 MAINS WATER SUPPLY GUM CONTAINER GUM RECIRCULATION PUMP SOLENOID OPERATED VALVE 2-9 Service Manual, Plate Processors 85-125 2-10 ETHERNET USB MASTER I/O BOARD INTERFACE REMOTE ENABLING (Optional) MIO (Online installations only) SETTER SOM GNUIB (RS485) SLAVE I/O BOARD HPU GNUIB (RS485) SLAVE I/O BOARD (Some models only) MFU T31649 Service Manual - Plate Processors 85-125 0906 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. 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 Screen 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. T2636 0906 Service Manual, Plate Processors 85-125 2-11 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. DANGER 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 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. There will be NO advice when the JOG function starts. 0906 Service Manual, Plate Processors 85-125 3-1 3-2 Cleaning and Maintenance Safety check Safety check " Below described safety check should be performed at least once a year. Electrical • Check proper function of: – Lid switch: 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. – GFCI (F10): The processor must turn off when activating the yellow button. Emergency stop Upper side panel Control panel Field wiring box Lid switch Electronics cabinet Main switch T2640 GFCI Lower side panel 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 Safety check Fuses DIN rail 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 (see fig.) behind the left side panel. A fuse label on the inside of the lid shows the position and rate of the fuses. # 1 2 3 4 0906 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. Fuses T2622 Service Manual, Plate Processors 85-125 3-3 3-4 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 # 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 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 Cleaning Hand 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. T31621 Container contents " When one or more containers have been exchanged it is very important that the correct hoses are connected to them. • Check that the replenish containers are sufficiently filled. Refill or replace if necessary. • Empty/replace waste containers. • Replace gum if it is dirty, too thin or too thick. Removing rollers from block bearings 1 2 3 T31626 0906 Service Manual, Plate Processors 85-125 3-5 3-6 Cleaning and Maintenance Cleaning Removing rollers from clutch bearings 1 2 3 T31627 Developer section Major cleaning Follow the procedure described for cleaning in the User's Manual but use a solution 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 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: • Press the stand-by key to shut down the processor. • Lift up the top cover. • Lift the gum applicator roller (a) out and clean it. • Clean the upper gum roller (b) with a moist cloth. • Place the gum applicator roller in upper position ©) ready to next start-up. • Close the top cover. Start-up: • 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. a c b d 0906 T31631 Service Manual, Plate Processors 85-125 3-7 3-8 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 order to clear the pump of chemicals. If this does not help, take the pump apart and clean both of the small valves in warm water. VALVE VALVE T436 Cleaning of the circulation pumps If the circulation pump ceases to function properly clean the pump following this description. • Cut off the power to the unit by removing the top cover. • Empty the tank section. • Dismount the hoses from the pump. Be careful not to spill the chemicals on the floor. • Note the position of the outlet nozzle (5). • Dismount the pump. • Dismount the cover (4) and pull out the impeller (3) and the impeller housing (1). • Clean the inside of the cover, the impeller and the impeller housing in warm water. • Reinstall in reverse order, observing that the outlet nozzle (5) of the cover is placed as it was before dismounting it, and that the O-ring (2) is placed correctly in the groove of the impeller housing (1). 1 2 3 4 5 Service Manual - Plate Processors 85-125 T 31064 0906 Cleaning and Maintenance Maintenance Maintenance Changing developer filter The developer filter unit is located underneath the top cover in the right side of the processor. • Lift up the top cover. • Unscrew the filter cover (1) (counterclockwise) and slowly lift it off. The filter element (2) will hang on to the cover. • Mount a new filter element underneath the cover and lower it slowly into the vessel to avoid splashing. • Make sure that the O-ring (3) is fitted properly in the filter vessel groove (4) then tighten the cover (1) (clockwise). • Reset the filter area: Enter the " -> Manual task" and select the "DEV filter replaced" dialog. $ F OF ON 1 2 3 4 Pressing "Confirm replace" will reset filter area counter. T31620 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 3-9 3-10 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. Ma x. a b n. Mi 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. • 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 other roller edge and hold it tight while fastening with a strip. • Mount the pin and bearing (1). • Reinstall the brush roller. 1 2 3 4 T31102... 0906 Service Manual, Plate Processors 85-125 3-11 3-12 Cleaning and Maintenance Maintenance Setting rollers and brush rollers Installation of rollers $ Make sure to align the gears on the upper and lower rollers. The gear on the lower rollers has a plate/guide that must fit into the gear of the upper rollers. 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 • Ensure the machine is switched off. • Lift the top cover. • Remove the roller and upon reassembling as pairs lay it flat on the top edges of the tank. • The initial 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 gauge, which should touch both rollers without rotating them. Pressure adjustment screws 0.5 mm feeler gauge (important to check both ends of rollers) Gears shown are not used in all applications 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 1¼ turns. 125-165 models: Tighten each adjusting screw 1 ¼ turns. Tighten the drive rollers in the gum section 1½ turns. Service Manual - Plate Processors 85-125 0906 Cleaning and Maintenance Maintenance Scrub roller in wash section Pressure adjustment screw For adjustment of scrub roller follow the procedure below: • Press 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. c Procedure described for "b" is then repeated in order to ensure accurate "base point". • Adjust the final scrub roller pressure as follows: Plush cover roller $ Adjust roller down to just before touch point and then turn the screws ¼ turn clockwise. Please do never exceed ½ 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 ½ 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 3-13 3-14 Cleaning and Maintenance Maintenance 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 m2 ... whatever comes first: • Check chain adjustment and rectify if necessary. After processing 2,500 hours/80,000 m2 ... whatever comes first: • Carry out above check • Check for wear on side plates of the chain link. • Check for chain elongation • 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 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: T31682 Service Manual - Plate Processors 85-125 0845 Cleaning and Maintenance Maintenance 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. T31845 The illustation below shows the idler sleeve bearings to be lubricated. A G D D H I D D G D D C B C F C E C T31846 B 0906 C H I Service Manual, Plate Processors 85-125 3-15 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. Step 3 Step 6 Step 4 T31683-1 Step 5 Total view - Processor 125-150-165: Refer to the steps described later and indicated in the drawing below. Step 3 Step 6 Step 4 T31683-1 Step 5 Service Manual - Plate Processors 85-125 0906 Cleaning and Maintenance Maintenance 2. Main motor and chain motor: • Dismount the cover (a). Loosen the screws holding the motor (b). • Adjust motors sideways position on eccentric (c) in order to adjust chain slack. Slack should be 8 mm. • Tighten screws (b) and mount the cover (a). b a c 3 Final chain: • Loosen the big sprocket (d) from the back side of the drive plate. • Adjust the sprocket sideways in the slot in order to adjust the chain slack. Slack should be 8 mm. • Fasten sprocket. 4 Main chain: • Loosen sprocket (e) on drive plate backside. Loosen lock nut. • Adjust chain tension on adjustment screw (f). Chain tension must be between 10° and 15° measured on tension scale on lower chain tensioner (g). • Fasten lock nut and fasten sprocket. 0906 c 8 mm d T31683-4 e f e T31683-5 g Service Manual, Plate Processors 85-125 3-17 3-18 Cleaning and Maintenance Maintenance 5 Scrub chain: • Adjust the chain tensioner (h) until the notch is aligned with thread M5 (i). Chain tension must be between 10° and 22.5°. • Mount the lock screw and fasten the chain tensioner. Position of scrub chain tensioner may vary from one processor model to another but tensioning method is the same. 6 Motors and drive plate: • 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 i h T31683-6 j T31683-7 j 0906 Cleaning and Maintenance Maintenance How to check for potential chain wear 2 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 3-19 3-20 Cleaning and Maintenance Maintenance Control the length • Control the length of the chain to measure the extension of the chain. 2 • This needs to be done each year or after 80,000 m plates. • 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 given 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 New = 248 mm Used = > 252 mm Service Manual - Plate Processors 85-125 26 pitches New = 248 mm Used = > 252 mm 0905 Cleaning and Maintenance Maintenance Chain Kit Roller drives 85 59 pitches New = 562 mm Used = > 570 mm Chain Kit Roller drives 125 43 pitches New = 409 mm Used = > 415 mm 0905 Service Manual, Plate Processors 85-125 3-21 3-22 Cleaning and Maintenance Maintenance Chain Kit Roller/Scrub motor 85 22 pitches New = 210 mm Used = > 213 mm 26 pitches New = 248 mm Used = > 252 mm Chain Kit Roller/Scrub motor 125 22 pitches New = 210 mm Used = > 213 mm 26 pitches New = 248 mm Used = > 252 mm Changing roller bearing • 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 bottom 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 BEARING, TURCITE L=50 MM 10*/12 3 BEARING, TURCITE L=45 MM 2* 4 BEARING, TURCITE “A” D20.15 / D25 12 2 * models 85 only Kit picture 1 2 4 3 Roller bearing kit 85 - 125 • 1. Drain the processor from chemistry and water. • 2. Take all the transport rollers, plush scrub roller and segment roller out of the processor. See illustration opposite. 0905 Service Manual, Plate Processors 85-125 3-23 3-24 Cleaning and Maintenance Maintenance • 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 the “turcite” bearing (item 2). Use a 6 mm mandrel to drive out the pin. 1 2 • 6. Mount the new “turcite” 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. SLOT 1 2 • 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. 9 • 9. Mount the new milled bearing (item 10) part number at the segment roller in drier section. (see bullet no 5 and 6 regarding the tubular pin item 9). 10 • 10. Fill up the processor again and start up the processor. • 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. " 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 4-1 4-2 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 • Mains switch turned off or power cable not connected to main power outlet. • Fuse(s) blown. • Connect cable to main power outlet and/or turn main switch on. • Replace fuse. PROCESSOR CANNOT INITIALIZE • Configuration error. (If main power has been cut off temporarily the processor switches to off mode - green led flashes). • Defective PCB. • Cables not properly connected. • Reload software. MACHINE WILL NOT START UP • MMU-PCB defective. • Replace defective part. MACHINE DOES NOT START WHEN A PLATE IS INSERTED • Input sensor (s) defective. • Replace defective sensor. • Water tap closed. NO WASH WATER • Water solenoid valve ALTHOUGH MACHINE defective. IS IN “PROCESS” MODE. • Water solenoid valve filter clogged. • Processor with filter: Filter valve closed. • Processor with level sensor: Level sensor in wash dirty or defective. • Electronics defective. Service Manual - Plate Processors 85-125 • Replace PCB. • Check cables and make proper connections. • Open water tap. • Replace valve. • Clean filter. • Open valve. • Check sensors and clean/replace whatever is necessary. Replace defective electronics. 0906 Trouble shooting Problems with the processor DRYER BLOWER WORK, • Fuse(s) blown. • Temperature sensor HEATER DOES NOT defective. • Heating element defective. • Electronics defective. 0906 • 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 “PROCESS” MODE. • Gum container empty. • Gum hose blocked. • Pump valves blocked or defective. • Pump defective. • Fuse(s) blown. • Electronics defective. • • • • • • GUM PUMP RUNS BUT NO FINISHER. (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. • Replace pump. • Replace defective electronics. DEVELOPER REPLENISHMENT PUMP RUNS BUT NO REPLENISHMENT. • Clean hose. • Replenishment hose blocked. • Clean or replace valves. • Pump valves blocked or defective. • Replenish container empty. • Refill container. 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 • Replenish container empty. • Fuse(s) blown. • Processors with filter: Filter clogged. • Processors with filter: Filter valve closed. • Developer circulation pump defective. • Fill replenish container. • Replace fuse. • Replace filter insert. Refill container. Clean hose. Clean or replace valve. Replace pump. Replace fuse. Replace defective electronics. • Replace defective electronics. • Open valve. • Replace pump. Service Manual, Plate Processors 85-125 4-3 4-4 Trouble shooting Problems with processed material NO WATER CIRCULATION. • Pump defective or clogged. • Clean and/or repair pump. • Replace filters. • Water filter clogged. • Clean spray bar. • Water spray bar clogged. See Part 3. • Replace fuse. • Fuse blown. • Level sensor in wash dirty • Check sensor and clean/replace whatever is or defective. 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 COMPLETELY DRY • Dryer temperature is set too low. • Gum section applying to much gum. • Dryer section is malfunctioning. • Set dryer temperature a little higher. • Check gum section. • Check dryer section. PLATE HAS STRIPES LENGTHWISE OR CROSSWISE • Defective or dirty rollers or • Take rollers and/or guides out, inspect and wash them. guides. Rollers with dents or other marks must be changed. • Clean the spray tubes. • Wash spray tubes clogged. 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. • Refill container. • Take rollers out and clean • Gum rollers dirty. them. • Gum distributing roller not • Correct the placement of the roller. in place. • Gum pump clogged. • Take pump apart and clean valves. PLATE HAS AN UNEVEN • Gum container nearly empty. GUM Service Manual - Plate Processors 85-125 0906 Spare parts 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. The Service Technician must download software from a CD. See "Electrical" in this chapter for Software CD spare part number. Instructions for downloading and upgrading software are stored on the software CD. 0906 Service Manual, Plate Processors 85-125 5-1 5-2 Spare parts 1 4 3 2 29 5 9 10 11 6 15 7 20 27 14 24 26 28 16 22 25 12 17 12 12 13 8 19 23 T8574 PANELS Service Manual - Plate Processors 85-125 0906 Spare parts Panels Panels Pos. 85 125 1 10026005 10024856 2 35362 35362 3 45764 4 21041091 Specification COVER, TOP, COMPLETE W. SPRING HANDLE SPRING,GAS 200N 21108780 SPRING, GAS 500N D8/D19 21041091 ACTUATOR, SWITCH, SAFETY SEE APPENDIX A 5 6 10031354 10031354 SENSOR, OPTO, 60MM, CABLE, COMPLETE 7 10038499 10038496 PANEL ,SIDE ,FRAME ,RIGHT 8 10038501 10038497 PANEL, SIDE, FRAME, LEFT 9 10030464 10032426 COVER, PLUMB, RH 10 10030238 10032427 COVER, DRIVE, LH, 11 10039870 10039870 DISPLAY, COMPLETE 12 10037729 10037729 BLACK, TAPE, 1.5", VELCRO, LOOP, LONG SEE APPENDIX A 13 14 21839033 21839033 TUBE, SPACING, LONG 15 10031346 10031346 BRACKET, SENSOR, REAR 16 10040558 10040558 SWITCH, EMERGENCY STOP 17 21080333 21080333 DISC, YELLOW, EMERGENCY STOP, D70 19 10040560 10040560 CABLE, EMERGENCY STOP 20 10040092 10039978 PANEL, FRONT 22 21113212 21113172 FINGER, GUARD 23 10021826 10021826 COVER, SWITCH, LID, COMPLETE 24 35598 35598 25 0180202 0180202 26 10051708 10051708 TUBE, SPACING 27 21113708 21113708 SUPPORT, ROLLER, SHAFT 28 21113165 21113149 ROLLER, ASSY, INFEED, COMPLETE 29 10040089 10040052 PANEL, REAR 18 21 0906 CIRCLIP, D14, A2, DIN 471 GUIDE, SILICONE D25 INCL.BUSHING Service Manual, Plate Processors 85-125 5-3 5-4 Spare parts 13 8 12 11 7 2 3 14 1 4 9 6 5 15 10 T8575 STAND Service Manual - Plate Processors 85-125 0906 Spare parts Stand Stand Pos. 85 125 Specification CASTOR, SWIVEL 1 21050957 21050957 2 35933 35933 WASHER D13/24X2, 5 A4 3 35122 35122 NUT M12 HE 4 4 21050996 21050996 5 15078 15078 WASHER D17/30X3 4 6 15435 15435 NUT M16 HE 4 7 21050207 21050207 CLIP, SPRING, POLY, COAT 8 21060339 21060339 BRASS, HOSE, TAIL, 3/4", BSPx1/2" 9 10025109 10022931 PANEL, REAR, BASE 10 10025768 10022927 PANEL, FRONT, BASE 11 21050039 21050039 SPRAY GUN, NOZZLE 12 0011361 0011361 13 10017951 10017951 14 15427 15427 15 21114285 21114285 FOOT, STANDARD 135 HIGH, 16MM THREAD 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 NOT ALL MODELS 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-5 5-6 Spare parts 5 2 4 7 5 4 7 1 6 3 T8576 FEED TABLE Service Manual - Plate Processors 85-125 0906 Spare parts Feed, table Feed, table Pos. 85 1 2 21114758 125 Specification 21114763 TABLE, INPUT, LARGE, 1000 MM 21113957 TABLE, INPUT, 400 MM 21113399 TABLE, INPUT, 300MM 3 21050972 21050972 CLIP 1/4", RETAINING, GEAR 4 21110018 21110018 BUFFER, SKIFFY 049 0800 11407 5 22934224 22934224 LID, STOP 21800144 STAY, TABLE, INPUT 21070166 SCREW, M5X6, HE, SO, CH, DIN912 6 7 21070166 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 0906 Service Manual, Plate Processors 85-125 5-7 5-8 Spare parts 2 3 1 4 5 5 T8589 DELIVERY TABLE Service Manual - Plate Processors 85-125 0906 Spare parts Delivery, table Delivery, table Pos. 85 125 Specification 1 21107631 TABLE, TOP, DELIVERY 2 10021577 FOAM, STRIP, 15x6 3 21107633 TABLE, DELIVERY, STOP 4 21107632 LEG, TABLE, DELIVERY 5 21020129 SILICONE, RED, 1.5MM X 50MM, ROLL 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-9 5-10 Spare parts 6 A H D G D D C B C D D G D C C C C E F C C 21 21 20 1 5 4 2 3 2 8 8 7 9 10 A 8 C B 8 18 11 19 8 8 12 8 13 16 16 8 D 8 E F 18 14 15 19 G 8 H T8577 DRIVE PLATE (CD) Service Manual - Plate Processors 85-125 0906 Spare parts Drive plate (CD 125) Drive plate (CD 125) Pos. 125 Specification 1 21108632 FINAL DRIVE CHAIN, 125/150, 53 PITCHES 2 22602316 LINK, CHAIN, No.26, 3/8"x7/32 SIMPLEX" 3 10022028 CHAIN, MAIN, CD, 369 PITCHES 4 10021666 CHAIN, MOTOR SCRUB, 73 PITCHES 5 10021662 CHAIN, MOTOR, MAIN, 93 PITCHES 6 10032141 CHAIN, SINGLE/TWIN SCRUB, 123 PITCHES 7 10017451 SPROCKET, 11T 8 21050120 BEARING 22 SFT 3/4" 9 21101816 SPROCKET, 21T DUPLEX, CONCENTRIC 10 10021642 IDLER, MAIN, DRIVE, 19Z 11 10016630 DRIVE, SHAFT, ASSY, 19Z 12 21050094 DRIVE, SHAFT, ASSY, 19Z 13 21050091 SCRUB, SHAFT, ASSY, 19Z 14 10016631 SCRUB, SHAFT, ASSY, 19Z 15 10021661 IDLER, SCRUB, DRIVE, 19Z 16 21050089 SPROCKET, 19Z 06B-1, M8 BORE 18 10025418 SHAFT, LOCK, CLUTCH 19 10025802 BRACKET, LOCK, CLUTCH 20 10025415 CHAIN, TENSIONER, SE11, SCRUBCHAIN, COMPLETE 21 10025416 CHAIN, TENSIONER, SE11, DRIVECHAIN, COMPLETE 17 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-11 5-12 Spare parts 2 12 8 11 17 4 1 3 16 13 14 15 9 6 10 7 5 5 7 T8578 CHAIN DRIVE PLATE (CD) Service Manual - Plate Processors 85-125 0906 Spare parts Chain drive plate (CD 125) 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 15 16 17 1516 NUT M8 HE THIN 4 5111X086000 SET SCREW M8 X 60 DIN 933 5234 SCREW M6X20 10037749 SPACER, CLUTCH, DRIVE 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-13 5-14 Spare parts 6 G D D H D D A G C B C D G C E F 21 C C 21 20 1 5 4 3 2 2 8 8 7 9 10 A 8 C B 8 18 11 19 8 8 12 8 13 17 17 8 D 8 E F 18 14 16 19 G 8 H T8577 DRIVE PLATE (DOUBLE SCRUB) Service Manual - Plate Processors 85-125 0906 Spare parts Drive plate (double scrub 85) Drive plate (double scrub 85) Pos. 85 Specification 1 10032142 CHAIN, FINAL DRIVE, 57 PITCHES 2 22602316 LINK, CHAIN, No.26,3/8"x7/32 SIMPLEX" 3 10023774 CHAIN, MAIN, 275 PITCHES 4 10024015 CHAIN, MAIN SCRUB, 73 PITCHES 5 10024014 CHAIN, MOTOR MAIN, 73 PITCHES 6 10023772 CHAIN, DOUBLE SCRUB, 119 PITCHES 7 10032146 SCRUB, SHAFT, ASSY, 17Z 8 21050120 BEARING 22 SFT 3/4" 9 21101816 SPROCKET, 21T DUPLEX, CONCENTRIC 10 10021642 IDLER, MAIN, DRIVE, 19Z 11 10016630 DRIVE, SHAFT, ASSY, 19Z 12 21050094 DRIVE, SHAFT, ASSY, 19Z 13 21050091 SCRUB, SHAFT, ASSY, 19Z 14 10016631 SCRUB, SHAFT, ASSY, 19Z 16 10021661 IDLER, SCRUB, DRIVE, 19Z 17 21050089 SPROCKET, 19Z 06B-1, M8 BORE 18 10025418 SHAFT, LOCK, CLUTCH 19 10025802 BRACKET, LOCK, CLUTCH 20 10025415 CHAIN, TENSIONER, SE11, SCRUBCHAIN, COMPLETE 21 10025416 CHAIN, TENSIONER, SE11, DRIVECHAIN, COMPLETE 15 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-15 5-16 Spare parts 2 12 3 11 17 4 8 1 9 16 13 10 6 14 15 5 7 5 7 T8578 CHAIN DRIVE PLATE (DOUBLE SCRUB) Service Manual - Plate Processors 85-125 0906 Spare parts Chain drive plate (double scrub 85) Chain drive plate (double scrub 85) Pos. 85 Specification 1 35113 SCREW, M8X16 HE SO CP 4 2 35114 SCREW, M8X20 HE SO CP 4 3 10022306 SPROCKET, 36TX3/8"P, 15 MM BORE W. KEY 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 21113578 SPROCKET, 23Z 06B-1,15 MM BORE 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 4 439 15 5111X086000 SET SCREW M8 X 60 DIN 933 16 5234 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 5-17 5-18 Spare parts 12 13 9 10 11 24 7 28 15 25 26 only 125 10 1 14 3 2 6 28 24 16 20 18 28 17 5 28 4 22 24 only 85 8 27 7 21 23 19 T8579 GROUP FILTER DEV AC-5P Service Manual - Plate Processors 85-125 0906 Spare parts Group filter dev ac-5c Group filter dev ac-5c Pos. 85 125 Specification 1 10031098 21109444 AC-5C, PUMP, WIRED ASSY, ENCAP., IMPELLER 2 10035422 10035423 CONNECTOR, FILTER/PUMP 3 21114286 FITTING, HOSETAIL, 3/4"BSP x 3/4", MODIFIED 21060057 4 22080199 HOSE ADAPTOR 3/4" 90 DEG FTG ADAPTOR 3/4 X 3/4 M 22086216 FITTING, REDUCER, 1"BSP M X3/4"BSP M 5 22070447 22070447 HOSE CHEM EPDM 3/4 IN 6 10048114 10048114 BALL, VALVE, 3/4"BSP, 3WAY, MODIFIED 7 21060040 21060040 ADAPTOR HOSE, PP 3/4"X3/4" 8 21112093 21112093 FIT, ELBOW, 3/4"BSP M/F, 10MM THREAD 9 57727 57727 FILTER, INSERT, 9 7/8", 150 MIC, REUSE 10 35385 35385 O-RING, D19.3X2.4, FPM 11 21792259 21792259 TUBE, INNER, FILTER, 10" 12 21110139 21110139 LABEL, FILTER, TOP 13 10017804 10017804 LID, FILTER, COMPLETE 14 10035355 10035355 FILTER, HOUSING, 10" 15 21110489 21110489 O-RING, 77MMX3MM, VITON, SHORE 70 16 22085147 22085147 FITTING, ELBOW, 1/2" BSP, 3/4" HOSE 17 15847 15847 18 21060186 21060186 FITTING, PLUG, 1/4"BSP, PP 19 10031290 10031290 VALVE, 3/4" BSP, FITTING 20 21060422 21060422 FITTING, HOSETAIL, 1/4" BSP x 10MM 21 5313 5313 22 10030528 10030528 HOSE, SILICONE, D10/D14 23 21060150 21060150 VALVE, FP 226-8B-8B-F, SPE 5741890 24 21060674 21060674 HOSE, BRAIDED, 3/4", RED 25 - 22086380 VALVE 3/4BSP(FM) - PP 26 - 21114286 FITTING, HOSETAIL, 3/4"BSP x 3/4", MODIFIED 27 21792146 21792146 BRACKET, FILTER DRAIN VALVE, AC3C 28 6323 6323 0906 CLAMP, HOSE D12.0-13.7 CLAMP, HOSE D13.7-15.3 PL SNP8 CLAMP, HOSE D13-27 Service Manual, Plate Processors 85-125 5-19 Spare parts 5-20 48 49 50 42 41 39 46 53 47 45 10 44 11 39 25 18 26 25 22 51 31 51 39 37 12 27 30 43 2 29 28 7 19 39 17 39 3 23 32 26 26 26 6 52 5 29 36 35 25 21 29 8 7 25 26 32 9 2 13 34 35 17 17 14 25 39 20 14 34 20 15 53 14 33 16 53 14 20 53 40 T8580 PUMP / CIRCULATION Service Manual - Plate Processors 85-125 0906 Spare parts Pump / circulation Pump / circulation Pos. 85 125 Specification 1 2 22085504 22085504 FTG, HOSETAIL, 3/4"BSP X 25, PP 3 10046848 10046848 VALVE, BALL, 2 WAY, 3/4" 90'ANGLE 5 10026036 10026036 BRACKET, PUMPS AND TAPS, W/LABEL 6 10031094 10031094 PUMP, OSC, GUM, COMPLETE 7 21060040 21060040 ADAPTOR, HOSE, PP 3/4"X3/4" 8 22085087 22085087 FITTING, ELBOW, 1/2" BSPx1/2" HOSE 9 10022908 10022908 PUMP, AD 550, WITH PLUG, 10 10031426 10031426 CAP, SEAL, MH57, M12 11 10032143 10032418 DRAIN, MANIFOLD 12 21060057 21060057 ADAPTOR, HOSE, 3/4" 90 DEG 13 22085528 22085528 FITTING, ELBOW 90, 3/4"BSPx25 HOSE 14 21060678 21060678 HOSE, BRAIDED, 1", RED 15 21060690 21060690 FITTING, TEE, HOSE, 25MM, BARB 16 21060685 21060685 FITTING, TEE, HOSE, 25MM, BARB 17 6062 6062 18 22085544 22085544 HOSE WIRE REINF PVC 10ID 19 21109550 21109550 VALVE, SOLENOID, TWIN, SDT 180 ,24V,DC 20 21060670 21060670 HOSE, BRAIDED, 1/2", RED 21 10032370 10032370 DRAIN, MANIFOLD, COMPLETE 22 21107092 21107092 PUMP, BELLOWS, DEV, M8, GRI, EPDM, COMPLETE 23 10032366 10032366 VALVE, BALL, 3-WAY, 1-1/2", BSP, COMPLETE 25 6332 6332 CLAMP, HOSE D09-16 26 6323 6323 CLAMP, HOSE D13-2790 27 10026012 10026012 BRACKET, VALVE 28 21240223 21154228 PIPE, DRAIN, 355 LG (14") 29 21060674 21060674 HOSE, BRAIDED, 3/4", RED 30 10034866 10034866 HOSE, SILICONE, D10/D17 4 CLAMP, HOSE D18-38 24 0906 Service Manual, Plate Processors 85-125 5-21 Spare parts 5-22 48 49 50 42 41 39 46 53 47 45 10 44 11 39 25 18 26 25 22 51 31 51 39 37 12 27 30 43 2 29 28 7 19 39 17 39 3 23 32 26 26 26 6 52 5 29 36 35 25 21 29 8 7 25 26 32 9 2 13 34 35 17 17 14 25 39 20 14 34 20 15 53 14 33 16 53 14 20 53 40 T8580 PUMP / CIRCULATION Service Manual - Plate Processors 85-125 0906 Spare parts Pump / circulation Pump / circulation Pos. 85 125 Specification 31 10018312 10018312 FTTTING, WASTE, WASH, COMPLETE 32 5371 5371 33 10040880 10040880 SINGLE, CHECK, VALVE, 1/2" HOSE 34 10017014 10017014 SUCTION, SENSOR, 2-PIN 35 26138 26138 36 21060239 21060239 39 6019 6019 40 21060176 21060176 TUBE, REPLENISH, BOTTLE, 1/2" DIA 41 21060128 21060128 HOSE, ADAPTOR, FEMALE, 3/4"BSP, TO, 13 42 45592 45592 O-RING, D15.54x2.62, EPDM 43 15862 15862 CLAMP, HOSE D16.8-18.4 SNP12 44 21060679 21060679 45 6080 6080 46 21060671 21060671 HOSE, BRAIDED, 1/2" BLUE 47 21060176 21060176 TUBE, REPLENISH, BOTTLE, 1/2" DIA 48 10041041 10041042 TUBE, SPRAY, NOZZLE, GUM 49 10036016 10036016 FLOWREGULATOR, GUM 50 21059084 21059084 O-RING, D12.29X3.53 51 6341 6341 HOSE, D10/D14, PVC, RED, PER METER 52 6342 6342 HOSE, D10/D14, PVC, BLUE, PER METER 53 15510 15510 CABLE-TIE 150X3.5 T30R HOSE, SPIRAL D25/30 HOSE Y, 3/4" 37 38 CLAMP, HOSE, D8-22 HOSE, BRAIDED, 1", BLUE HOSE 1/2", REINFORCED (PER M) CLAMP, HOSE D11-18MM 54 55 56 57 58 59 60 0906 Service Manual, Plate Processors 85-125 5-23 5-24 Spare parts 3 2 1 7 7 4 5 6 8 11 9 2 4 5 23 22 17 10 18 33 3 14 12 13 12 13 16 13 19 20 15 22 25 24 23 21 31 30 20 27 32 26 19 28 29 T8581 TANK BASE Service Manual - Plate Processors 85-125 0906 Spare parts Tank base Tank base Pos. 85 125 Specification 1 21116265 PLATE, GUIDE, COMPLETE 2 5124 3 21050028 FINAL DRIVE COLLAR 1/2" 4 21655209 BLOCK, SPRAYBAR, END 5 21153206 SUPPORT, BLOCK SCREW M5X6 HE SO CP 6 21153150 21154132 TUBE, CHILLER 7 21040073 21040073 CABLE GLANDS, M20, 8-13MM 8 21060178 21060178 BSP HEX PLUG 3/4" 9 21253216 21253216 MANIFOLD, DISTRIBUTION, BLOCK 10 10014671 10014671 FITTING, ELBOW, 3/4"RG(BSP), 1/2" HOSE 11 21112247 21112247 FITTING, HOSETAIL, 1/2" 12 15510 15510 13 6080 6080 14 10025918 10025918 15 35355 35355 16 10040806 10040806 17 88820 88820 STOPPER, TANK, D12 18 21060191 21060191 PLUG, HEX, 1/2", BSP 19 21106975 21106975 HEATER, TANK, COMPLETE 20 25302 25302 O-RING 19X4 46 6051 21 87520 87520 SENSOR, LEVEL, 90, DEGREE, COMPLETE 22 35386 35386 O-RING D16.3X2.4 FPM 23 10037727 10037727 24 44968 44968 FITTING, BUSHING, ½"RG-D6 25 43724 43724 SENSOR, TEMP NTC (90MM CABLE) 26 10023498 10023498 SENSOR, CONDUCTIVITY, DIGITAL 27 10023497 10023497 WASHER, NITRILE, SENSOR 28 10023496 10023496 NUT, 3/4", BSP, PLASTIC 29 21793104 21793104 BRACKET, TANK, BASE 30 10031354 10031354 SENSOR, OPTO, 60MM, CABLE 0906 CLAMP, HOSE D11-18 MM HOSE 1/2", REINFORCED, PER METER STACKPIPE, DRAIN O-RING D5.0X2.5 EPDM SWITCH, FLOAT, 15KOHM, COMPLETE NUT M12 HE 4 Service Manual, Plate Processors 85-125 5-25 5-26 Spare parts 3 2 1 7 7 4 5 6 8 11 9 2 4 5 23 22 17 10 18 33 3 14 12 13 12 13 16 13 19 20 15 22 25 24 23 21 31 30 20 27 32 26 19 28 29 T8581 TANK BASE Service Manual - Plate Processors 85-125 0906 Spare parts Tank base 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 5-27 5-28 Spare parts 1 1 2 2 4 7 3 3 5 11 4 25 12 8 15 16 22 13 18 17 6 19 16 9 10 6 17 16 16 8 25 14 17 24 14 17 22 20 21 9 14 24 14 23 14 21 T8582 GROUP ROLLER Service Manual - Plate Processors 85-125 0906 Spare parts Group roller Group roller Pos. 85 125 Specification 1 35598 35598 CIRCLIP, D14, A2, DIN 471 2 21114912 21114922 SHAFT, IDLER, LONG 3 21839023 21793020 SHAFT, IDLER, SHORT 4 10042645 10042645 ROLLER, GUIDE, NYLON D25 5 21114911 - 6 10037188 10037189 IDLER, DRIVE, BAR, NYLON, COMPLETE 7 10046059 10046059 BEARING ,ROLLER, D54 8 21050125 21050125 FINAL, DRIVE, WHEEL 3/4", RUBBER 9 10017387 10017387 PIN, TUBULAR D6X45, DIN 1481 10 10017500 10019189 FINAL, DRIVE, BAR, COMPLETE 11 10026001 SHAFT, IDLER, SHORT GEAR, 2.5M, 19 TEETH, SS, WITH GRUBSCREW 21050172 GEAR, DRIVE, 78 PCD, M3, 26 TEETH 12 10018253 10019286 ROLLER, GUM, W/PIN, UPPER, COMPLETE 13 10018095 21722302 ROLLER, DRIVE, LOWER 14 10019170 10018180 BLOCK, BEARING, QUICK RELEASE, COMPLETE 15 21103503 21103630 ROLLER, SPREADER, GUM 16 10018251 10019284 ROLLER, DRIVE, W/PIN, UPPER, COMPLETE 17 10018089 21250301 ROLLER, DRIVE, LOWER 18 10018252 10019285 ROLLER, BRISTLE, W/PIN, COMPLETE 19 10035958 10035952 ROLLER, SLICK, LOWER 20 21050783 21050783 SPRING, 1/2"X3/4" 0.064 21 10037392 10037392 BEARING, TURCITE "A" D20.35 / D25.33 22 10019179 10019179 BLOCK, BEARING, BRUSH, QUICK, COMPLETE 23 - 54316 24 10037393 10037393 BEARING, TURCITE "A" D20.15 / D25 25 10044377 10018180 BLOCK, BEARING, QUICK RELEASE, COMPLETE SPRING, D12.6/1.2, L=42 26 27 28 29 0906 Service Manual, Plate Processors 85-125 5-29 5-30 Spare parts 1 15 3 5 15 8 2 16 36 32 33 35 34 24 9 10 12 11 26 3 8 13 4 15 37 23 8 7 16 21 6 25 27 22 20 28 11 18 17 14 19 25 29 30 31 T8584 GROUP DEV KIT CD TWIN-SCRUB Service Manual - Plate Processors 85-125 0906 Spare parts Group dev kit cd twin scrub Group dev kit cd twin scrub Pos. 125 Specification 1 10025705 LID, DEVELOPER 2 21793302 ROLLER, DEVELOPER, ¥40, TWIN SCRUB 3 21050064 GEAR, 23T, 25 MM BORE, DELRIN 4 10044445 BUSH, LONG, GEARBOX TURCITE 5 10025397 BEARING, BLOCK 6 35434 7 21050123 8 15074 9 10041446 BUSH, SHORT, GEARBOX TURCITE 10 10022037 SHAFT, LONG, GEARBOX 11 10017387 PIN, TUBULAR D6X45, DIN 1481 12 6191 13 21150403 SHAFT, GEARBOX, SHORT 14 21982594 BUSH, RING, TURCITE 15 21982595 BUSH, FLANGE, TURCITE 16 21450218 GEAR BOX, RETAINER (SHORT) 17 10022045 SHAFT, GEAR, DRIVE 18 10022104 CIRCLIP, D12X1.3, A2, DIN6799 19 21050997 GEAR, 26T, ROLLER 20 21050993 GEAR, 41T 21 21050992 BUSH, FLANGE, 52 LONG 22 21073397 GRUB SCREW, M5x16, HE, SO, CP, DIN916 23 21545304 ROLLER, DRIVE, LOWER 24 21545303 ROLLER, DRIVE, UPPER 25 10041447 TURCITE BUSH-SCRUB & RUBBER ROLLERS 26 10026001 GEAR, 2.5M, 19 TEETH, SS, WITH GRUB SCREW 27 10031301 GUIDE, DEV, REAR 28 21112908 GUIDE, FRONT, DEV 29 21050220 RE-ENTRY CAM 30 21153206 SUPPORT, BLOCK 0906 O-RING 13.3x2.4 EPDM GEAR, 18T, SS, 45, PCD SCREW M5X10 BUSHING D5/13X6 Service Manual, Plate Processors 85-125 5-31 5-32 Spare parts 1 15 3 5 15 8 2 16 36 32 33 35 34 24 9 10 12 11 26 3 8 13 4 15 37 23 8 7 16 21 6 25 27 22 20 28 11 18 17 14 19 25 29 30 31 T8584 GROUP DEV KIT CD TWIN-SCRUB Service Manual - Plate Processors 85-125 0906 Spare parts Group dev kit cd twin scrub Group dev kit cd twin scrub Pos. 125 Specification 31 21072912 NO 8 X 1 1/2, S/TAP, PAN, HD, SCREW S/S 32 21585301 ROLLER, DEV EXIT, LAY ON, COMPLETE NOT ALL MODELS 33 21982567 BLOCK, 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 5-33 5-34 Spare parts 1 22 12 3 11 14 13 2 15 8 14 10 3 6 5 12 16 16 4 7 4 19 9 20 21 18 4 16 14 10 10 17 T8588 GROUP DEV KIT DOUBLE SCRUB Service Manual - Plate Processors 85-125 0906 Spare parts Group dev kit double scrub Group dev kit double scrub Pos. 85 Specification 1 10025720 LID, DEVELOPER 2 10025998 ROLLER, DEV EXIT, LAY ON 3 21792220 BLOCK, BEARING, ROLLER 4 21113447 GEAR, 15T, 30 PCD, STAINLESS STEEL 5 5124 6 21792263 SUPPORT, STRIP, DEVELOPER, MESH 7 21153115 PRESSURE, PLATE, SUPPORT (NP) 8 21005120 DEV, ROLLER, ASSY 9 10030126 MESH, DEVELOPER, LONG 10 21153206 SUPPORT, BLOCK 11 15038 NUT M5 KN BK PL 12 6191 BUSHING D5/13X6 13 10030974 SLAVE, BEARING, BLOCK, DRILLED 14 10041444 GEARBOX BUSH, LONG 85 TURCITE 15 21109996 BLOCK, SLAVE, SINGLE, ADJUST 16 10041443 GEARBOX BUSH, SHORT 85 TURCITE 17 21850403 SHAFT SHORT, GEARBOX 18 10022104 CIRCLIP, D12X1.3, A2, DIN6799 19 21109258 BLOCK, GEARBOX, ADJUSTMENT 20 10017387 PIN, TUBULAR D6X45, DIN 1481 21 10023915 SHAFT, GEARBOX, (LONG) 22 10024519 SCRUB, COVER, D35 SCREW M5X6 HE SO CP 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-35 5-36 Spare parts 2 1 3 11 12 2 2 3 3 9 7 10 8 5 6 6 7 8 4 7 8 8 T8583 GROUP TUBE SPRAY WATER GUM Service Manual - Plate Processors 85-125 0906 Spare parts Group tube spray water gum Group tube spray water gum Pos. 85 125 Specification 1 10035138 10035280 TUBE, GUM 2 21107930 21107930 VALVE, BALL, 1/2 BSP MALE PLUS ONE NUT 3 21107931 21107931 O-RING 13 I/D X 3 WALL EPDM 4 10024865 5 TUBE, WATER, SINGLE 21050028 FINAL, DRIVE COLLAR 1/2 TUBE, SPRAY, WATER, DOUBLE, COMPLETE 6 10020204 21107870 7 5127 5127 8 21801115 21801115 BLOCK, SPRAY BAR, END 9 - 21107871 TUBE, SPRAY, WATER, COMPLETE 10 - 5124 11 10036016 10036016 FLOWREGULATOR,GUM 12 21059084 21059084 O-RING, D12.29X3.53 SCREW, GRUB 5 X 16 MM SCREW M5X6 HE SO CP 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-37 12 6 7 1 2 8 3 10 4 11 13 5 9 7 6 10 11 T8585 GROUP DRYER Service Manual - Plate Processors 85-125 0906 Spare parts Dryer Dryer Pos. 85 125 Specification 1 10025859 10025858 COVER, GUARD, AIRTUBE, COMPLETE 2 21839009 10024952 DRYER, TUBE, TOP, COMPLETE 3 10040234 10025864 DRYER, TUBE, BOTTOM, COMPLETE 4 6295 6295 5 26385 26385 6 21835086 21835086 DUCT, DRYER 7 10017818 10017818 HEATER, ELEMENT, COMPLETTE 8 - 10017894 FAN, RIGHT, DRYER 9 10017895 10017895 FAN, LEFT, DRYER 10 35396 35396 11 10023607 10024370 12 6293 6293 13 10040356 10040357 GROMMET D6/9X1.5 SENSOR, TEMP THERMISTOR, PLASTIC GUARDS, FINGER COVER, DUCT, DRYER HANDLE, BLACK BLACK, TAPE, 30MM, VELCRO, LOOP 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 0906 Service Manual, Plate Processors 85-125 5-39 5-40 Spare parts 10 32 11 12 1 14 13 11 30 9 31 10 3 28 29 16 8 17 2 24 18 33 26 27 15 19 22 20 4 5 6 7 25 21 23 ENCLOSURE ELECTRICS Service Manual - Plate Processors 85-125 T8586 0906 Spare parts Electrical Electrical Pos. 85 125 Specification 1 16414 16414 SWITCH, 194L-16, 66.5X66.5 2 54563 54563 CAPACITOR, 2MF,CA-250, COMPLETE 3 36501 36501 GLAND,CABLE,ST-M 32x1.5 4 36500 36500 LOCKNUT FOR CABLE GLAND M32x1,5 5 10019245 10019245 GUARD, METAL, FAN, (FG-12), 120X120 6 10015202 10015202 BLOWER, COMPLETE 7 10017988 10017988 SHIELD 8 10030625 10030625 GFCI, RELAY, COMPLETE 9 45926 45926 HINGE, SOUTHCO, 96-50-510-50 10 45865 45865 BUSHING, 258-68, D45/50X1.6 11 10007152 10007152 TERMINAL, LOCK, WAGO249-116 12 10007158 10007158 TERMINAL, BLIND, FUSEHOLDER, WAGO, 281-311 13 70158 70158 14 10007154 10007154 TERMINAL, FUSEHOLDER, WAGO, 281-611 15 10033257 10033257 TRANSFORMER, 9.5V/4A+24V/3.5A, 36X108MM 16 10015147 10015147 TRANSFORMER 17 10035096 10035096 PCB, HPU-V, SPAREPART 18 10039871 10039871 PCB, SYSTEM-ON-MODULE, SOM 19 6716 6716 FUSE 2A, 6.3X32 MM S/B 20 6896 6896 FUSE 4A, 6.3X32 MM 21 26508 26508 FUSE 15A SC15 22 53794 53794 COVER, PANEL, FUSE 23 36563 36563 PCB, FUSE, F. SINGLE HPU, W. VARISTOR 24 10019350 10019350 PCB, GNUC-II, MIO 25 10030889 10030889 PCB, FILTER, 2xTRANSFORMER, 4A-PTC-RESISTOR 26 10011111 10011111 FUSE, 5X20MM, 3.15AT 27 10040265 10040265 FUSE, 5X20MM, 0.63AT 28 10040488 10040488 RELAY, MOTOR, OVERLOAD, 0.63-1A 29 10017780 10017780 CAPACITOR, 5uF440V AC 30 10021365 10021365 LOCKING, PIN 0906 FUSE, 4A, 5x20 Service Manual, Plate Processors 85-125 5-41 5-42 Spare parts 10 32 11 12 1 14 13 11 30 9 31 10 3 28 29 16 8 17 2 24 18 33 26 27 15 19 22 20 4 5 6 7 25 21 23 ENCLOSURE ELECTRICS Service Manual - Plate Processors 85-125 T8586 0906 Spare parts Electrical 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 5-43 5-44 Spare parts Service Manual - Plate Processors 85-125 0906 Spare parts Cables (not illustrated) Cables (not illustrated) Pos. 0906 85 125 Specification 10025190 10025085 WIRING HARNESS, Q-SUPREME, GNUC II 10025281 10023964 CABLE, EMERGENCY STOP/COVER SW 10025721 10025721 CABLE, MOTOR 10021834 10016678 WIRING HARNESS, HIGH VOLTAGE 10014821 10014821 CABLE, SHORT. CUT, EMERGENCY STOP 10014793 10014793 CABLE, MAIN SWITCH->FUSE PANEL, HFI 88377 88377 10017196 10017196 CABLE, FUSE PANEL TO HPU 10009030 10009030 CABLE, FUSEPANEL, FILTER, PCB 10015166 10015166 CABLE, BLOWER 10015205 10015205 CABLE, GROUND 10011057 10011057 CABLE, MAINS, IEC 60320, RECEPTACLE 98515 10012827 CABLE, GNUIB, MMU-HCU CABLE, HPU-TRAFO Service Manual, Plate Processors 85-125 5-45 5-46 Spare parts Service Manual - Plate Processors 85-125 0906 Appendix A: Additional spareparts 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): 5 10033731 10033744 COVER, SIDE, RIGHT, UPPER, W. LOGO 13 10033730 10033745 COVER, SIDE, LEFT, UPPER, W. LOGO 0906 Service Manual, Plate Processors 85-125 A-1 A-2 Appendix A: Additional spareparts Service Manual - Plate Processors 85-125 0906 Appendix B: Electrical diagrams Appendix B: Electrical diagrams This chapter includes all electrical diagrams for the processor. The diagrams cover: • Main Power Distribution, Fuse panel and Interlocks • 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 B-1 B-2 Appendix B: Electrical diagrams Main Power Distribution Fuse panel and Interlocks Service Manual - Plate Processors 85-125 0906 5 4 3 2 1 L1 L2 L3 N PE L1 L2 (N) PE L1 L2 L3 Red Yellow Brown Blue 2 4 6 . . . I Brown Yellow Red 3 2 1 2 4 6 . . . I 1 3 5 Field Wiring Box . . . Ground Fault Interruptor F10 N or 1 W + N + PE 2 4 6 . . . . . . Yellow Red Brown 1 Jumpers between 1 and 2 Jumpers between 3 and 4 No jumpers ! Single Phase, 230V, L1, L2 + PE or L1, N + PE Three Phases With Neutral, 400V, L1, L2, L3, N + PE 2 No jumpers ! Terminal Strip, X7 Three Phases Without Neutral, 230V, L1, L2, L3 + PE Line Voltage: Jumper Settings : 3 X4, X5 and X6 closed X4, X5 and X6 open X4, X5 and X6 open Fuse PCB 1 3 5 7 4 Main switch 2 4 6 8 9 10 Blue 11 12 3 1 1 3 5 7 9 11 Main switch 2 4 6 8 12 Orange S21 1 3 5 7 9 11 Main switch 2 4 6 8 10 12 Black Red Yellow Brown Blue Orange 5 Field Wiring Box Option I S21 Black Red Yellow Brown Blue Orange S21 IMPORTANT Check wiring at Main Terminal X7, Ground Fault Interruptor F10 and Main Switch S21 before the power supply is switched on. Rewire if necessary accordingly to attached column on schematics. Also set jumpers as shown in table below. X7 Yellow Red Brown 2 1 Blue 4 3 Ground Fault Interruptor F10 N N Three Phases With Neutral, 400V, 3 W + N + PE X7 Blue 4 1 3 5 Field Wiring Box . . . Ground Fault Interruptor F10 N Single Phase, 230V, 2 W + PE X7 1 2 3 4 Black Red Yellow Brown Blue Organge Black Red Yellow Brown Blue Organge Black Red Yellow Brown Blue Orange Black Phase3 Phase2 Phase1 Return3 Return 2 1 2 3 4 5 C8 C9 1 2 F17 3 4 5 6 6 Fuse Panel And Interlocks Function: 1 2 X43 X42 2 3 4 F6 F4 F2 5 X5 7 6 15 AT 15 AT 15 AT F3 15 AT Page: 1 Approval: Black: 0V S9 1 2 0V 8 4AT 2AT 3 T1 24V X2 Green Green Blue Blue 1 2 9.5V X1 35V 35V Grey Grey White White 4 1 2 3 4 9 X40 X41 2 3 4 1 2 3 4 1 9 unauthorized pers on without our s pecific perm is s ion. and m us t not be us ed or handed over to any This drawing belongs to Glunz & Jens en A/S 6 5 4 3 2 1 X 11 J1,1 J1,5 J1,2 J1,6 Brown Yellow/green Blue To HPU, To HPU, To HPU, To HPU, Doc. No.: 10 OrCAD 10025469 D Number: J1,3 J1,7 J1,4 J1,8 Rev.: X10 Appliance coupler For Stacker Match Line To J2 on High Voltage Wiring Diagram, page 2 10 Transformer secondary connections are shown on page 4 To HPU, To HPU, To HPU, To HPU, Yellow/green Return 1 Phase 1 Return 2 Phase 2 Return 3 Phase 3 ELECTRONIC AND MECHANICAL ENGINEERING Built-In thermoswith with automatic reset 110 °C T2 Built-In thermoswith with automatic reset 110 °C Cover Switch Lid Black: RV1 15 AT X1 short circuit on PCB F8 Orange: 240V Red: 230V Brown: 200V KEL Of: 5 Constructor: F5 F7 X6 8 Orange: 240V Red: 230V Brown: 200V Date: Thursday, July 05, 2007 S12 Emergency Stop Switch (ONLY ON 165) 1 3.15AT F18 L1 470K 4n7 Y2 C4 R7 X1 OR1 RD1 BN1 BK1 OR2 RD2 BN2 BK2 1 2 4n7 Y2 X50 1 2 0.63AT X51 1 2 R1 C3 4n7 Y2 C7 R6 15 AT C6 C2 R5 F1 X4 PCB Transformer Filter 240 230 200 240 230 200 RTN OUT RTN IN C1 L OUT 100nF L IN R2 S7 Emergency Stop Switch X52 1 2 3 4 X57 C5 100n X1 Main Power Distribution Title: 6 X2, 1 X2, 2 5 S7,6 S12,5 S12,2 S7,3 S8 Emergency Stop Switch 1 2 3 4 5 Return 1 Fuse Panel X3 6 C1 S8,3 PE S7,2 4n7 Y2 4n7 Y2 4n7 Y2 X52,2 Three Phases Without Neutral, 230V, 3 W + PE S8,6 7 S8,5 6 X52,4 5 S12,3 470K 100n X1 470K 100n X1 X52,1 4 S7,5 S12,6 3 X52,3 2 S8,2 L IN RTN IN 1 X42,1 Brown X42,2 Blue 5 4 3 2 1 B-4 Appendix B: Electrical diagrams High Voltage Wiring 230V AC, Control Devices, HPU Service Manual - Plate Processors 85-125 0906 M19 4 3 M 2 1 Dev. Autofill Pump 1 Water Repl. Pump M 2 K2,5 M19 3 K2,2 M13 M13 4 K2,6 2 1 Dev. Heater 1000W E3 63 °C E1 3 X25 From X11, Fusepanel 3 1 Dev. Heater 1000W Only on 125, 150 & 165 Variants E4 6 5 M13,2 4 4 3 1 RV406 2 Plug For Chiller 3 2 2 3 M19,3 1AT F10 Chiller Q413 K1,2 BTA 16 1AT F11 1 1 M6 4 RV407 3 M 1 Q416 BTA 16 2 2 S14K275 1 Gum. Circ. Pump M6 3 4 K1 Q414 BTA 16 E1,2 RV408 Chiller,2 Q415 E1,1 BTA 16 RV409 S14K275 M8 4 2 K4,2 Dev. Repl. Pump M8 M K4,3 3 1 1500W E6 65 °C M53 4 M53 M 1 2 3 C3 3 1 2 Q420 BTA 16 3 RV411 4 K3 Only on 125, 150 & 165 Variants 1 1AT F12 Q418 BTA 16 Dryer Blower Right 2 1 RV410 Dryer Heater Right 3 2 3 4 1AT F13 Q417 BTA 16 Only on 125, 150 & 165 Variants E6 5 RV412 6 K4 Q419 BTA 16 M6,3 K2 K1,4 2 63 °C E2 6 K3,3 5 M6,1 4 K3,4 S14K275 M8,3 S14K275 K5,6 return, X11,6 RV413 1 S14K275 Capacitor Dryer Blower Right C3 2 K5,5 hot, X11,5 M4 3 1 K3,1 Dev. Circ. Pump M4 M K3,2 2 M53,3 2 M 1 M 1 2 K6,3 1 1500W E5 RV414 M51 4 3 4 K6 Q421 BTA 16 65 °C 230 VAC Control Devices, HPU Function: S14K275 3 K6,4 Dryer Heater Left E5 1 2 RV415 3 Q422 BTA 16 Electronic Fan M18 2 K5,3 High Voltage Wiring Title: 1AT F14 M18 3 4 RV416 5 Wash Circ. Pump M12 M12 3 6 K5 Q423 BTA 16 C3,1 S14K275 C2,1 3 M51,2 return, X11,4 J2 M12,2 2 M12,1 S14K275 M19,2 K1,1 M18,1 S14K275 E2,2 X25 Ground bar K2,3 E2,1 K4,6 Chiller,3 K4,4 E5,1 hot, X11,3 K1,4 Chiller,1 K1,3 84°C M13,3 K1,3 84°C K5,5 E5,2 1 S14K275 E6,1 M53,1 M8,2 Yellow/green M51,3 K5,3 E6,2 C3,2 Blue M53,2 K5,2 M4,2 Black M18,2 K5,1 S14K275 C2 RV405 Page: 2 Of: Approval: 5 Constructor: KEL Date: Thursday, July 05, 2007 Dryer Blower Left M51 M 1 2 3 1 2 Q412 BTA 16 M2,2 return, X11,2 K5,6 Blue 3 S14K275 hot, X11,1 K5,5 Black M4,1 Brown C2,2 Brown Q2,1 High Power Unit, HPU Yellow/green M51,1 1 K5,5 M2 4 K6,2 2 1 Q2,2 Q2 Scrub Motor M2 M C1,2 3 2 4 3 This drawing belongs to Glunz & Jensen A/S unauthorized person without our specific permission. and must not be used or handed over to any 6 5 C1 3 C1 2 1 Q2,2 Capacitor Scrub Motor Doc. No.: D OrCAD Rev.: 10025469 Number: Motor Overload Relay K6,1 1 C1,1 - M2,1 ELECTRONIC AND M ECHANICAL ENGINEERING Capacitor Dryer Blower Left C2 2 M2,3 B-6 Appendix B: Electrical diagrams Low Voltage Wiring Sensors and Control Devices Service Manual - Plate Processors 85-125 0906 2 1 R1,2 R1,1 2 1 10K R2 2 4 1 J11,4 S4 1 J9 2 7 8 5 + 3 +12VDC 6 B9 1 3 9 4 DEV. Water Cont. Min. 3 2 3 2 4 4 S6 1 3 1 10 S6 2 4 B2 DEV. Waste Cont. Max. 3 1 3 12 1 2 +15VDC 11 J17 3 Output Sensor NC 14 4 3 - 4 1 3 J12,12 Input Sensor NC S2 2 B3 1 J10 4 1 J10,14 S2 1 2 J10,13 1 S5 1 3 4 4 4 6 11 12 4 S3 S3 1 S6,3 S5,3 S4,3 S3,3 S2,3 2 +12VDC S1 8 2 3 4 Title: B4 11 10 9 DEV. Sect. Safety Level 2 1 1 4 GND 3 Rewash Sensor 7 S6,2 S5,2 S4,2 S3,2 S2,2 DEV. FILL Cont. Min. 3 2 3 2 5 B7 1 Output Sensor NC S5 2 3 4 3 1 2 3 GUM Cont. Min. 3 2 3 2 4 + J12 S5 S5 1 2 2 1 B5 Q 2 4 GND 3 0VDC 1 2 2 1 2 1 6 24V S4 S4 1 2 2 1 24V GUM water Valve Y3 10 9 8 Thursday, July 05, 2007 Approval: Page: 3 4 GND 3 7 Of: 5 Constructor: KEL Date: GUM drain Valve Y2 5 +24VDC 4 24V 4 GND 3 Input sensor Input sensor (Where optical sensors are fitted) 2 3 S2 S2 1 WASH water Valve Y1 J11 Sensors And Control Devices Function: Low Voltage Wiring Wash sect. Level 2 1 2 1 14 13 DEV. Sect. Level 2 S6 S6 1 Vcc Output sensor Output sensor (Where optical sensors are fitted) 12 1 4 GND 3 11 H1 14 +12VDC 15 B1 1 16 4 DEV. Repl. Cont. Min. 3 2 3 2 P2 unauthorized pers on without our s pecific perm is s ion. and m us t not be us ed or handed over to any This drawing belongs to Glunz & Jens en A/S ELECTRONIC AND MECHANICAL ENGINEERING 2 Alarm Indicator (Optional) 2 13 1 20 See Setter manual for actual pin connections, or contact your Service Suplier. 12 X21 1 8 Plate Setter Optional P3 5 Rev.: Doc. No.: OrCAD 10025469 D Number: Conductivity Sensor Optional 4 3 2 Green J11 S4,4 Input Sensor NC S4 2 J12,11 + High Power Unit, HPU Dryer. temp. sensor Rntc R2 1 13 14 S2,1 - +24VDC 1 10K R1 2 DEV. temp. sensor Rntc R1 1 J10,1 R2,1 J10,2 R2,2 J10,5 S2,4 J10,6 6 - 15k J11,3 S4,1 15k J12,12 J10,9 J12,4 S3,1 J10,10 J12,11 - J10,5 + J12,3 J12,12 + J10,6 J12,11 + B3,2 15k S6,4 S1,1 - J10,1 B3,3 J10,2 S5,4 J12,2 S5,1 J12,11 S1,2 - S6,1 J12,1 + J12,11 Vcc J12,12 - J10,13 B2,3 J10,14 B2,1 15k + B5,1 Q J11,14 Q - B5,2 L/D J12,12 15k J10,3 L/D + B9,2 - B9,3 J10,4 B4,1 - B4,2 J10,11 + 15k Y1,2 Vcc J10,12 Q Y1,1 + Vcc 5 Y2,1 2 J11,5 L/D 15k Y3,2 - B7,2 J10,7 B7,3 J10,8 Q Y3,1 1 J11,4 L/D J11,6 Y2,2 J11,3 L/D Red Yellow J10 J11,9 J11,10 Blue Main Processor Unit, MIO 15k Vcc X21,2 J11,8 X21,1 J11,7 1 1 2 2 3 5 + B1,2 - J11,15 B1,3 J11,16 (Shield) B-8 Appendix B: Electrical diagrams Motors and Internal Bus Wiring 8, 24 and 35 VAC Distribution Service Manual - Plate Processors 85-125 0906 5 4 3 2 1 From X40 & X41 on page 1 X40,3 X40,4 X40,1 X40,2 X41,3 X41,4 X41,1 X41,2 2 4 8 3 7 2 10AF F403 C456 D420 1 AT 1 6 F2 5 J1 + D45 10AF F401 3 M1 1 2 3 2 4 5 1 3 1 6 C455 2 1 4 5 4 6 F19, 4AT 5 3 D419 D417 6 D418 J4 4 C454 D416 DC supply to C113 4700uF/25V mikroprocessor Dual Motor Controller D423 + J5 2 C457 D422 D421 - 0V S11 1 2 X11 1 2 4 . Q4112 3 D428 . . D426 4 4 3 3 #2 #7 #3 #1 #6 #5 #9 2 7 3 1 6 5 9 9 8 7 6 5 4 3 2 1 6 8, 24 and 35 VAC Distribution Function: 5 Transport Motor M1 +24V GND RX RX TX TX #8 8 P1 #4 4 Motors And Internal Bus Wiring Title: M S11 Encoder DC supply to valves and solenoids See page 5 of 5 D427 . . D425 F405 4AT GND RX RX TX 7 Page: 4 Approval: Of: 5 Constructor: KEL 8 Date: Thursday, July 05, 2007 unauthorized pers on without our s pecific perm is s ion. and m us t not be us ed or handed over to any This drawing belongs to Glunz & Jens en A/S ELECTRONIC AND MECHANICAL ENGINEERING P3 Rev.: Doc. No.: 10 OrCAD 10025469 D Number: Man Machine Interface, MMI 50 P 9 10 See page 3 for connection to input Parts of MIO and temperature sensors. 50 P CKT 9 #1 1 TX 8 #2 2 P1 7 #3 3 6 #4 4 1 5 #5 5 4 #6 6 Part of High Power Unit, HPU 2 X 10uF/100V #7 7 3 3 1 #8 8 J1 at HPU : pin 1 & 5 : 8,5 VAC pin 2 & 6 : 24 VAC pin 3 & 7 : 35 VAC pin 4 & 8 : 35 VAC 2 X11,2 X11,3 1 3 #9 9 1 X11,1 2 X 10uF/100V M1,1 F19,1 J4,4 X11,4 J4,1 M1,4 F19,2 J4,5 Signal 4 J4,6 1 J4,3 +5V + J4,2 + GND 3 3 1 4 4 + 2 x 25 pair, 1:1 + 2 X T filter1 5 4 3 2 1 B-10 Appendix B: Electrical diagrams Service Manual - Plate Processors 85-125 0906