Plate Processor 86-860 PDF

Service Manual
Plate Processor 86/860

Plate Processor 125/126/1250
Service Manual
Plate Processor 86/860
Plate Processor 125/126/1250
Edition BI, January 2015

This book has part No 10067524
0-2
#
This manual is for Service Technicians only.
The directions given must not be followed by unauthorized personnel.
Always read the Safety Instruction Manual part No 21741 before installing or
operating the equipment.
This manual is published by: GLUNZ & JENSEN A/S

Selandia Park 1
DK-4100 Ringsted
Denmark
Phone:+45 57 68 81 81
E-mail: gjhq@glunz-jensen.com
Internet: www.glunz-jensen.com
Copyright © 2012 by GLUNZ & JENSEN A/S.
Service Manual - Plate processor 86/860, 125/126/1250 1245

General information
0-3
The processor
Part 0: General information

Reservations
• This manual was written and illustrated using the best possible information
available at the time of publication.
• Any differences between this manual and the equipment reflect improvements
introduced after the publication of the manual.
• Changes, technical inaccuracies and typographic errors will be corrected in
subsequent editions.
• As a part of our policy of continuous improvement, we reserve the right to alter
design and specifications without further notice.
Notes, cautions, and warnings !

Throughout the manual notes, cautions, and warnings are written in bold like the
example below:
$
Always replace a fuse with one of the same size and rating as the old one.
Symbol Meaning Explanation

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

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

damage to the equipment.
The operator must observe and/or act according to the
# Warning information in order to avoid any personnal injury.
Other manuals
Please see description of "Manuals available for the plate processor" later in this
chapter.
The processor
Approvals
• Approvals will appear from the labels attached to the name plate or the frame part
of the processor.
1245 Service Manual - Plate processor 86/860, 125/126/1250

General information
0-4
The processor
Unintended use of the equipment

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

• Development of photographic materials as specified in “Technical specifications” in
Part 1 in this manual.
Installation
• Never install the processor in explosive environments.
• It is the responsibility of the owner and operator/s of this processor that the
installation is made in accordance with local regulations, and by engineers
authorized to carry out plumbing and electrical installations.
• Installation, service and repair must be performed only by service technicians who
are trained in servicing the equipment. The installation procedure is described later
in this manual.
• The manufacturer cannot be held responsible for any damage caused by incorrect
installation of this processor.
• The processor is intended for installation in a restricted access location only.
Technical data
• Observe technical data from the processor name plate and from Part 1 in this
manual.
Chemicals
• It is the responsibility of the owner of this equipment that data is available
concerning possible health risk from the chemicals used with the equipment.
"End of lifetime" disposal

The equipment is designed for easy disassembling. All disposal of parts from the
machine must be made according to local regulations with special regards to following
parts:
• For recycling purposes significant components are marked with material
specification according to the ISO 11469 standard.
• PVC, tank etc., must be sent to a waste deposit with recycling in view. Alternatively
the PVC can be incinerated at a suitable incinerating plant.
• PCB's and other electric equipment must be sent to a suitable waste deposit.

General information
0-5
The processor
Service assistance
• If help is needed to correct any problem with the equipment, please contact your
local supplier.

General information
0-6
Table of contents
Table of contents
Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Notes, cautions, and warnings ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Unintended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Intended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
"End of lifetime" disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Service assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
User's manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-12
Part 1: Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

General information
0-7
Table of contents
Part 2: Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Installation hours for off-line machine: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Standard installation hours for on-line machine:. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Customer training hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preparing the installation site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CTP online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Power outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Cleaning facilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Drain connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Environmental requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Unpacking/preparing the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Installation kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Transport through narrow doorways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Transport security items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Lifting the processor off the pallet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Removing the fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Electrical installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Main power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Stacker connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Processor/setter connections (ctp online processors) . . . . . . . . . . . . . . . . . . . . . . . 2-8
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Adjustment of lid switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Cleaning the processor tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installation of the hand shower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Configuration of water solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Instalation to tap water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Change of wash configuration via Remote Enabling System . . . . . . . . . . . . . . 2-13
Installation to the water saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Change of wash configuration via Remote Enabling System . . . . . . . . . . . . . . 2-15
Mounting of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Installing the developer filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Filling up developer and wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Mounting the delivery table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Installation of level sensors for replenish and waste . . . . . . . . . . . . . . . . . . . . . . 2-20
Mounting the feed table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mounting the fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Hose connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Gum (10) (Blue) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Repl. (1) (Red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

General information
0-8
Table of contents
Fill up (Clear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Dev. waste . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Dev. drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Wash drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Gum return hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Tap water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Installation of setter interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Finishing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Software settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Part 3: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Master input/output unit (MIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Power control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Control panel (MMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setter connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Function keys - standard function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
(1) Eject plate/manual function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
(2) Manual replenisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
(3) Scroll up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
(4) Accept. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Function keys - service mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
(2) Pump calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
(5) Power (white), (6) Ready (green) and (7) Alarm (red). . . . . . . . . . . . . . . . . 3-9
Jog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Change of settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Connecting to Remote Enabling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Setting up the service connection between the processor and the Remote Enabling
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Static IP address setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Change of processor parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Plate sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Change of wash configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Change of conductivity configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Configuration file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Part 4: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

General information
0-9
Table of contents
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Motor fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
PCB fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
IMPORTANT!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cleaning accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Standard recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Special recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Cleaning of developer heating element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removing rollers from clutch case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Removing drive clutch from clutch bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Normal cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Normal cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Daily cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cleaning of the circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Cleaning of valves in the replenish and small circulation pumps. . . . . . . . . . . . . . 4-11
Cleaning of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Developer and gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Wash section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Replacement of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Adjusting the transport rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Tools: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Adjusting the brush pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Processor conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Adjustment - method A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Adjustment - method B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Mounting of r-clips for gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
NEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
ALWAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Calibration of the replenish pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Calibration of the solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Calibration of the developer fill pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

General information
0-10
Table of contents
Calibration of the conductivity sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Chain servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
After processing of 400 hours/6,500 m2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
After processing of 2,500 hours/80,000 m2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
How to check for potential chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Measurement point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Measure between a given numbers of pitches . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Control the length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Chain adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Complete view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Main chain (1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Scrub chain (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Preventive Maintenance Kit Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Part 5: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Before starting trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
PCU PCB analyzing LED signals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Level sensor LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Digital ouput LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
MIO PCB analyzing LED signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
MIO inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Appendix A: Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

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

General information
0-11
Manuals
Manuals
A complete set of manuals consists of the following:
Service manuals
The manuals listed below are for service technicians only. In addition the service
technicians will need the manuals listed opposite as "User Manuals".
Spare Parts Manual, Plate Processor (1)

Language: English
Contents: Spare parts
Service Manual, Plate Processor (2)

Language: English
Contents: Technical specifications
Installation
Functional description
Maintenance
Troubleshooting
Electrical diagrams

General information
0-12
Manuals
User's manuals
User's manuals available for the equipment:
CE Declaration Of Conformity (3)

Languages: 26
Contents: Survey of the directives to which the equipment conform
Safety Instruction Manual (4)

Languages: 28
Contents: General safety information
User's Manual, Plate Processor (5)

Languages: 5
Contents: Operating and cleaning procedures
Quick Intro, Control Panel (6)

Languages: 5
Contents: Quick guide to control panel user functions
Maintenance Chart, Plate Processor (7)

Languages: 5
Contents: Maintenance instructions
Recycling Passport, Plate Processor (8)

Languages: 5
Contents: Material list of the complete product
Keep the manuals with the machine for reference at all times.

Technical specifications
1-1
General environmental information
Part 1: Technical specifications
General environmental information
The processor does not contain

• Ozone depleting substances according to Montreal protocol
• Asbestos
• Polychlorinated biphenyl or Poly- Cyclohexylenedimethylene Terephthalate
• Mercury
• Cadmium
• Lead as additive to plastic parts
Plastic parts
Significant plastic parts are marked according to ISO 11469.
Batteries
No batteries in this equipment.
End of life
Estimated product life: 10 years
Spare parts and service period: 7 years after last sales.
Recycling
The processor should be disposed at a certified appliance recycling centre or
processing centre.
Recycling Passport with specifications of components and materials used in this
processor is available on www.glunz-jensen.com/support.
Packaging
Plastic packaging materials are marked according to ISO 11469.
Noise emission
Acoustical noise according to ISO 11201:1996
Sound pressure level
Operational mode: < 62 dB
Stand-by mode: < 51 dB

1-2
Mechanical specifications
Chemical emissions
3
Ozone: 0 mg/m
3
Dust: 0 mg/m
3
Styrene: 0 mg/m
Heat emissions
See "Power consumption" on page 1-5.
Performance
86/860 125/126/1250
Plate types single sided thermal offset plates
Plate width 240 - 860 mm 240 - 1250 mm

min.- max. (9.5 - 33.9") (9.5 - 49.2")
Plate length 325 mm

min. (12.8 ")
Plate thickness 0.15 - 0.40 mm

min.- max. (0.008 - 0.016")
Plate speed 50 - 240 cm/min

(15.7 - 94.5 "/min)
Brush speed 40 - 125 rpm
Tank capacities
86/860 125/126/1250
Developer, total 46.0 l 64.0 l
ex. pumps etc. (12.2 US gal.) (16.9 US gal.)
Wash (optional with

14 l 19.5 l
integrated water circulation)
(3.7 US gal.) (5.2 US gal.)
ex. pumps etc.
Gum N/A

1-3
Temperatures
86/860,125/126/1250
Developer 18 - 35 °C
min. - max. (64 - 95 °F)
Dryer, process 50 °C (122 °F)

default non-adjustable
Water requirements
86/860,125/126/1250
Pressure > 1 bar (15 psi)
Water consumption
86/860,125/126/1250
Operation 16 l/min
(tap water in wash) (4.2 US gal/min)
Stand-by 0.0 l/min

(tap water in wash) (0.0 US gal/min)
Hose connections
86/860,125/126/1250
Water supply 12 mm (¾")
Drain, developer 20 mm (0.79")
Drain, wash 20 mm (0.79")
Weights
86/860 125/126/1250
Weight, crated (± 5%) 400 kg (880 lb) 453 kg (997 lb)
Weight, processor 312 kg (688 lb) 340 kg (749.6 lb)
Exit table
Capacity max. 30 plates

NOTE! Consider risk of scratches

1-4
Dimensions
Side view
311.4 cm (122.6")
101 - 116 cm
82.0 - 97.0 cm (39.8 - 45.7")
(32.3 - 38.2")
79.6 - 94.6 cm
(31.3 - 37.2")
Top view
123.6 cm (48.7")
125/126: 138.8 cm (54.6")
126: 183.5 cm (72.2")

126: 131.6 cm (51.8")
86: 144.5 cm (56.9")

86: 93.4 cm (36.8")
86: 99.8 cm (39.3")
40 cm (15.7") 147.8 cm (58.2")
T31977

1-5
Electrical specifications
Power supply
$
The requirements below are specifications for preparing the installation
protection. It is important to prepare the fuses/circuit breakers with adequate
capacity as specified here.
"
Specifications on the processor's name plate is the actual input current and
will thus not be identical to below mentioned.
Supply / fuse Recommended cable type

Single Phase, 1W + N + PE Min. 3 x 1.5 m2
EUR
230V / 1 x 16 Amps, 50-60 Hz type H03VV-F
Single Phase, 2W + PE Min. 3 x 14 AWG
US
230V / 2 x 20 Amps, 50-60 Hz type SJ or SJO
Single Phase, 2W + PE Min. 3 x 14 AWG
JAP
200V / 2 x 15 Amps, 50-60 Hz type SJ or SJO
All Voltage tolerance ±10%
Fuses
$
The fuses must have a breaking capacity of min. 100kA.
If using automatic circuit breakers make sure that they are Type D.
Power consumption
Power consumption at …
230 VAC operation:
EUR/ approx. 3.6 kWh (12000 BTU/hour)
US Stand-by:
approx. 1.2 kWh (200 BTU/hour)
Noise level
See “General environmental information” on page 1-1.

1-6

Installation
2-1
Installation hours
Part 2: Installation
Installation hours
How many working hours are planned for the installation?
Installation hours for off-line machine:

• Provided the machine is unpacked and will stay in the room and all electrical, water
and drain installations are in place, the estimated installation time is 4 – 5 hours .
• If the machine must be disassembled to get into the room before installation
add another 4 - 5 hours for disassembling and reassembling.
• Unpacking and transportation from pallet to the floor, add 2 – 3 hours.
Standard installation hours for on-line machine:

• Provided the machine is unpacked and will stay in the room and all electrical, water
and drain installations are in place, the estimated installation time, including
interface installation and connection to the setter, is 6 – 8 hours.
• If the machine must be disassembled to get into the room before installation
add another 4 - 5 hours for disassembling and reassembling.
• Unpacking and transportation from pallet to the floor, add 2 – 3 hours.
Customer training hours

How many working hours are planned for training the customer?
• Introduction and training of the customer (daily user) in normal use of the
processor, operating, etc., is estimated to 2 – 3 hours.
• Training of the customer (daily user) in normal daily cleaning and maintenance is
estimated to 2 – 3 hours.

Installation
2-2
Preparing the installation site
Space requirements
Make sure that the free space around the machine at the installation site makes
servicing possible.
The recommended minimum free space around the machine is specified in the
illustration below.
> 412 cm ( 162.2")
> 60 cm (23.6")
125/126: > 344 cm ( 135.4")
86: > 304.5 cm ( 119.9")
Feed table
Processor
Exit table > 50 cm (19.7")
> 50 cm (19.7") (optional)
> 100 cm (39.4")
T32205
CTP online
For the CTP On-line processors the space requirements at the processor front has to be
decided separately.

Installation
2-3
Power outlet
If not already there, a main power outlet should be installed in the room where the
machine will be installed. Max. distance to the machine 2 m (6 ft.).
See power outlet and fusing requirements earlier in this manual.
Cleaning facilities
It is essential to have easy access to a sink and a water tap with hot water where
rollers, guides, and brushes can be washed.
The minimum recommended size of the sink is:
Minimum recommended size of the sink

86/860 100 x 40 cm (39.4 x 15.8")
125/126/1250 150 x 40 cm (59.6 x 15.8")
Drain connections
"
Never lead drain hoses from the developer section to a drain, as most
developers are strong pollutants and it is strictly forbidden to empty this type
of chemistry into the public sewer system.
$
When establishing central reception systems for waste chemicals, copper or
brass should not be used in the draining system as the chemicals involved are
highly corrosive.
Therefore plastic or rubber is recommended.
Check with the chemicals supplier for details.
Environmental requirements
Provide a heating and ventilating system capable of maintaining room temperature
between 15 and 25°C (59 and 77°F) and relative humidity on max. 80%.
"
Capacity of the air condition/ventilation system must be adequate for heat
emission (see "Power consumption" on page 1-5).

Installation
2-4
Unpacking/preparing the processor
General
Carefully unpack the machine and check that all parts are present according to the
enclosed packing list and in good condition.
Installation kit
Installation and spare parts kits are included with the processor. They comprise the
different parts necessary to make the installation and some key components as spare
parts.
See enclosed packing list for further information.
Transport through narrow doorways

Dependent on the width of the door(s) through which the processor has to be
transported to the installation site, the Service Technician may have to perform the
actions described in the table below.
If width of the door is… Then…

> 159 cm (62.6") No action is required as the crated processor can be transported
immediately to the installation site.
125 - 159 cm (49.2 - 62.6") The Service Technician has to unpack the processor.
< 125 cm (49.2") The Service Technician has to unpack and strip down the
processor.

Installation
2-5
Transport security items

During transportation many of the parts outside and inside the processor have been
secured using tape, plastic, strips, and various pieces of sponge rubber. Make sure to
remove all items.
Lifting the processor off the pallet

Enter the fork lift under the processor from either the input or exit end of the
processor.
If the forklift is entered under the processor from the side, make sure that the forks are
placed under the transport member and not under the processor stand rails.
"
Carefull handling can prevent damage or accidents.
T32206
T32206
After handling remove the transport member by removing the screws, the washers
and the nuts.

Installation
2-6
Removing the fenders

In order to make the electrical installation it will be necessary to remove the fenders
from the processor.
See illustration below.
• Lift and remove the top cover.

• Loosen the screw inside the processor in front and rear side, lift and pull the right
side fender to remove it.
T32000

Installation
2-7
Electrical installation
General
"
Electrical installation must conform to local regulations and guidelines.
#
The processor is Class 1 equipment. Therefore, the processor must be
connected to earth to avoid electrical shocks.
Main power connections

The main power connection must be made to the main connector (b) in the electronics
cabinet (a) by the delivered cable (c).
• Check the processor connections (see pages 1-5) for the current wiring type.
T32207

Installation
2-8
Stacker connection
See the Stacker Manual.
Processor/setter connections (ctp online processors)

See the Interface Manual.
"
Mechanical installation of the setter can be done now. Software settings and
test need to be done after the completion of the processor installation.

Installation
2-9
Mechanical installation
Adjustment of lid switch

Adjustment of the lid switch may be needed after levelling of the processor.
Loosen the screws (1) and adjust the actuator (2) sidewards until it fits smoothly (3)
into the switch (4).
Cleaning the processor tanks

Remove all rollers and vacuum clean the tank (5) to remove sponge rubber remains
and dust etc.
T32208

Installation
2-10
Installation of the hand shower
"
Not all models.
To mount the hand shower please follow the description below and the illustration on
the following page.
• The hose (1) is mounted to the solenoid valve (2) underneath the processor.
• Mount the shower head (3) and the washer (4) on the hose (1).
• Fix the shower head to the snap locks (5) inside the front panel.
1
4
3
T33049

Installation
2-11
Water connection
The water supply connection is made by
means of the plastic hose and the fitting
(WRG) delivered with the processor. WATER
TAP
As shown in the figure the hose must be

connected between the water tap and the GASKET SOLENOID
VALVE
water inlet solenoid valve located at the
NIPPLE
rear base panel, underneath the processor. 3/4" - 1/2"
(WRG)
GASKET
The hose can be connected to a water tap
with ½" or ¾" male thread (WRG). When
connecting to ¾", the reduction nipple PLASTIC
HOSE
shall not be used.
When water connection has been made

open the water tap and check that all
connections for water inlet are tight.
T3225

Installation
2-12
Configuration of water solution
"
The processor can be set to the tap water system or to the water saving system
from the factory.
Installation to the water saving system or to the tap water system is described
and illustrated on the following pages.
Installation to the water saving
$
For the water saving system installation is recommended min. 2 bar of the
water pressure.
• Turn the processor off and disconnect the main power supply.
• Turn off the main water supply at the main tap.
• Remove the top covers and the left fender from the processor.
• Drain the liquid from the processor.
• Remove the rollers (a, b, c).
b
c

Installation
2-13
• Remove the stopper (d) from the block (e) and install the filter (f) to the block.
e
d
f
• Mount the drain pipe (g) and the bracket (h) to the tank by using the screw and
install the rollers (a, b, c).
a
h
b
c

Installation
2-14
"
Be aware of the small amount of the chemistry in the hoses and the pump
which can leak out when dismounted.
• Disconnect the wires from the pins on the solenoid (i) used for tap water
configuration and connect the wires to the pins on the solenoid (j) used for water
saving configuration.
• Dismount the hose (k) from the fitting (l) on the tank by loosing the clamp.
• Dismount the stopper (m) from the hose (n) and secure the hose (k) with the
stopper (m).
• Connect the hose (n) to the fitting (l) by using the clamp.
• Connect the pump (o) to the slot X109 on the electric box.
o n
n
k
k
i
TAP WATER
WATER SAVING PINS
PINS
• Reinstall the left fender and the top cover on the processor.
• Turn on the water supply.
• Connect the processor to the main power supply and turn the processor on.

Installation
2-15
Change of wash configuration via Remote Enabling System

• Click 'Change access level' and set to 'Service'.
• Enter password 'duy'.
• Go to 'Data' -> 'Configuration' -> 'Hardware' -> 'Wash configuration'.
• Doubble click on 'Tap water' and set it to 'Recirc + valve' .
• Click 'Ok'.
• Click 'Restart'.
• After the restart of the processor go to 'Data' -> 'Settings' -> 'Preferences' -> 'Level
set up' -> 'Fill up mode' and set it to 'Automatic'. And do the same for 'Top up
mode' and set it to 'Automatic'.
• Click 'Ok'.
"
Calibrate the solenoid valve is necessary. See procedure on page 4-19 in the
Service manual.
Instalation to tap water

• Turn the processor off and disconnect the main power supply.
• Turn off the main water supply at the main tap.
• Remove the top cover and the left fender from the processor.
• Drain the liquid from the processor.
• Remove the rollers (a, b, c).

Installation
2-16
• Remove the filter (f) from the block (e) and mount the stopper (d) to the block.
e
d
f
• Remove the drain pipe (g) and the bracket (h) from the tank by loosening the screw.

Installation
2-17
#
Be aware of the small amount of the chemistry in the hoses and the pump
which can leak out when dismounted.
• Disconnect the wires from the pins on the solenoid (j) used for the water saving
configuration and connect the wires to the pins on the solenoid (i) used for the tap
water configuration.
• Dismount the hose (n) from the fitting (l) on the tank by loosing the clamp.
• Dismount the stopper (m) from the hose (k) and secure the hose (n) with the
stopper (m).
• Connect the hose (k) to the fitting (l) by using the clamp.
• Disconnect the pump (o) from the slot X109 on the electric box.
o n
n
k
k
i
TAP WATER
WATER SAVING PINS
PINS
#
Always disconnect the pump from the electric box when is not in use to avoid
the damage.
• Fill the processor with the liquid.

• Reinstall the left fender and the top cover on the processor.
• Turn on the water supply.
• Connect the processor to the main power supply and turn the processor on.

Installation
2-18
Change of wash configuration via Remote Enabling System

• Doubble click on 'Recirc + valve' and set it to 'Tap water'.
• Click 'Ok'.
• Click 'Restart.
Mounting of rollers
On the top of the upper safety cover is placed a label (a) showing the roller
configuration.
Each roller is marked with a small number (b). Install the rollers by referring to the
roller numbers shown on the label on the top of the upper safety cover.
DV 2U
Roller location:
U = Upper
L = Lower
Roller pair number
Section:
DV = Developer
W = Wash
G = Gum
DR = Dryer
a b
T32209

Installation
2-19
Levelling
$
The machine must be placed on a steady surface, so that it does not shake
easily and the chemicals cannot be spilled from one section to the other.
Do not rely on the floor being absolutely in level.
$
For CTP ONLINE PROCESSORS the final height from floor to bottom of the
processor entrance (1) must be: SETTER OUTPUT HEIGHT ÷2 mm.
• Use the adjustable feet (2) in the legs to level out the processor.
It will be necessary to use e.g. a crowbar (3) to lift the legs slightly before being able
to turn the feet.
• Level out the processor lengthwise by placing a spirit level on the left (4) and right
(5) tank side.
• Level out the processor crosswise by placing the spirit level on the upper input
roller in the developer section (6) and the gum distribution roller in the gum
section (7).
• Check levelling in all 4 positions and make final leveling if required.
6 7
6 5
SETTER OUTPUT
HEIGHT ÷ 2 mm
R
O
O
3
FL
2
T32210

Installation
2-20
Installing the developer filter element

The developer filter element must be installed in the filter vessel at the leftt tank side.
• Close the valve (1).
• Loosen the filter vessel (2) by means of the filter key (3) and unscrew the vessel
(counterclockwise).
• Install the filter element (4) inside the filter vessel.
• Mount the filter vessel and make sure that O-ring (5) fits properly into the groove in
filter vessel. Tighten with filter key (clockwise).
• Make sure that the drain valve (6) is closed (counterclockwise).
• Open the valve (1).
1 180°
O
PE
CL
O
SE
D
4 N
CL
O
SE
3 D
T32009

Installation
2-21
Filling up developer and wash
Developer
Make sure that the developer drain stand
pipe is closed (see illustration).
Fill up the developer section manually as

shown in the illustration below.
Wash
Wash water recirculation system.
If the processor is equipped with a wash T31556
water recirculation system the wash section
will fill up automatically when the
processor is switched into stand-by mode.
"
Remember to calibrate the solenoid
valve. See description on page 4-19.
No wash water recirculation. OPEN CLOSED

The water solenoid valve will let in water
when a plate is entered through the input slot.
T31981
Mounting the delivery table

On the front end of the delivery table is a supporting bar. Mount the delivery table by
attaching the supporting bar inside the exit slot of the plate processor.

Installation
2-22
Installation of level sensors for replenish and waste

Enclosed in the installation kit are 3 sets of level sensors for developer replenishment
and gum replenishment containers.
• Locate the cables for level sensors (1). The cables are marked with name tags for
each sensor.
• Connect the enclosed sensor cables and mount sensors as shown on the
illustrations:
– "Dev repl min. cont. B10" to developer replenishment container (2).
– "Developer fill up min. cont. B11" to developer replenishment container (2).
– "Gum min. cont. B9" to gum replenishment container (3).
2 3
a b a b
c c
T33050

Installation
2-23
Mounting the feed table

Offline processors only!
• Mount the screws (1), into the front panel, do not tighten yet.
• Mount the screw (2) with lock stay (3) into the front panel, and tighten the screw (2).
• Hang the feed table on the two screws (1), do not tighten yet.
• Mount the two screws (4) and tighten them. Make sure the lock fits into the
counterpart (5).
• Check that the distance between the surface of the feed table and the edge of the
entrance slot in the front panel is approximately 1.5 mm (as shown on picture
below).
• Tighten the two screws (1).
1.5 mm
3
2
4
5
4
T32211
Mounting the fenders

• Mount the left and right fenders with the screws as shown below.
T32001

Installation
2-24
Hose connections
The illustration at the next page shows the hose configuration. Make the following
hose connections underneath the tank:
"
All drain hoses must have a positive fall from the processor to the waste
containers and drain.
Q R
T31366
"
Never lead drain hoses from the developer section to a drain, as most
developers are strong pollutants. It is also illegal to empty these types of
chemicals into the public sewer system.
$
Particularly when preparing the drain connection, ensure that copper or brass
is not used in the draining system since the chemicals involved might corrode
it. Plastic or rubber is therefore recommended. Check with your chemicals
supplier for details.
"
Be careful that the drain hoses do not sag or form water traps.
Gum (10) (Blue)

Connect to gum container.
"
The gum hose (10) should be cut off to the shortest possible length to avoid
any sagging and formation of water traps and/or air pockets.
Repl. (1) (Red)

Connect to developer replenishment container.
Fill up (Clear)
Connect to developer replenishment container.
Dev. waste
Connect to waste container.
Dev. drain
Wash drain

Installation
2-25
Gum return hose

Connect to gum container.
"
When inserting the gum return hose into the gum container, make sure that
the hose end is never below the gum surface (see illustration below).
Tap water
Make connection from water tap to solenoid valve underneath the processor.
Tap water
Gum return hose
Dev. drain
Gum (10)
Fill up Repl. (1)
Wash drain
Dev. waste
T32354
Power supply cable
"
The cable/plug required for main power connection is delivered with some
models only.
See the power supply table earlier in this manual. The table shows recommended
power supply cables for processors delivered without cable.

Installation
2-26
$
The conductors in the power supply cable must be of copper.
When deciding what type of cable to use take into account the chemical
resistance (chemicals may leak onto cable) and the mechanical resistance
(operator may step onto cable).
Provide for additional cable protection, e.g. cable covers, if cable is exposed to
heavier transport such as fork-lift trucks etc.
T32213
Installation of setter interface

If the processor is part of an online system, now make the installation of the setter
interface as described in the Interface Manual.
When installation of the setter interface is complete please return to this manual for
finishing the entire installation.

Installation
2-27
Finishing installation
Finishing installation
Software settings
The processor is configured from the factory. The default parameters are set as follows:
Parameter Program 1 Program 2 Program 3 Program 4

Speed 110 cm/min 110 cm/min 110 cm/min 110 cm/min
Developer
120 rpm 120 rpm 120 rpm 120 rpm
brush speed
Developer set
24 °C 24 °C 24 °C 24 °C
temperature
Developer
29 s 29 s 29 s 29 s
dwell time
Parallel plates No No No No
Change of settings is possible only via the Remote Enabling System. See page 3-10 for
more information.
Safety check
A safety check must be performed after installation. See page 4-2.

3-1
General
Part 3: Functional description
General
The basis processor contains four major sections:
1 2 3 4
T11264
1 Developer Developing of the plate and removing of the remaining unexposed emulsion.
2 Wash Washing off the developer chemicals from the developed plate.
Application of a thin layer of gum onto the developed and washed plate to
3 Gum
protect it from oxidation, dirt, fingerprints etc.
4 Dryer Drying of the plate to ensure immediate handling of the plate.
The processor sections are described in detail on the following pages.
Controls and indicators

The controls and indicators are described later in this chapter.

3-2
General
DEVELOPER
S1
INPUT SENSOR
OVERFLOW
M1 TRANSPORT M E1 DEV. HEATING B1 DEV. TANK

ROLLER MIN. SENSOR
MOTOR
M2 DEV.
M S28 COND.
BRUSH R1
MOTOR SENSOR
TEMP. SENSOR
M19
DEV AUTOFILL.
M4 PUMP
DEV M3
REPLENISH DEV. CIRC.
PUMP
(IWAKI)
DEVELOPER
FILTER
B11
DEV FILL UP
CONT. MIN. COOLER
SENSOR
OPTIONAL
REPLENISH
NOT ALL MODELS
B10 WASTE
DEV REPL.
CONT. MIN.
SENSOR
OPTIONAL
T31992

3-3
General
WASH, TAP WATER
TAP WATER
K8
VALVE
FLOW LIMITERS
SPRAY TUBE
SPRAY TUBE
DRAIN
WASH, CIRCULATION WATER
TAP WATER
REPLENISH
K8
VALVE
FLOW LIMITERS
OVERFLOW
SPRAY TUBE
WASH TANK
MIN. SENSOR B2
SPRAY TUBE
DRAIN
VALVE
CIRC. PUMP
M10 DRAIN
T31993

3-4
General
GUM
APPLICATION TUBE
M23
GUM CIRC. PUMP
DRAIN
B9
GUM
CONT. MIN.
SENSOR
GUM
OPTIONAL
NOT ALL MODELS
DRYER
S2
OUTPUT SENSOR
R2
TEMP. SENSOR T31994
M M
HEATING M51 M53 HEATING

ELEMENT ELEMENT
FAN FAN
E2+E3 E4+E5

3-5
General
TRANSPORT
DV 2U
Roller location:
U = Upper
L = Lower
Roller pair number
Section:
DV = Developer
W = Wash
G = Gum
DR = Dryer

3-6
General
REMOTE
ENABLING
(Optional)
ETHERNET
MMI
USB
X50
MASTER
I/O BOARD MIO INTERFACE
SoM
GNUIB (RS485)
SETTER
SLAVE
I/O BOARD PCU (Online installations only)
T32249

3-7
Electronic control
Electronic control
See illustration opposite.
The electrical control system consists of:
Master input/output unit (MIO)

The electrical control system is controlled by the MIO board via the SoM (System on
Module).
There are two separate communication lines (buses):
• GNUIB for all internal communication in the processor (RS485).
• ETHERNET for Remote Enabling System.
Power control unit (PCU)

The PCU-board holds all the high voltage in- and outputs for the control of heaters,
motors etc.
Control panel (MMI)

The user operates the processor from the control panel with one line display.
Setter connection
Connection of a setter interface is made to the terminal block X50 positioned outside
the electronics box (see illustration below).
T32355

3-8

The processor is equipped with the function keys located on the right fender (see
illustration below).
Function keys - standard function
(1) Eject plate/manual function

Starts the transport system to eject a plate jammed inside the processor.
(2) Manual replenisher

Gives a fixed amount of replenisher to the finisher section.
(3) Scroll up
Scrolls up in the menu of the control panel.
(4) Accept
Accepts the chosen function.
3 1
7 6 5 4 2
T32053
Function keys - service mode

To enter the service mode press scroll up button (3) until "Service/Info" appears and
confirm it by pressing button (4) twice.
All service activity must be done via Remote Enabling System.
(2) Pump calibration

Calibrating of the pump is done via the Remote Enabling System. See page 4-18 for the
procedure.

3-9
Indicators
The control panel holds 3 indicators:
(5) Power (white), (6) Ready (green) and (7) Alarm (red).
WHITE GREEN RED CONDITION

OFF OFF OFF For software older than xxx-20111201
> 1 minute Power off or initializing.
For software newer than xxx-20111201

Power off or malfunction SoM/MIO.
Check cable connection to LDM if system stays in
this state. See "PCU analyzing LED signals" on page
5-5 and "MIO analyzing LED signals" on page 5-7
too.
TOGGLING OFF OFF For software newer than xxx-20111201

Power up sequence. Sequence lasts approximately 1
minute. White LED goes off/on approximately 5
times in an irregular pattern.
ON OFF OFF Sleep mode. Display shows "z Z z Z z Z z Z".

Error. See display for status.
ON FLASHING OFF Warming up. Display shows ":-I".

5 sec loop Processing plates. Display shows ":-)".
ON ON OFF Ready to process plates. Display shows ":-)".
ON OFF ON Alarm requiring user intervention.
Jog function
The jog function will make the rollers and brushes turn for a while at intervals to
prevent crystallization of chemicals on the rollers and brushes.
The initial jog (after power has been applied to the processor) runs for ½ minute.
After that the jog will run for ½ minute every 10 minutes.
Change of settings
Change of settings is possible only via the Remote Enabling System.

3-10
Connecting to Remote Enabling System

Making settings of this processor requires the Remote Enabling System software and
connection to a PC.
• If not already installed, please download the Remote Enabling System from
www.glunz-jensen.com/support/download/software and install on a local PC.
For this processor, select the Remote Enabling System for GNUC 2. Download and
unzip the file to a separate folder on the PC's harddisk.
• To access the Remote Client, please activate the 'grclient.exe' stored in the folder
'GrClient Copy Install/GrClient'.
"
Tip! Copy a shortcut of the 'grclient.exe' to the PC's desktop for easy access to
the Remote Client.
Electrical connection
• If a LAN (Local Area Network) cable is
Network cable
connected to the processor, or the PC is
connected to wireless LAN, make sure to
disconnect the cable/connection now.
• Connect the Ethernet cable delivered
with the processor between the PC and T32182
the processor (see illustration).
Setting up the service connection between the processor and the Remote
Enabling System
• Enter the menu on the processor's control panel by pressing the button. See also
the control panel Quick Intro guide.
$
If the display shows 'Service Code 2' the software configuration is missing,
e.g. due to replaced SOM PCB. Back-up configuration file can be loaded with
the Remote Enabling System. Please continue as described below.
• Press to scroll to the Service/Info menu and press enter .

• Press to scroll to the LAN IP address (marked with 1)
) and press enter .
2)
• You will now see a 'service' IP address 169.254.11.xx in the display.
1) A preset IP address which needs to be changed in case the processor will be connected permanently to the Remote
Enabling System via an internal network. See the Remote Enabling System Installation Guide.
2) This is a 'service' IP address dedicated for service technicians to connect to the Remote Enabling System either for
making settings and configuration of the equipment as described in the following, or for setting up the equipment to a
permanent Remote Enabling System installation (permanent LAN IP address) at the customer's site.

3-11
• Make a note of the 'service' IP address. It is needed for connecting to the Remote
Enabling System.
• Start the Remote Client (shortcut icon on the desktop).
• In the Remote Client select 'Server Admin' (1). See illustration below.
• Enter IP address from the processor (169.254.11.x) in the 'Server' field (2) and click
'Add'. This will create the connection between the processor and the Remote
Enabling System.
• Click OK.
• Check that connection to the processor is established: Re-open the ‘Server Admin’
and make sure that status field (3) for IP address 169.254.11.xx shows 'OK'. When
'OK' the processor tab (4) will appear in the upper left corner of the Remote Client
window.
"
For more information about the Remote Enabling System please see the
general installation manual enclosed with the Remote Enabling System
software.
Static IP address setting

In case of a permanent connection to a local installation of the Remote Enabling System
via a LAN the IP address of the equipment needs to be set to a static IP address:
• Contact the local IT administrator for obtaining an IP address.

• Enter 'Server Admin' (1).
• Select the processor IP address 169.254.11.xx (3) and click 'Change access level' (5).
• Enter Password 'duy'.
• Select 'Config' (6).

3-12
• Select 'Network'.
• Select the static IP addresses and change the IP address field to the IP address
informed by the IT administrator.
• Click 'OK' and confirm 'Restart' by pressing 'OK'.
• When the Remote Enabling System is ready, please verify, on the processors control
panel, (by scrolling to the IP address marked with ) that the IP address now
listed is identical to the one added in 'Static IP address' in the Remote Enabling
System.

3-13
Change of processor parameters

• Press the processor tab (4).
• Select 'Data -> Settings -> Programs'.
• The processor parameters list will be shown in the 'Settings' view and new settings
can be made.
• Double click on the parameter.

3-14
• Change the value of the parameter.

• Press 'OK'.
Plate sizes
"
Plate sizes must be entered in order to obtain exact calculation of
replenishment.
• Select 'Data' -> 'Settings' -> 'Plate sizes'.

• Define new, or select already used plate sizes.

3-15
Change of wash configuration

• Enter Password 'duy'.
• Double click on 'Tap water' and set it to 'Recirc + valve'.
• Click 'OK'.

3-16
Change of conductivity configuration

• Go to 'Data ' -> 'Configuration' -> 'Hardware' -> 'Developer configuration'.
• Double click on ''Conductivity' and set it to 'ReadOut current'.
• Click 'OK'.

3-17
Configuration file
"
Save a copy of the configuration file locally, and on the USB stick once the
installation is finished.
• Set access level to 'Service'.

• Go to 'Tools' -> 'Remote SW Tools'.
• Click 'Backup data'.
• Select the folder where the file will be saved and click 'OK'.

3-18

Maintenance
4-1
General
Part 4: Maintenance
General
This chapter holds the special service information such as adjusting procedures,
cleaning of pumps etc.
For user related maintenance and cleaning procedures refer to the Plate Processor
User's Manual.
"
Download of software for upgrade or repair purpose is available from the
manufacturer's website: www.glunz-jensen.com.
WARNING!
Please note that where this label DANGER
appears on the processor, electrical ELECTRICAL SHOCK HAZARD
shock hazard still exists when the DISCONNECT ALL EXTERNAL POWER
SUPPLY BEFORE SERVICING
main switch is turned off.
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.

Maintenance
4-2
Safety check
Safety check
#
The safety check described below should be performed at least once a year.
Electrical
Refer to the electrical diagrams in the back of this manual.
• Check proper function of:
– Lid switch:
Processor must stop when the switch is deactivated.
– Main switch:
Processor must turn off when set to "0".
– Emergency stop:
Processor must turn off when activated.
Emergency
stop
Control
panel
Emergency
stop Main switch
Electronics
cabinet
Upper
side panel
T32214
Mechanical
• Check proper function/location of:
– Upper side panels, left/right:
Make sure they are properly secured with 2 screws each.
– Lid, electronics cabinet:
Make sure the lid is secured by screws.

Maintenance
4-3
Fuses
Fuses
Motor fuses F17 and F18 are located in cables leading to connectors X4 and X5.
Other fuses for the various functions are located in the electronics cabinet behind the
right fender. The fuses are placed on the PCU board and in the fuseholder on the
inside of the cabinet bottom and on the PSU board on the inside of the cabinet lid.
Motor
fuses
Fuses
T32215
#
When changing a fuse, first switch off all power to the machine.
Always ensure that the new fuse is of the correct rating according to the label.
Motor fuses
Fuse Fuse for Type / part No.

5AT, 6.3 x 32 mm S/B
F17 Transport motor M1
5659
4AT, 6.3 x 32mm
F18 Brush motor M2
6896
PCB fuses
Fuse Fuse for Type / part No.

12AT, 6.3 x 32 mm
F1 & F2 & F3 Main power supply
5527

Maintenance
4-4
Rollers and brush rollers
Rollers and brush rollers

General
The label showing the roller configuration (a) is placed on the top of the upper safety
cover and on page 3-5 in this manual. Each brush/roller is marked with a small
number (b). Install the rollers by referring to the roller numbers on the label.
DV 2U
Roller location:
U = Upper
L = Lower
Roller pair number
Section:
DV = Developer
W = Wash
G = Gum
DR = Dryer
a b
T32209
Installation of rollers
"
A minimum of two persons are 3
required for this operation.
• Open the locks (1) and dismount the

brush adjustments (2).
• Mount the bearings on the transport
rollers ensuring that the bearings (3) are 4
turned upwards as shown on the
illustration on the opposite page.
• Mount the bearings on the brush rollers
ensuring that the bearings (4) are turned
downwards with the spring.
• Insert the rollers into the clutches (5), 1
then lower the rollers into the grooves
and then mount the adjustments (2), 5
and close the locks (1).
2
T32361

Maintenance
4-5
Cleaning
Cleaning
IMPORTANT!
Thorough cleaning of the processor tank interior, tank parts, pumps, filters etc.
on a regular basis will minimize the risk of sediment build-up in and around vital
parts of the equipment and prolong the lifetime of the equipment.
Cleaning accessories
$
Never use any hard tools or abrasive materials when cleaning any part of the
processor.
Apron, rubber gloves and eye goggles.

For personal protection
Lint-free cloth, sponge and soft brush.

For cleaning of rollers, guides, tank walls, and all surfaces, especially the exit table and
the feed table (if fitted).
Long-handled bottle brush and thin wire (i.e. Paper clip).

For cleaning the inside and the holes of the spray tubes.
Cleaning agents
#
Never use cleaning agents containing chlorinated solvents, acetic or
phosphoric acid. These constitute a health hazard and could damage the
processor.
$
Cleaning components with anything other than a mild detergent or a
recommended cleaning agent may cause irreversible damage and invalidate
any warranty.
Standard recommendations
Warm water 35-40°C (95-104°F).
For normal cleaning purposes and to rinse after using other cleaning agents.
Citric acid 10%/Nitric acid 5%

For major cleaning purposes.
Commercially available biocide/strong alkalic liquid

For cleaning off heavy algae-, fungal- or bacterial growth in the wash section.
Special recommendations
As some chemicals may require special cleaning agents, contact your chemicals
supplier for recommendations about cleaning agents for your processor.

Maintenance
4-6
Cleaning
Cleaning of developer heating element
$
Keeping the developer heating element and it's surroundings clean,
eleminates the risk of sediment build-up underneath the heating element, and
eleminates the risk of heating damages of the tank.
When cleaning the tank, make sure to wash off all residues around the developer
heating element. Use plenty of water, a soft brush and a soft cloth to clean the gab
between the heating element and the tank bottom (see illustration below).
T32302

Maintenance
4-7
Cleaning
Removing rollers from clutch case
CLOSE
OPEN
1 2
3 4
T31626
Removing drive clutch from clutch bearings
1 2 3
T31627

Maintenance
4-8
Cleaning
Developer section
Normal cleaning
• Turn the processor off.
• Remove the top cover.
• Drain the tank.
• Remove spray tubes and rollers from the section.
• Clean rollers with a cloth or soft brush and water.
• Wash the tank bottom and walls with water using a cloth or soft brush.
• Clean the spray bars outside with a cloth or brush and water and the inside using a
long-handled bottle brush.
Clean the holes in the spray bars with a piece of thin wire (e.g. paper clip).
• Make sure that all parts are replaced in their original positions after cleaning. Please
refer to the label of roller configuration placed on the top of the upper safety
covercover.
• Mount back the top cover and press the stand-by key to start up the processor.
Major cleaning
• Follow the procedure described for normal cleaning but use a solution of tank
cleaner if needed.
Wash section
Normal cleaning
• Turn the processor off.
• Drain the tank.
• Remove spray tubes, transport rollers and brush from the section.
• Clean transport rollers with a cloth or soft brush and water.
• While running water over the brush roller, draw it through your hand (use rubber
gloves).
• Wash the tank bottom and walls with water using a cloth or soft brush, removing
all slime.
• Clean the spray bars outside with a cloth or toothbrush and water and the inside
using a long-handled bottle brush.
Clean the holes in the spray bars with a piece of thin wire (e.g. paper clip).
• Make sure that all parts are replaced in their original positions after cleaning.
• Mount back the top cover and press the stand-by key to start up the processor.
Major cleaning
• Follow procedure described for normal cleaning, but use a 10% citric acid solution
instead of water.

Maintenance
4-9
Cleaning
Gum section
Daily cleaning
The gum lay-on roller ensures a uniform distribution of gum on the gum roller. The
lay-on roller needs to be cleaned each time the processor is shut down in order to
ensure proper distribution of gum to the plates. Follow the steps below:
Shut down:
• Shut down the processor at the main switch.
• Take the gum spray tube (a) out and clean it.
• Take out the lay-on roller and after cleaning place it in the rest position (b).
• Release the roller lock (c) and clean the upper gum roller (d) with a moist cloth.
• Place back the top cover.
Start-up:
• Lower the lay-on roller to the process position (e).
• Lock the roller lock (c).
• Mount back the top cover.
e
T32389

Maintenance
4-10
Cleaning
Major cleaning
• Stop the processor and replace the gum container with a container with hot water.
• Start the cleaning cycle via the control panel and let run.
• Stop the processor and replace the hot water container with the Gum container.
Cleaning of the circulation pump

If the circulation pump ceases to function properly clean the pump following this
description.
• Cut off the power to the unit by removing the top cover.
• Empty the tank section.
• Dismount the hoses from the pump. Be careful not to spill the chemicals on the
floor.
• Note that the position of the outlet nozzle (5) should point as shown.
• Dismount the pump.
• Dismount the cover (4) and pull out the impeller (3) and the impeller housing (1).
• Clean the inside of the cover, the impeller and the impeller housing in warm water.
• Reinstall in reverse order, observing that the outlet nozzle (5) of the cover is placed
as it was before dismounting it, and that the O-ring (2) is placed correctly in the
groove of the impeller housing (1).
T31064

Maintenance
4-11
Adjustment of spray tubes
Cleaning of valves in the replenish and small circulation pumps

If a replenishment or a small circulation
pump ceases to function properly, run it
with some warm water in order to clear the
pump of chemicals. VALVE
If this does not help, take the pump apart VALVE
and clean the small valve in warm water.
VALVE T436
Cleaning of spray tubes
Developer and gum section

Clean the spray tubes in the developer section with hot water to remove potential
blocking of the holes. Occasionally it may be necessary to use a drill bit to clean the
holes and remove sediments mechanically.
Wash section
Clean the spray tubes in the wash section with hot water to remove potential blocking
of the holes. Occasionally, depending on the local water quality, it may be necessary to
use a drill bit to clean the holes and remove sediments mechanically.
Adjustment of spray tubes

The pressure in the spray tubes can be adjusted to obtain the best possible application
of water to the plate. Pressure is adjusted as shown on the illustration below.
The valve is fully open from the factory. Normally no adjustments are necessary.
t31558

Maintenance
4-12
Replacement of bearings
Replacement of bearings
See the illustration below.
• Pull out the pin (1) at the gear side of the rollers. Use a 6 mm mandrel to drive out
the pin.
• Remove the roller bearings (2).
• Remove the springs (3) from the bearings on the brush rollers.
• Replace the bearing.
• Mount back the springs on the new bearings for the brush rollers.
3
T32011

Maintenance
4-13
Adjusting the transport rollers
Adjusting the transport rollers
Tools:
– 10 mm hex key.
General
• Make sure that roller locks (1) are properly closed.
• Use key (2) to turn eccentrics (3). Turn eccentric in locking direction to increase
roller pressure and against locking direction to decrease pressure.
Adjust the rollers as follows:

• Turn eccentrics (3) against the locking direction until the roller locks (1) in both
sides can move freely between the roller bearings.
• Turn eccentrics (3) in the locking direction until the locks (1) in both sides require a
light push to lock (feel the 'click').
• From this point turn eccentrics (3) 2.5 marks in the locking direction.
"
The adjustment must be made on locks on both sides of the tank in order to
reach correct pressure on whole width of the roller.
2 1
T 31642

Maintenance
4-14
Adjusting the brush pressure

General
The following describes a standard adjustment for the brushes in the developer and
wash sections. The brush adjustment can vary from one processor to another since it
must apply to the specific plate and chemical type etc.
Tools: • 5 mm hex T-key

• Test plate 100 x 200 x 0.15 mm (developed)
Processor conditions
Place the plate between the brush roller and the lower guide and activate the manual
function button.
Recommended brush speed setting: as specified on page 2-20.
Preparations
• Lift up the processor top cover.
• Remove the upper roller (1) in the developer section before adjusting.
• Activate the interlock switch.
• Start (3).
Adjustment - method A
See top illustration opposite.
• While the brush (4) runs use the test plate (5) to test the brush pressure in both sides
and in the middle. Make sure that the test plate (5) is entered at right angles (5a) to
the rollers.
• Adjust the brush pressure on the screws (2) (clockwise = tighten) until you feel a
slight grip ("kiss'n touch").
Make sure that you obtain a uniform grip in both sides and in the middle.
• From this point turn the screws (2) 1/4 turn clockwise in each side. 1/4 turn is a
common pressure which will work in most occasions. Please refer to plate
manufacturers specifications.
Adjustment - method B
See bottom illustration opposite.
Use a strip of polyester film (7) and a spring balance (6) and proceed as follows:
• Insert a strip of polyester film (7) (10 cm wide, approximately 50 cm long, 0.10 mm
thick/4 x 20 x 1/128”) between the brush roller (8) and the lower roller (or guide).
• Activate the manual function button and hold the film strip with the spring balance
(6) against the rotation of the brush, pulling the spring balance upwards.
• Adjust the pressure to a balance depending on a recommendation from plate
manufacturer over the entire brush roller width.
Repeat the procedure for the all brush rollers. All brushes should be adjusted to the
same settings.

Maintenance
4-15
Adjustment - method A
Adjustment - method B
6
400
300
200
100
7
T31942

Maintenance
4-16
Mounting of r-clips for gears
Mounting of r-clips for gears
$
Following the lower instructions is very important for the correct function of
the processor.
See the illustration below.
NEVER
mount R-clips as shown in the upper illustration.
ALWAYS
mount R-clips as shown in the lower illustration.
R
T32010

Maintenance
4-17
Calibration of the replenish pump

Calibrating of the pump is done via the Remote Enabling System. See page 3-10.
• Activate the service mode in the processor menu.
P1 : - ) 2 5C 2 0 S
Service/Info >
Service mode ?
T32390
! Service mode !
• Place the suction tube from the replenish pump into a measuring container with
developer.
• Start up the Remote Enabling client.
• Click 'Change access level'.
• Set Access Level to 'Service' and enter Password 'duy'.

Maintenance
4-18
• Click on 'Devices' -> 'Developer devices'.

• Double click on 'Replenisher pump'.
• Start the pump to remove air from the tube and let the pump run till no air is in the
tube.
• Stop the pump.
• Fill-up the container so it contains 2 litres of developer.

• Let the pump run for 1 min. exactly.
PUMP
X
Y
T 31943

Maintenance
4-19
Calibration of the solenoid valve
• Go to 'Data' -> 'Configuration' -> 'Calibrate' -> 'Replenish pump'.

• Set the measured value and press Ok.
Calibration of the solenoid valve

Calibration of the solenoid valve is done via the Remote Enabling System. See page 3-10.
The processor must be in service mode, and access level must be set to 'Service' as
described on page 4-17.
• Dismount the hose leading from solenoid valve to wash spray fitting, and place it
into the measuring container.
• Go to 'Devices' -> 'Wash devices'.
• Double click on 'Water valve' and let it run for one minute.
• Measure the volume of water pumped into the container.
• Go to 'Data' -> 'Configuration' -> 'Calibrate' -> 'Water valve capacity'.
• Set the measured value.

Maintenance
4-20
Calibration of the developer fill pump

• Start up the Remote Enabling client.
• Click 'Change access level'.
• Set Access Level to 'Service' and enter Password 'duy'.
"
If the developer fill pump is mounted to the processor as an option, is
necessarry to configure the fill pump as shown below.
• Go to 'Data' -> 'Configuration' -> 'Hardware' -> 'Developer configuration'.

• Double click on 'Fill pump' and set it to 'Yes'.
• Click 'Ok' and restart the processor.

Maintenance
4-21
Calibrating of the pump is done via the Remote Enabling System. See page 3-10.
• Activate the service mode in the processor menu.
P1 : - ) 2 5C 2 0 S
Service/Info >
Service mode ?
T32390
! Service mode !
• Place the suction tube from the developer fill pump into a measuring container with
developer.
• Click on 'Devices' -> 'Developer devices'.
• Double click on 'Fill pump' and set it to 'On'.
• Click 'Ok'.

Maintenance
4-22
• Start the pump to remove air from the tube and let the pump run till no air is in the
tube.
• Stop the pump.
• Fill-up the container with the developer.
• Let the pump run for 1 min. exactly.
• Go to 'Data' -> 'Configuration' -> 'Calibrate' -> 'Fill pump capacity'.
• Set the measured value and press 'Ok'.

Maintenance
4-23
Calibration of the conductivity sensor
Calibration of the conductivity sensor

Calibration of the solenoid valve is done via the Remote Enabling System. See page 3-10.
The proccesor must be in service mode, and access level must be set to 'Service' as
described on page 4-17.
• Place an external calibrated conductivity meter in the developer section filled up
with a liquid and measure the conductivity of the liquid.
• Compare the measured value with the value measured by the processor
conductivity sensor via the Remote Enabling System. Note the deviation between
these values.
• Go to 'Data' -> 'Configuration' -> 'Conductivity' -> 'Conductivity reading
adjustment'.
• Double click on 'Value' of 'Conductivity reading adjustment' and type the value
equal to the deviation between the two measured values (e.g. if the value measured
by the conductivity meter is 40 mS and the value measured by the processor
conductivity sensor is 38 mS then the 'Value' of 'Conductivity reading adjustment'
should be set to '2'.
The range for 'Conductivity reading adjustment' parameter is ± 20 mS.
"
Conductivity measured by the processor can be temperature compensated if
chemistry supplier has a recommended 'Temperature coefficient'.

Maintenance
4-24
Chain servicing
Chain servicing
"
Regular chain servicing is important if maximum life is to be achieved.
Find data regarding processed total amount of the processing hours via the Remote
Enabling System:
• Go to 'Data' -> 'Statistics' -> 'Counters' -> 'Plate counters'.
After processing of 400 hours/6,500 m2

... whatever comes first
• Check the chain tension and adjust if necessary. See chain adjustment procedure on
page 4-28.
After processing of 2,500 hours/80,000 m2

... whatever comes first:
• Carry out the chain tension check.
• Check for wear on side plates of the chain link.
• Check for chain elongation. See the following page for how to check for potential
chain wear.
• Check cleanliness of components, remove any accumulations of dirt or foreign
materials.
• Check for shaft and sprockets alignment.
• Check for wear on sprockets.
• Check the condition of the lubricant, lubricate the chain working surfaces.

Maintenance
4-25
Chain servicing
How to check for potential chain wear

2
The below guidelines should be followed after processing 2,500 hours/80,000 m of
plates.
Measure the length of the chain between a given number of pitches (see latter
illustrations).
Measurement point
Measure between a given numbers of pitches

Maintenance
4-26
Chain servicing
Control the length

• Measure e.g. 5 pitches. First rivet in first pitch to first rivet in fifth pitch.
• Multiply the measured length to equal 20 pitches and compare the result with the
lengths listed below. Replace the chain and gears if worn out.
$
Length of 20 pitches should not exceed the length for a worn out chain as
specified below.
$
Be aware that in case either the chain or the gears are worn out, both chain
and gears have to be replaced.
$
To ensure continues high quality and maximize productivity and processor
up-time, it is recommended to change the chains after 5000 production hours
or 4 years what comes first.
C E C
C C E C
D C C
B D
A A D
20 pitches
New = 378 mm
Used = 381 mm
C E C
C C E C
D C C
B D
A A D
12 pitches
New = 225 mm
Used = 227 mm

Maintenance
4-27
Chain servicing
Lubrication
Chain drive should be protected against dirt and moisture and be lubricated with
good quality, non-detergent petroleum based oil. Re-lubrication of chain working
surfaces is desirable.
$
Heavy oils and greases are generally too thick to enter the chain working
surfaces and should NOT be used.
Mineral Oil to ISO VG (SAE30) oil would be suitable.
Care must be taken to ensure that the lubricant reaches the bearing area of the chain.
This can be done by directing the oil into the clearances between the inner and outer
link plates, preferably at the point where the chain enters the sprocket on the bottom
strand. Please see below:
T31682
a
"
Some processors are manufactured with bearing with a
lubricator nipple (a). There will be no need for grease/oil,
as bearing has been lubricated from manufacturer of the
bearing and it will last longer than the life time of your
processor.
T565

Maintenance
4-28
Chain servicing
Chain adjustment procedure

Follow the procedure below when chain adjustment is needed.
Complete view
Refer to the steps described later and indicated in the drawing below.
1 2
T31999
Main chain (1)

• Loosen the sprocket (a) on the drive plate
backside. Loosen the lock nut.
• Adjust the chain tension on the adjustment
screw (b).
a
• Fasten the lock nut and the sprocket. b
T32002
Scrub chain (2)

• Adjust the chain tensioner (c) until the
notch is aligned with thread M5 (d). The
chain tension must be between 10° and
22.5°.
• Mount the lock screw and fasten the chain
tensioner. c
d
T32003

Maintenance
4-29
Preventive Maintenance Kit Program

To ensure a continuous high quality and maximize productivity and processor
up-time, it is recommended to carry out preventive maintenance at regular intervals.
To facilitate this a Preventive Maintenance Program has been developed, consisting of

a number of relevant service parts to be replaced at specific service intervals.
It is recommended that the following Preventive Maintenance Kits are implemented, at

the mentioned intervals, at which point the cycle will start over.
• Minor Preventive Maintenance at 500 production hours or every year what comes
first.
• Medium Preventive Maintenance at 1000 production hours or every year what
comes first.
• Minor Preventive Maintenance at 1500 production hours or every year what comes
first.
• Major Preventive Maintenance at 2000 production hours or every year what comes
first.
"
Please refer to the Spare Parts manual for order numbers for particular kits.
"
Read more about our Preventive Maintenance Kits on www.glunz-jensen.com
and see the content of the Preventive Maintenance Kits - or contact us at
order-department@glunz-jensen.com.

Maintenance
4-30

Trouble shooting
5-1
General
Part 5: Trouble shooting
General
If the processor does not work properly, refer to the following pages to find the
paragraph that comes closest to your problem.
The trouble shooting guide is divided into 4 sections:
A. Problems with the processor

B. Problems with processed material
C. LED signals on PCU PCB
D. LED signals on MIO PCB
For cleaning and maintenance subjects see the processor user manual and chapter 5 in
this manual.
The electrical diagrams are located in Appendix A.
"
To change a fuse, switch off all power to the machine first.
Always ensure that the new fuse is of the correct rating according to the
diagram.
WARNING!
When performing any service, maintenance, calibration, or trouble shooting
etc. it may be necessary to override the function of the processor’s
interlock switches.
In these cases please be aware, that the processor’s jog function is still
active, making the drive system run idle at intervals.

Trouble shooting
5-2
Before starting trouble shooting
Before starting trouble shooting
IMPORTANT!
Plates and chemicals are very sensitive materials and correct storage is vital to obtain a
satisfactory production result. Incorrect storage may very well result in unsatisfactory
processing quality etc.
Contact your local supplier for information about storage requirements for plates and
chemicals.
$
Before making adjustments of the equipment make sure that incorrect storage
of plates and chemicals can be excluded.
Problems with the processor
SYMPTOM PROBABLE CAUSE REMEDY

NO FUNCTION ACTIVE • Main switch turned off or • Connect cable to main
power cable not connected power outlet and/or turn
to main power outlet. main switch on.
• Fuse(s) blown. See PCU • Replace fuse(s).
analyzing on page 5-5.
MACHINE WILL NOT • PCB defective. See PCU • Replace defective part.
START UP analyzing on page 5-5.
MACHINE DOES NOT • Input sensor(s) defective. • Replace defective sensor(s).

START WHEN A PLATE IS See PCU analyzing on page
INSERTED 5-5.
NO WASH WATER • Water tap closed. • Open water tap.

ALTHOUGH MACHINE IS • Water solenoid valve • Replace valve.
IN “PROCESS” MODE defective.
• Water solenoid valve filter • Clean filter.
clogged.
• Processor with level sensor: • Check sensor and clean/-
Level sensor in wash dirty replace whatever is
or defective. necessary.
• Electronics defective. • Replace defective
electronics.
DRYER BLOWER WORKS, • Fuse(s) blown. • Replace fuse(s).
HEATER DOES NOT • Temperature sensor defective. • Replace temperature sensor.
• Heating element defective. • Replace heating element.
electronics.
DRYER BLOWER DOES • Fuse(s) blown. • Replace fuse(s).
NOT WORK • Blower defective. • Replace blower.
electronics.

Trouble shooting
5-3
Problems with processed material

NO GUM ALTHOUGH • Gum container empty. • Refill container.
MACHINE IS IN • Gum hose blocked. • Clean hose.
“PROCESS” MODE • Pump valves blocked or • Clean or replace valve.
defective.
• Pump defective. • Replace pump.
• Fuse(s) blown. • Replace fuse(s).
• Electronics defective. • Replace defective electronics.
GUM PUMP RUNS BUT • Gum hose blocked. • Clean hose.
NO GUM (NO ALARMS) • Pump valves blocked or • Clean or replace valve.
defective.
DEVELOPER • Fuse(s) blown. • Replace fuse(s).
REPLENISHMENT PUMP • Pump defective. • Replace pump.
DOES NOT WORK • Electronics defective. • Replace defective
electronics.
DEVELOPER • Replenishment hose blocked. • Clean hose.
REPLENISHMENT PUMP • Pump valves blocked or • Clean or replace valves.
RUNS BUT NO defective.
REPLENISHMENT • Replenish container empty. • Refill container.
REPLENISHMENT SYSTEM • Replenishment parameters • Make correct settings.

DOES NOT WORK settings not correct.
ALTHOUGH THE MACHINE • Electronics defective. • Replace defective
IS IN ”PROCESS” MODE electronics.
NO DEVELOPER • Fuse(s) blown. • Replace fuse(s).

CIRCULATION • Developer circulation pump • Replace pump.
defective.
NO WATER CIRCULATION • Pump defective or clogged. • Clean and/or repair pump.
• Water spray bar clogged. • Clean spray bar. See Part 4.
• Fuse blown. • Replace fuse.
• Level sensor in wash dirty • Check sensor and clean/-
or defective. replace whatever is
necessary.
ROLLER DRIVE MOTOR • Drive gears and/or worms • Check all gears and worms
RUNS,BUT NO PLATE defective. gears on rollers and make
TRANSPORT sure they move freely.
Replace any defective part.

PLATE IS NOT • Gum section applying too • Check gum section.
COMPLETELY DRY much gum.
• Dryer section is • Check dryer section.
malfunctioning.

Trouble shooting
5-4

PLATE HAS STRIPES • Defective or dirty rollers or • Take rollers and/or guides
LENGTHWISE OR guides. out, inspect and wash them.
CROSSWISE Rollers with dents or other
marks must be changed.
• Brush(es) misadjusted. • Adjust brush(es) according
to description on page 4-14.
• Brush(es) defective. • Replace defective brush(es).
PLATE IS • Developer exhausted. • Change developer.
UNDERDEVELOPED • Machine runs too fast. • Reduce the transport speed
(EXPOSURE IS CORRECT slightly.
AND PLATE NOT TOO OLD) • Developer temperature too • Increase developer
low. temperature slightly.
• Developer circulation • Check function of circulation
insufficient. pump and spray tubes.
• Replenishment insufficient. • Increase replenishment rate
slightly. Calibrate replenish
pump according to
description on page 4-17.
• Brush out of adjustment. • Adjust brush according to
PLATE IS • Machine runs too slow. • Increase the transport speed
OVERDEVELOPED slightly.
(EXPOSURE IS CORRECT • Developer temperature too • Reduce developer
AND PLATE NOT TOO OLD) high. temperature slightly.
• Replenishment setting too • Reduce replenishment rate
high. slightly. Calibrate replenish
pump according to
WASHING NOT • Water tap closed. • Open water tap.
SUFFICIENT • Water solenoid valve • Check valve and filter.
defective or water filter
clogged.
• Spray-tubes clogged or • Clean or adjust whatever is
misadjusted. necessary.
• Water circulation pump • See page 4-10.
does not run.
• Brush misadjusted. • Adjust brush according to
description on page4-14 .
PLATE HAS AN UNEVEN • Gum container nearly • Refill container.
GUMMING empty.
• Gum rollers dirty. • Take rollers out and clean
them.
• Gum distributing tube • Take tube out and rinse or
clogged or out of readjust.
adjustment.
• Gum pump clogged. • Take pump apart and clean
valves.
PLATE'S TRAILING EDGE • Brush pressure too high. • Adjust brush according to
IS BENT description on page 4-14.
• Brush speed too high. • Reduce brush speed.

Trouble shooting
5-5
PCU PCB analyzing LED signals
GREEN RED YELLOW GREEN CONDITION

LED D88 LED D3 LED D2 LED D1
OFF - - OFF The CPU PBC power supply missing.
ON OFF FLASHING ON Waiting for SoM/MIO to power up. If

1.5 sec flashing continues for more than 6
pause seconds after power up, please check
the RS485 cable connection and
follow up on the status stated in this
table.
ON OFF OFF ON Malfunctioning PCU PBU.
ON OFF ON ON The PCU PBU is ready to receive

messages from the MIO/SoM.
ON OFF ON ON The PCU PBU is receiving messages

from the MIO/SoM.
ON ON OFF ON Malfunctioning PCU PBU.
ON ON ON ON Possible hardware error detected but

trying to continue normal operation.
T32012
• LEDs D5 - D12 (green)

– show the status of level sensor inputs 0 - 7
• LEDs DI1 - DI8 (green)
– show the status of digital inputs
• LEDs DO1 - DO8 (green)
– show the status of digital outputs
LED STATUS INPUT/OUTPUT/SENSOR STATUS

ON OK (in level)
FLASHING Disconnected
OFF Not OK (not in level) or not in use

Trouble shooting
5-6
Level sensor LEDs
T32013
LED CONNECTOR COMPONENT IN USE

D6 X9, 5 (c) and 6 Developer min. level sensor
D7 X10, 3 (c) and 4 Wash max. level sensor
Digital ouput LEDs
T32015
LED CONNECTOR COMPONENT IN USE

DO1 X9, 7 and 8 (sink) Wash valve

Trouble shooting
5-7
MIO PCB analyzing LED signals
GREEN RED CONDITION

LED D16 LED D17
OFF OFF The CPU PCB power supply missing or malfunction SoM/MIO.
> 1 minute • Remove all cables from the electronics cabinet (except power
and emergency switch) and try again.
• Check the SoM PCB board connection.
• If still not good, replace the MIO/SoM/LDM PCB board.
ON ON Maybe malfunctioning SoM PCB.
> 1 minute • Remove all cables from the electronics cabinet (except
power, emergency switch and the RS485 cable [P1¬®P1])
and try again.
• Check the SoM PCB board connection.
• If system still don't start up, create (via PC) 2 files -
a "platform" and a "platform.txt" file with the platform text
inside (acu, rtp, hdx, etc.). Store the 2 files on the memory
stick, insert it to the processor's electronics cabinet and power
off and on. Wait at least 3 minutes. Then check (via PC) that
the "platform" or the "platform.txt" file is renamed to
"platform.old" file.
If no file is renamed, replace the MIO/SoM/LDM PCBboard.

ON TOGGLING For software newer than xxx-20111201
Power up sequence: The sequence lasts for approximately 1
minute. The green LED goes off/on approximately 5 times in an
irregular pattern.
OFF ON For software newer than xxx-20111201

Software started: Please see display for status.

Trouble shooting
5-8
MIO inputs
SENSOR CONNECTOR COMPONENT IN USE

R1 J10, 1 and 2 Developer temperature sensor
R2 J10, 5 and 6 Dryer temperature
S1 input sensor J10, 13 and 14 Input sensor
S2 output sensor J10, 15 and 16 Output sensor

Appendix A:
A-1
Electrical diagrams
Appendix A: Electrical diagrams
This chapter includes all electrical diagrams for the processor.
The diagrams (3 pages) cover:

• Page 1 of 3:
Primary wiring
230 VAC, control devices
• Page 2 of 3:
Low voltage wiring
Sensors and control devices
• Page 3 of 3:
Motors and internal bus wiring
24 VDC distribution

A-2
Primary wiring
Primary wiring
230 VAC, control devices

F3 Power Control Unit, PCU
12AF 6 hot 3
F2
5 return 3
12AF 4 hot 2
F1
3 return 2
12AF 2 hot 1
1 return 1
Non interrupted
Non interrupted
X6 RV17 RV13 RV18 RV14 RV27 RV21 RV19 RV20 RV22 RV26 RV31 RV32 RV15 RV16 RV29 RV30
BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24 BTA 24
10057738
L1
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
R46 Q36 Q28 Q44 Q30 Q55 Q45 Q42 Q43 Q46 Q53 Q64 Q66 Q34 Q35 Q54 Q61
150k
Cx
Cy Cy F6 F8 F7
4.7n 100n 4.7n
1AT 1AT 1AT
Max 1A
Max 1A
Max 1A
Max 1A
X102
X101
X109
X104
X103
X108
X105
X106
X107
L4
0.64 mH
8 7 4 3 5 6 1 2 4 2 3 1 8 7 4 3 6 5 1 2 8 7 4 3 5 6 1 2 4 2 3 1 6 5 2 4 1 3 8 7 4 3 6 2 5 1 4 2 3 1 8 7 4 3 6 5 1 2
Cx
100n
L
N
PE
X16,3
X39,2
X39,1
X34,4
X14,2
X14,1
X34,3
X20,3
X31,3
X33,1
X31,2
X21,1
X20,2
X27,2
X27,1
X34,2
X14,4
X14,3
X34,1
X16,1
X16,2
X12,2
X12,1
X37,2
X15,2
X37,1
X15,1
X13,2
X13,1
X26,2
X26,1
X27,1
X27,1
Ground screw
10057740
in Electronics
10058856
10053844
S1
OPTIONAL
OPTIONAL
ON/OFF
10057218
L2
PE
L
N
X21,2
X20,1
X33,2
X31,1
16A 3 2 1
X106,4
X106,2
X102,5
X102,1
X106,3
X106,1
X107,7
X107,4
X104,6
X104,1
X101,4
X101,2
X101,3
X101,1
X101,1
X101,4
X101,2
X104,6
X104,1
X101,3
X101,1
X101,1
X105,6
X105,1
X105,4
X105,5
X105,2
X109,5
X109,1
X12 X15 X26 X37 X14 X20 X21 X34 X31 X33 X39
3 2 1 3 2 1 3 2 1 3 2 1 4 3 2 1 4 3 2 1 3 2 1 4 3 2 1 4 3 2 1 3 2 1 3 2 1 X27
X107,5
X107,1
3 2 1 R40
X29
3 2 1 R
10072807
3 2 1
Blue
Blue
Black
Black
L3
Yl/grn
Yl/grn
Brown
Brown
IEC 60320 M 75 °C 75 °C M 75 °C 75 °C M M 0.4 mH

L PE N Appliance Inlet M X16 M
X13
1000W
C1 C2 Cy Cy
230V AC M3 M4 M23 620W 620W M51 620W 620W M53 M34
3 2 1 M10 2.2n 2.2n
1 W + N + PE M 63 °C E2 E3 E4 E5
X103,4
X103,2
or M13 Dryer Motor Capacitor Dryer Motor Capacitor

Dryer Heating, Dryer Heating, Cx
230V AC E1 Gum Pump Blower Dryer Blower Blower Dryer Blower 68n
2 W + PE Dev. Circ. Dev. Repl. E2 : basis E4 : basis Motor Cooling Fan Plug for Chiller
Pump Pump E3 : reg. E5 : reg. Wash. Circ.
Pump
L
Dev. Water Repl. Dev. Heating

N
Pump M19
OPTIONAL
Dev. Autofill
Pump
10061547 OPTIONAL
Connections for emergency switches Connections for cover switch(es)

on processors with double emergency switch (OPTIONAL) for processor with double top cover (OPTIONAL) OPTIONAL: Power supply for Stacker
X42 X42
10061536 (short vers.)/
1 2 3 4 1 2 3 4 5 6 10076507 (long vers.) 8 7 4 3 6 5 1 2
U2 To PCU X1,1
10063345
24 VDC SUPPLY, 225W CN? To PCU X1,4 10075674
1 X109
For motors 2
+24 VDC 3
4
5
6 To PCU X1,2 X43 X42 X43 X42
X52 7
GND 8 8 7 4 3 6 5 1 2
CN? 9 To PCU X1,5 F7
10 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6
11 L5
4 3 2 1 1 2AT
12
2 +24 VDC 13
3
14
10057309 15 X109
16
10057309 10057309 10063826 10063826
17 To PCU X1,3
GND 18
X109 19 To PCU X1,6
20
10061549 X10
1 2 3 4
X42 S14 S14* S3 S8
Emergency Emergency Cover Switch Cover Switch Mains for stacker
switch switch Double cover Double cover
1 2 3 4 5 6
S14
10063826
Emergency Switch Title: Number: Rev.:
S8 Date: Tuesday, December 16, 2014
Front Primary Wiring
Cover Switch O
Constructor: MLS
ELECTRONIC AND MECHANICAL ENGINEERING
10058007
Function:
Doc. No.:
Approval: This drawing belongs to Glunz & Jensen A/S
230 VAC Control Devices and must not be used or handed over to any
unauthorized person without our specific permission.
Page: 1 Of: 3 OrCAD
A-4
Low voltage wiring
Low voltage wiring
Sensors and control devices

J17
Master In - Out, MIO Serial Peripheral Interface Bus, SPI
1 2 3 4 5 6 7 8 9 10 (for external use)
Processor Interface
Module, PIM
J10 J11 J12 P3 P2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 8 20
2 3 4 5
1
2
Red
S1,1
S1,2
S2,1
S2,2
R1,1
R1,2
R6,1
R6,2
R2,1
R2,2
Blue
Green
Yellow
10041307
Optional Optional
2
1
J10,1
J10,2
J10,3
J10,4
J10,5
J10,6
J10,15
J10,16
J10,13
J10,14
5
3
10035580
1 1 1 1
1 Plate Setter
Red
Blue
Green
Yellow
See Setter manual for actual

R1 R6 R2 S2 S1 pin connections, or contact your
Service Suplier.
Rntc 10K Rntc Rntc 10K
50K
NC NC 2 3 4 5
S28
2 2 2 2 2
Dev temp Preheat temp Dryer temp Output Input

sensor Conductivity Sensor
sensor sensor sensor sensor
(optional)
Power Control Unit, PCU, level input and valve output

0 Vdc Sinus +24Vdc 0 Vdc Sinus +24Vdc 0 Vdc Sinus
LEV0 LEV1 VAL0 VAL6 VAL7 LEV1 LEV2 LEV3 LEV4 LEV5 LEV6 LEV7 VAL0 VAL1 VAL2 VAL3 VAL4 VAL5 LEV0
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
X116 X117
IN 1
IN 0
X9 X10 X11
1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
B1,1
B1,2
K8,1
K8,2
Optional
B15,1
B15,2
B22,1
B22,2
B10,1
B10,2
B11,2
B11,1
B2,1
B2,2
B9,1
B9,2
10057195
X21,2
X21,1
10058855 10061551
OPTIONAL OPTIONAL 10077463
X9,5
X9,6
X9,7
X9,8
1 1
X10,13
X11,9
X10,3
X10,4
X10,14
X10,5
X10,6
X10,7
X10,8
X11,10
X10,9
X10,12
X10,11
1 1 1 1 1
X10,10
X21
15k
24V 1 2
15k
K8
15k
15k
15k
15k
B1 2 2
1 2 1
2 2 2 2 M
Dev tank Wash valve
M24
min sensor 2
15k
Tank Min.
B2 Cont. Min. Cont. Min. Sensor: Cont. Max. Sensor: Cont. Min. Sensor: Sensor :
2 Wash tank Sensor: Dev. fill-up - B11, Dev Waste - B15 Water - B22
max sensor Gum - B9 Biocide Pump
Dev repl. - B10,
(Optional)
Title: Number: Rev.:

Date: Tuesday, December 16, 2014
Low Voltage Wiring
Constructor: MLS
ELECTRONIC AND MECHANICAL ENGINEERING
10058007 O
Function:
Doc. No.:
Sensors And Control Devices and must not be used or handed over to any
Page: 2 Of: 3 OrCAD
A-6
24 VDC distribution

Part of Power Control Unit, PCU P1
DC F20 2.5 AT
+ 3.3 Vdc
(mikrocontroller circuitry) 4 #4
DC TX
F19 4AT 8 #8
24 VDC from CN 5 on PSU 1 3 2 + 24 Vdc TX
X1 (DC output supply)
U? 2 #2
F18 .
RX
CN5, 5 4 LM78L05 98516
8 1 + 5 Vdc Q? 7 #7
IN OUT RX
GND
+
1 3 #3
3
CN5, 1 0.6 AT 0V GND
100 R 1 #1
+ 24 Vdc 6 #6
5 #5
CN2, 3 5 Dual Motor Controller
BTN7930 9 #9
+
CN2, 6 2 10AF
CN2, 15 6 P1
BTN7930
+
CN2, 18 3 10AF 4
TX
#1
#2
#3
#4
#5
#6
#7
#8
#9
8 P2
TX
2
IN 6
IN 7
RX
1
2
3
4
5
6
7
8
9
24 VDC from CN 2 on PSU 2 Part of Master In- and Out, MIO

(interrupted by E-stop 7 See page 2 of 3 for connection to input
RX
BTN7930
BTN7930
BTN7930
BTN7930
and cover switch) 3 and temperature sensors
GND
100 R 1
6
5
X36 1 2 3 4 5 6 7 8 9 10
9 J16
J4
Display driver plug-in PCB 10062307 (optional)
10057540
390 R
390 R
signal
signal
X5 X4 X12 X13
+ + + + J3
1 4 2 6 3 5 1 4 2 6 3 5 1 4 2 6 3 5 1 4 2 6 3 5
M2,5
M2,1
M2,7
M2,2
M2,6
M1,5
M1,1
M1,7
M1,2
M1,6
F18 F17
4AT 5AT
OUT RED
OUT GREEN
OUT (EXTRA)
DISPLAY (SERIAL)
IN 1
IN 2
IN 3
IN 4
IN SIGNAL E-STOP
GND
GND
GND
GND
GND
GND
GND
OUT WHITE
+12VDC
+12VDC
+12VDC
+12VDC
+12VDC
GND
GND
J2
X1 X2 X3
10057223
10057224
1
2
1
2
3
4
1
2
3
4
1
2
3
4
7
8
9
10
11
13
14
15
16
12
10062011
DISP.,2
DISP.,1
J21,3
J21,1
J21,2
J20,2
J20,8
J20,3
J20,1
J20,4
J20,5
J20,6
J20,8
10062070
10061537
X2,3
X2,1
J2,2
J2,4
J2,1
J2,9
J2,8
J2,14
J2,16
J2,12
J2,11
J2,13
J2,10
1 2 J20
X5,4
X5,1
X5,3
X5,5
X5,2
X4,4
X4,1
X4,3
X4,5
X4,2
1 2 3 4 5 6 7 8
Keyboard with
M2 M1 diodes.
H1
S10
S11
H3
H2
S13
S12
GND
Man Machine Interface, MMI 1 2 3

1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8 TOUCH DISPLAY
S13
S12
GND
10069154 10069154 8 5 4 6 7
GND
GND
GND
GND
GND
H1 H2 H3 S10 S11
1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8
150R
150R
150R
One-line display
Error Ready Power On

LED LED LED Arrow up Plate Eject
RED GREEN WHITE
3 2
GND
GND
S12 S13
Red
Red
Black
Black
White
White
Enter Man. Replenish
Vcc
Vcc
Black
Black
White
White
M
M
X X
Brush motor, Dev, M2 Transport motor, M1

Processor is equipped with EITHER
Encoder S31 Encoder S30 Title: Number: Rev.:
Date: Tuesday, December 16, 2014
touch display OR one-line display Motors and Internal Bus Wiring
Constructor: MLS 10058007 O
Function: ELECTRONIC AND MECHANICAL ENGINEERING
Doc. No.:
24 Vdc distribution and must not be used or handed over to any
Page: 3 Of: 3 OrCAD
A-8

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Service Manual

Plate Processor 86/860

Edition BI, January 2015

The directions given must not be followed by unauthorized personnel.

This manual is published by: GLUNZ & JENSEN A/S

Copyright © 2012 by GLUNZ & JENSEN A/S.

Service Manual - Plate processor 86/860, 125/126/1250 1245

Part 0: General information

Notes, cautions, and warnings !

Symbol Meaning Explanation

" Note information in order to obtain the best possible function of

The operator must observe and/or act according to the

$ Caution information in order to avoid any mechanical or electrical

The operator must observe and/or act according to the

# Warning information in order to avoid any personnal injury.

1245 Service Manual - Plate processor 86/860, 125/126/1250

Unintended use of the equipment

Intended use of the equipment

"End of lifetime" disposal

Service Manual - Plate processor 86/860, 125/126/1250 1245

1245 Service Manual - Plate processor 86/860, 125/126/1250

Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3

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

Service Manual - Plate processor 86/860, 125/126/1250 1245

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

1505 Service Manual - Plate processor 86/860, 125/126/1250

Fill up (Clear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Part 3: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Part 4: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Service Manual - Plate processor 86/860, 125/126/1250 1505

1505 Service Manual - Plate processor 86/860, 125/126/1250

Calibration of the conductivity sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Part 5: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

Service Manual - Plate processor 86/860, 125/126/1250 1505

Spare Parts Manual, Plate Processor (1)

Service Manual, Plate Processor (2)

1245 Service Manual - Plate processor 86/860, 125/126/1250

CE Declaration Of Conformity (3)

Safety Instruction Manual (4)

User's Manual, Plate Processor (5)

Quick Intro, Control Panel (6)

Maintenance Chart, Plate Processor (7)

Recycling Passport, Plate Processor (8)

Service Manual - Plate processor 86/860, 125/126/1250 1411

Part 1: Technical specifications

General environmental information

The processor does not contain

1245 Service Manual - Plate processor 86/860, 125/126/1250

Plate width 240 - 860 mm 240 - 1250 mm

Plate length 325 mm

Plate thickness 0.15 - 0.40 mm

Plate speed 50 - 240 cm/min

Brush speed 40 - 125 rpm

Wash (optional with

Service Manual - Plate processor 86/860, 125/126/1250 1505

Dryer, process 50 °C (122 °F)

Pressure > 1 bar (15 psi)

Stand-by 0.0 l/min

Water supply 12 mm (¾")

Drain, developer 20 mm (0.79")

Drain, wash 20 mm (0.79")

Weight, processor 312 kg (688 lb) 340 kg (749.6 lb)