Service Manual: Plate Processor 85

Service Manual
Plate Processor 85
Service Manual
Plate Processor 85
T31888
Edition AE, February 2011

This book has part No. 51658
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

Haslevvej 13
DK-4100 Ringsted
Denmark
Phone:+45 57 68 81 81
E-mail: gjhq@glunz-jensen.com
Internet: www.glunz-jensen.com
Copyright © 2010 by GLUNZ & JENSEN A/S.
Service Manual - Plate Processor 85 1008

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 personal 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.
1008 Service Manual - Plate Processor 85

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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
User's manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
Part 1: Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

General environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
The processor does not contain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Plastic parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
End of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Chemical emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Heat 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
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Exit table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dimensions (thermal/conventional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dimensions (polymer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrical specifications (thermal/conventional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

General Information
0-7
Table of contents
Electrical specifications (polymer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Processor/setter connections (ctp online processors) . . . . . . . . . . . . . . . . . . . . . . . 2-7
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Adjustment of lid switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Cleaning the processor tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Water connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Mounting of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Levelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Mounting the filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Filling up developer and wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Pre-wash/wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Installing the cooler unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Mounting the feed table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Mounting the fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Mounting the exit table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Placing the containers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Installation of setter interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

General Information
0-8
Table of contents
Finishing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Switching the processor on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Part 3: Gecko setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Necessary tools and software requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Downloading PCLoadW.exe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Installing USB to COM driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Connecting to PCU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Setting up of HyperTerminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Parameter setting/calibrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Plate sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Part 4: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Pre-heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Pre-wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Power control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Printed circuit board foil (PCB foil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Controls and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Function keys - standard function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
(1) Eject plate/manual function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
(2) Manual replenisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Function keys - service function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
(1) Test function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
(2) Pump calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
(3) Power (yellow) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
(4) Ready (green) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
(5) Alarm (red) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Jog function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Part 5: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

General Information
0-9
Table of contents
Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Standard recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Special recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Cleaning of the circulation pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Cleaning of valves in the replenish and small circulation pump . . . . . . . . . . . . . . . 5-7
Adjustment of gum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cleaning of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Developer section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Wash section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Replacement of bearing bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Adjustment of gears for wash brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Adjusting the brush pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Processor conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Adjustment - method A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Adjustment - method B. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Calibrating of the replenish pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Part 6: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Before starting trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
MMI alarm signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
PCU analyzing LED signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Appendix A: Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

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

General Information
0-10
Manuals
Manuals
A complete set of manuals consists of the following:
1 2 3 4 5
nual ual ctions ual
s Ma e Man Instru s Man
Part Servic Safety User’
Spare
T3191
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".
Processor Spare Parts Manual (1)

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

Language: English
Contents: Technical specifications
Installation
PCU software installation
Functional description
Maintenance
Trouble shooting
Electrical diagrams

General Information
0-11
Manuals
User's manuals
User's manuals available for the equipment:
CE Declaration Of Conformity (3)

Languages: Various
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
Keep the manuals with the machine for reference at all times.

General Information
0-12
Manuals

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: 61 dB (thermal/conventional) or 60 dB (polymer)
Stand-by mode: 41 dB (thermal/conventional) or 57 dB (polymer)

1-2
Mechanical specifications
Chemical emissions
Ozone: 0 mg/m3
Dust: 0 mg/m3
Styrene: 0 mg/m3
Heat emissions
See "Power consumption" on pages 1-6 and 1-7.
Performance
Plate types Single sided

thermal and polymer offset plates
Plate width 200 - 850 mm

min.- max. (7.9 - 33.5")
Plate length 290 - 1100 mm

min.- max. (10.8 - 43.3")
Plate thickness 0.15 - 0.30 mm

min.- max. (0.006 - 0.012")
Plate speed 50 - 140 cm/min

(19.7 - 55.1 "/min)
Brush speed 100 rpm
Tank capacities
Pre-wash (optional with

13 l
integrated water circulation)
(3.5 US gal.)
ex. pumps etc.
Developer, total 22.0 l
ex. pumps etc. (5.8 US gal.)
Wash (optional with

13.5 l
integrated water circulation)
(3.6 US gal.)
ex. pumps etc.

1-3
Temperatures
Pre-heat 70 - 140 °C
min. - max. (158 - 284 °F)
Developer 20 - 40 °C
min. - max. (68 - 104 °F)
Dryer, process 35 - 55 °C
min. - max. (95 - 131 °F)
Water requirements
Thermal/Conventional Polymer
Pressure
min. - max. 1 - 6 bar (15 - 87 psi) 2 - 6 bar (29 - 87 psi)
Water consumption
Operation 16 l/min 16 l/min

(if no wash recirculation) (4.2 US gal/min) (4.2 US gal/min)
Stand-by 0.0 l/min 0.0 l/min

(if no wash recirculation) (0.0 US gal/min) (0.0 US gal/min)
Weights
Weight, crated approx. 305 kg (672 lbs) approx. 430 kg (948 lbs)*
Weight, processor approx. 235 kg (331 lbs) approx. 307 kg (677 lbs)*
*) w.o. tables, w. 3 brushes)
Exit table
Capacity Max. 30 plates

NOTE! Consider risk of scratches

1-4
Dimensions (thermal/conventional)
Side view
264.7 cm (104.2”)
97.6 - 106.6 cm
82.7 - 91.7 cm 79.3 - 88.3 cm (38.4 - 42")
(32.5 - 36.1") (31.2 - 34.8”)
75.3 cm (29.6")
98.5 cm (38.8")
Top view
115.5 cm (45.5”)
125.4 cm (49.4")
97.1 cm (38.2")
88.5 cm (34.8")
93.2 cm (36.7")
40 cm (15.8") 110.2 cm (43.4")

T31886

1-5
Dimensions (polymer)
Side view
344.7 cm (135.7”)
97.6 - 106.6 cm
82.7 - 91.7 cm 79.3 - 88.3 cm (38.4 - 42")
(32.5 - 36.1") (31.2 - 34.8”)
117.3 cm (46.2”)
140.5 cm (55.3”)
Top view
194.5 cm (76.6”)
54.8 cm (21.6”)
125.4 cm (49.4")
97.1 cm (38.2")
88.5 cm (34.8")
93.2 cm (36.7")
40 cm (15.8") 30 cm (11.8") 110.2 cm (43.4")
T31886

1-6
Electrical specifications (thermal/conventional)
Electrical specifications (thermal/conventional)
Power supply
Supply/Fuse Recom. cable type

Single Phase, 1W + N + PE Min. 3 x 1.5 m2, type H03VV-F
EUR
230V / 1x16 Amps, 50-60 Hz
Single Phase, 2W + PE Min. 3 x 16 AWG, type SJO
US
230V / 2x15 Amps, 50-60 Hz
JAP
200V / 2x15 Amps, 50-60 Hz
All Voltage tolerance +10%/-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 V AC operation:
EUR/ approx. 6000 BTU/hour
US Stand-by:
approx. 200 BTU/hour
Noise level
See “General environmental information” on page 1-1.

1-7
Electrical specifications (polymer)
Power supply
Supply/Fuse Recom. cable type

Single Phase, 1W + N + PE Min. 3 x 1.5 m2, type H03VV-F
EUR
230V / 1x16 Amps, 50-60 Hz
US
230V / 2x20 Amps, 50-60 Hz
JAP
200V / 2x15 Amps, 50-60 Hz
All Voltage tolerance +10%/-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 V AC operation:
EUR/ approx. 9000 BTU/hour
US Stand-by:
approx. 3400 BTU/hour
Noise level
See “General environmental information” on page 1-1.

1-8

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.
> 365 cm ( 143.7") - thermal/conventional
> 445 cm ( 175.2”) - polymer
> 60 cm (23.6")
> 286 cm ( 112.6”)
Feed table
Exit table
(optional)
(optional)
> 50 cm (19.7") > 50 cm (19.7")
Processor
> 100 cm (39.4")
T31885
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

100 x 40 cm (39.4 x 15.7")
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 pages 1-6 and 1-7).

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 doorways are …
If width of the door is… Then…

> 1400 mm > 2200 mm No action is required as the crated
processor can be transported
immediately to the installation site.
1250 - 1400 mm 2000 - 2200 mm The Service Technician has to unpack
the processor.
< 1250 mm < 2000 mm 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

4 persons are needed for lifting the processor down from the pallet. Follow the
procedure described below (see illustration below).
• Two persons are needed on each side of the processor for lifting. Mount the two
pipe bars (1) enclosed with the processor as shown on the illustration (2).
• Lift the processor down the pallet and place it on the installation site.
Do not use a fork lift truck or a pallet mover to lift the processor off the pallet.
"
T31918

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.

Remove the screws (1) securing the fenders (2) to the stand and lift of the left and right
fenders.
T31919

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

The main power connection must be made to the main connector (a) in the electronics
cabinet (b).
• Check the processor connections (see pages 1-6 and 1-7) for the current wiring type.
a
b
T3192
Stacker connection
Not all models (accessory equipment). See separate stacker manual.
Processor/setter connections (ctp online processors)

Not all models (accessory equipment). See separate interface manual.

Installation
2-8
Mechanical installation
Adjustment of lid switches

Adjustment of the lid switches may be needed after leveling 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

Before installing rollers and covers it is necessary to vacuum clean the tank (5) to
remove sponge rubber remains and dust etc.
3
5
T31921

Installation
2-9
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 to the
NIPPLE
front left, 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
Mounting of rollers
On the top of the dryer cover is(are) mounted label(s) (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 inside the top cover.
a b
10
T31922

Installation
2-10
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 ex. 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 levelling if required.
6 7
5
6
SETTER OUTPUT
HEIGHT ÷ 2 mm
OR
FLO
T31923
3 2

Installation
2-11
Mounting the filter

Install the filter insert. The filter is placed underneath the unit in the left side and
mounted on a bracket.
180°
O
PE
CL N
O
SE
D
CL
O
SE
D
T3192
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.
Pre-wash/wash
Pre-wash/wash water recirculation system.
If the processor is equipped with a T3155
pre-wash/wash water recirculation system
the pre-wash/wash section will fill up
automatically when the processor is
switched into stand-by mode.
No pre-wash/wash water recirculation.

The water solenoid valve will let in water
when a plate is entered through the input slot. OPEN CLOSED
T31925

Installation
2-12
Installing the cooler unit

Not all models.
! The cooler unit cannot be installed with the conventional model.
An external cooler unit can be connected to the developer section.

• Place the cooler (a) behind the processor.
• Lead the hoses for the cooler unit through the hole (b) in the rear panel.
• Connect the "COOLER OUTLET" hose (c) to the cooler outlet (f) and the "COOLER
INLET" hose (d) to the cooler inlet (e). Tighten the nuts of the cooler in- and outlets.
It is very important that the "COOLER OUTLET" and "COOLER INLET"

" hoses are connected correctly according the description above.
• Lead the cooler cable (g) through the hole (h) in the tank into the fender. Ensure
smooth passage for the cable.
• Fix the cooler cable in the cable clamp (i) and mount the wires in the terminal X16 (j),
located next to the electronics cabinet inside the fender on the right side of the
processor. Connect:
– the brown wire to the terminal 1 - line regulation,
– no connection to the terminal 2 - line constant,
– the blue wire to the terminal 3 - neutral,
– the yellow-green wire to the terminal 4 ( ) - PE.
a
f b
e
ENTRATA
IN
USCITA
OUT
c
d
j
ENTRATA
IN
USCITA
OUT
g
h
T31926
g

Installation
2-13
Mounting the feed table

Offline processors only!
• Mount the guide pins (1) on the feed table (2) by using the screws (3).
• Insert the nuts (4) into the tank wall throughout the front panel and adjust them
with the screwdriver if needed to secure that the screws (5) fit the nuts (4). Do not
tighten the screws. For polymer use the screw (7) instead of the nut (4) and the
screw(5).
• Hang the feed table (2) on the screws (5) and then tighten the screws.
• Secure the feed table from the bottom by using the two screws (6) .
4 3 T31927
5
7
6
Mounting the fenders

• Mount the left and right fenders (1) with the screws (2).
T31928

Installation
2-14
Mounting the exit table
• Mount the two brackets (1) by using the four screws (2).
• Mount the exit table (3) by using the two screws (4) and lift it to the horizontal
position.
• Insert the supports (5) from the inside of the exit table (3) and secure them by using
the screws (6).
• Lead the supports through the lower holes in the rear panel (7) and secure them
inside using the enclosed locking split pins (8).
2
4
1
7 6
8
T31929

Installation
2-15
Placing the containers

• Place the waste container (1) underneath the processor in the right side, and place
the replenishment containers (2) in the left side as shown on the illustration.
T3193

Installation
2-16
Power supply cable

The cable/plug required for main power connection is delivered with some models
only. The power supply table shows recommended power supply cables for processors
delivered without cable.
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.
T31931
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
2-17
Finishing installation
Start-up
Switching the processor on

• Make sure that the containers (4) are sufficiently filled.

• Turn main switch (1) to ON/I.
• The “Power" indicator (2) is lit. The processor initalizes for about 3 sec. then turns in
to wait mode ("Ready" indicator (3) flashing) until the temperature in the developer
section is at the set point, and the water section (not at all models) is filled up.
• When "Ready" indicator (3) lights up constantly the processor is ready to process
the plates.
T31932
The initial jog (after power has been applied to the processor) runs for 1 minute.

Installation
2-18

Gecko setup
3-1
Part 3: Gecko setup

Software is installed from the factory and software installation is required only for
# upgrade or repair situations.
Necessary tools and software requirements

• PC for online connection to the processor,
• A-B USB cable (G&J part number 10018226),
• Driver software CDM 2.04.16 or higher (can be downloaded from G&J home page
www.glunz-jensen.com),
• Microsoft HyperTerminal (standard communication tool under Windows) or
PuTTY terminal (can be downloaded from www.chiark.greenend.org.uk).
Software is downloaded from a Windows PC connected to the processor using the USB
cable (see illustration below).
Windows PC
Processor
USB cable T31933

Gecko setup
3-2
Downloading PCLoadW.exe
Downloading PCLoadW.exe
• Enter www.glunz-jensen.com/support and download the Gecko software package
to a folder on your PC hard drive.
• Unzip the files.
• On your PC locate and open the folder copied from the web site.
Installing USB to COM driver

Supported OS:
# - Windows Server 2008,
- Windows Server 2008 x64,
- Windows Vista,
- Windows Vista x64,
- Windows Server 2003,
- Windows Server 2003 x64,
- Windows XP,
- Windows XP x64,
- Windows 2000.
• Locate the driver CDM X.XX.XX in

the PCLoadW folder.
• Run the CDM X.XX.XX.exe.
• Wait for driver installation to complete.

Gecko setup
3-3
Connecting to PCU board

• Open Windows Device Manager:
Start -> Settings -> Control Panel.
• Open Performance and Maintenance
folder.
The Control Panel view and it's

# folder structure depends on the
settings made for the Explorer
and the actual Windows version.
• Open the System folder.
• Select the Hardware tab.

• Click Device Manager.

Gecko setup
3-4
• Power ON the processor.

• Connect a USB cable from the PC to
the processor's X112 USB plug in the
electronics box.
• Wait for the USB COM port to show

up in the Device Manager.
If the device is not displayed

# as serial port the possible
causes are:
- Processor power is off.
- The USB cable is damaged.
- USB to COM driver is not
installed.
• If COM port number is between 1 and

8, continue on the page 3-7. If not,
continue with the description of
changing COM port below.
• Right mouse button click on USB
Serial Port (COMX) and left mouse
button click on Properties.
• Select the Port Settings tab.

• Click Advanced.

Gecko setup
3-5
Setting up of HyperTerminal
• Change COM Port Number to a

number between 1 and 8.
• Close all windows (click the OK
button).
• Reopen the Device Manager to verify
that the COM port number in device
name is updated.
• Close the Device Manager again.
• Make sure that the processor is powered ON.
• Make sure that a USB cable is connected from the PC to the processor's X112 USB
plug in the electronics box.
• Open a new hyper terminal: Start -> Programs -> Accessories -> Communication
-> HyperTerminal (alternatively use a PuTTY terminal; see page 3-2 for download
reference).
• Enter an appropriate name and click

OK.

Gecko setup
3-6
• Select the COM port number found in

the Windows Device Manager (see
page 3-4).
• Setup the Port Settings:

– Bits per second: 38400,
– Data bits: 8,
– Parity: Even,
– Stop bits: 1,
– Flow control: None.
• Click OK.
• Press the Enter key in the blank area

to show menu system.

Gecko setup
3-7
Parameter setting/calibrating
All default setting is taken out from a general Thermal plate/chemistry setting and can
be changed for special plate/chemistry application.
Name Unit Default Min. Max.

Processed plates 0 0 2147483648
Processed area (m2) 0 0 2147483648
Total process time (min) 0 0 2147483648
Variant 0* 0 2
Preheat set temperature (°C) 110 70 140
Speed (cm/min) 100 50 140
Dev set temperature (°C) 24 20 40
Dev time replenish (ml/h) 50 0 200
Dev area replenish (ml/m2) 100 0 500
Dev replenish pump capacity (ml/min) 2500 0 5000
Dev manual replenish amount (ml) 500 0 36000
Wash re-circulation 0 0 1 (=ON)
Wash area replenish (ml/m2) 500 0 5000
Dry duty cycle (dryer temperature)** (%) 100 0 100
*) Default setting for polymer model is 1.

**) Dry duty cycle is the temperature regulation for dryer section.
Dry duty cycle set to 100% is equal to dryer temperature 52-55°C.
Plate sizes
Plate table contains the 10 most common sizes and in case there are used special plate
sizes please change the plate sizes at on the number where the sizes is closest to the
new sizes.
Length (mm) Width (mm)

370 260
260 370
520 370
410 520
550 560
560 550
740 520
610 740
810 570
1030 790

Gecko setup
3-8
• Follow the on screen guide to change

settings.
To setup serial number type

! "duy" to list serial numbers
menus. To hide serial number
menus type "logout".
Example how to change settings:

• Choose one of the settings to be
changed, e. g. speed.
• Type "6" and press "Enter".

Gecko setup
3-9
• Type a new value, e. g. "100" and

press "Enter".
• Continue with the next settings.

Gecko setup
3-10

4-1
General
Part 4: Functional description
General
The basis processor contains four major sections:
3 4 5 6
Thermal/Conventional
1 2 3 4 5 6
Polymer
T11199
1 Pre-heat Hardening of the emulsion of the exposed plate by ciculation of hot air.
2 Pre-wash Washing and brushing off the PVA-coating from the plate.
3 Developer Developing of the plate and removing of the remaining unexposed emulsion.
4 Wash Washing off the developer chemicals from the developed plate.
Application of a thin layer of gum onto the developed and washed plate to
5 Gum
protect it from oxidation, dirt, fingerprints etc.
6 Dryer Drying of the plate to ensure immediate handling of the plate.
The processor sections are described in detail on the following pages.
Plate sizes must be entered in the "PLATE SIZES" menu in order to obtain
! exact calculation of replenishment.
Controls and indicators

The controls and indicators are described later in this chapter.

4-2
General
PRE-HEAT
S1
INPUT SENSOR
RESETABLE
THERMAL CUT-OUT
E10 + E11
HEATING ELEMENTS
R6
PRE-HEAT
TEMP. SENSOR
M
M7
PRE-HEAT
FAN
AIR
T31898

4-3
General
PRE-WASH, TAP WATER
TAP WATER
K6
VALVE
FLOW LIMITERS
SPRAY TUBE
DRAIN
PRE-WASH, CIRCULATION WATER
TAP WATER
REPLENISH
K6
VALVE
FLOW LIMITERS
OVERFLOW
SPRAY TUBE
PRE-WASH TANK
MIN. SENSOR B16
M8
PRE-WASH M
BRUSH
MOTOR
DRAIN
VALVE
CIRC. PUMP
M5 DRAIN
T31952

4-4
General
DEVELOPER
S1
INPUT SENSOR
OVERFLOW
SPRAY TUBE
M1 TRANSPORT M E1 DEV. HEATING B1 DEV. TANK

ROLLER MIN. SENSOR
MOTOR
M2 DEV.
M
BRUSH R1
MOTOR
TEMP. SENSOR
M3
DEV. CIRC.
PUMP
(IWAKI)
M4
DEV REPLENISH FILTER
10"
50 my
COOLER
REPLENISH NOT ALL MODELS WASTE
T31898

4-5
General
WASH, TAP WATER
TAP WATER
K8
VALVE
FLOW LIMITERS
SPRAY TUBE
DRAIN
WASH, CIRCULATION WATER
TAP WATER
REPLENISH
K8
VALVE
FLOW LIMITERS
OVERFLOW
SPRAY TUBE
WASH TANK B2
MIN. SENSOR
DRAIN
VALVE
CIRC. PUMP
M10 DRAIN
T31899

4-6
General
GUM
APPLICATION TUBE
M23
GUM CIRC. PUMP
DRAIN
GUM
DRYER
S2
OUTPUT SENSOR
T31900
M M9
FAN
HEATING
ELEMENT
E2+E3

4-7
Transport system
Transport system
The plate is transported through the processor by a series of rollers and roller guides.
The rollers are driven by a drive motor and a worm gear drive system.
See the identification roller label(s) placed on the dryer cover as a reference.

4-8
Transport system
Remote surveillance
PC
GNUXB (optional)
PCU
GNUIB Plate
Setter
PCB foil
T31934

4-9
Electronic control
Electronic control
See illustration opposite.
The electronics consists of:
Power control unit (PCU)

The whole electronic system is controlled by the PCU-board.
It has two separate communication lines (buses):
• GNUIB for all internal communication in the processor.
• GNUXB for external communication between the processor and a PC.
The PCU-board holds all the high voltage in- and outputs for the control of heaters,
motors etc.
On the PCU-board is a switch S2 for PCU settings. The setting should be as illustrated
below:
S2
1 2 3 4
OFF
S2
1 2 3 4 ON
OFF
= ON = OFF
T31935
Printed circuit board foil (PCB foil)

The PCB foil is the Control Panel board from which the user operates the processor.

4-10

The processor is equipped with the function keys located at the back of 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 developer section.
(Red)
5
1
(Green)
4
2
(Yellow)
3
T31936
Function keys - service function
(1) Test function

Push and hold the key (1) for 10 sec. and all motors, pumps, blowers etc. will now start
and stop in a continuous loop until the key (1) is pushed and held once again for 10
sec.
(2) Pump calibration

When the test function is started, push the key (2) and the replenish pump M4 will
now run for one minute.

4-11
Indicators
The indicator panel is located on the right fender facing upwards.
The panel holds 3 indicators:
(3) Power (yellow)

When this indicator lights up then the processor is powered on.
(4) Ready (green)

This indicator has 3 different states indicating various processor conditions:
State Condition
Off The processor is initializing.
The processor is currently processing a plate.
The processor is in "Processing Mode".
Alarm indicator is lit:
The processor is in "Alarm State"
See description of Alarm indicator for details.
Lit The processor is in "Standby Mode" and ready to process.
Flashing The processor is in "Processing Preparation Mode".
(5) Alarm (red)

This indicator is flashing if:
• The processor is in "Alarm Mode".
See "Part 6: Trouble shooting" later in this manual for a list of possible
alarms/errors.
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 1 minute.
After that the jog will run for 1 minute every 11 minutes.

4-12

Maintenance
5-1
General
Part 5: 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 web site: 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
5-2
Safety check
Safety check
Below described safety check 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(es):
Processor must stop when the switch(es) is deactivated.
– Main switch:
Processor must turn off when set to "0".
– Emergency stop:
Processor must turn off when activated.
Control panel
Emergency
stop
Lid switch
Main switch
Electronics
cabinet
Upper
side panel
T31937
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
5-3
Fuses
Fuses
Fuses for motors are placed in the fuseholders in the cables
by the motors behind the left fender.
Fuse
T31938
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.
T31939
Fuses
When changing a fuse, first switch off all power to the machine.
! Always ensure that the new fuse is of the correct rating according to the label.

Maintenance
5-4
Rollers and brush rollers
Rollers and brush rollers
General
On the top of the dryer cover is(are) mounted label(s) showing the roller
configuration (a). Each brush/roller is marked with a small number (b). Install the
rollers by referring to the roller numbers on the label.
a b
10
Installation of rollers
Make sure to align the gears on the upper and lower rollers.
" The gear on the lower rollers has a plate/guide that must fit into the gear of
the upper rollers.
T31590

Maintenance
5-5
Cleaning
Cleaning
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
5-6
Cleaning
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 the position of the outlet nozzle (5).
• Dismount the pump.
• Dismount the cover (4) and pull out the impeller (3) and the impeller housing (1).
• Clean the inside of the cover, the impeller and the impeller housing in warm water.
• Reinstall in reverse order, observing that the outlet nozzle (5) of the cover is placed
as it was before dismounting it, and that the o-ring (2) is placed correctly in the
groove of the impeller housing (1).
1
2
3
4
T31064

Maintenance
5-7
Cleaning
Cleaning of valves in the replenish and small circulation pump

If a replenishment or a small circulation
pump ceases to function properly, run it
with some warm water in order to clear
the pump of chemicals.
If this does not help, take the pump
apart and clean the small valve in warm VALVE
water. INLET
NOZZLE
OUTLET
NOZZLE
OW
FL
! T438
Adjustment of gum pump

The gum pump is set with a default approx. 7.5 mm
pulsation from the factory. In case the
amount of the gum pumped into the
application roller is too high or too low
adjustment of the pulsation can be
changed by adjusting as described
below.
Loosen the nut (1) and adjust the screw (2)

on the bottom of the pump bracket to set
up the correct amount of gum by moving
the coil of the pump forward or
backward.
1
2
T31945

Maintenance
5-8
Cleaning
Cleaning of spray tubes
Developer section
Clean the spray tubes in the developer section with hot water to remove potential
blocking of the holes.
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
Replacement of bearing bush

• Remove the spring (1) from the roller bearing (2) by using screwdriver.
• Replace the bearing bush (3).
• Compress the spring and insert it into the roller bearing as shown in the illustration.
T31946
3

Maintenance
5-9
Cleaning
Adjustment of gears for wash brush

Important!
When the main drive shaft has been dismounted/remounted due to change of
! parts, service checks, etc. it is very important to make a final adjustment
according to the description below.
• Mount the main drive shaft (1) on the tank wall and tighten the 2 screws (2) on each
of the 4 brackets (3) holding the shaft.
• Loosen the screws (2) on each bracket (3) 1/4 turn.
• Place a 0.5 mm feeler gauge (4) between the gear (5) and the bearing (6).
Alternatively use pieces of offset plate equal to 0.4 mm - 0.6 mm (e.g. 2 x 0.3 mm
offset plate).
• Turn the gear (7) manually to adjust the space gap between the gear (5) and the
bearing (6) to fit the feeler gauge (4).
• Tighten the screws (2) on the brackets (3) for the main drive shaft.
• Remove the feeler gauge (4).
• Finally make sure that the adjustment has left a small gap between the gears (5)
and (7).
1 3
2
5
6
2
4
7
T31941 6

Maintenance
5-10
Cleaning
Adjustment - method A
+
3
6 2
5a 90°
4 5
Adjustment - method B
400
300
200
100
T31942

Maintenance
5-11
Cleaning
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: default brush speed.
Preparations
• Remove the processor top cover.
• Remove the upper roller (1) in the developer section before adjusting.
• Activate the interlock switch (2).
• 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 (6) (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 (6) 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 film and a spring balance and proceed as follows:
• Insert a strip of polyester film (10 cm wide, approximately 50 cm long, 0.10 mm
thick/4 x 20 x 1/128”) between the brush roller and the lower roller (or guide).
• Activate the manual function button and hold the film strip with the spring balance
against the rotation of the brush, pulling the spring balance upwards.
• Adjust the pressure to a balance reading of 350-400 g (0.77-0.88 lbs) over the entire
brush roller width.
Repeat the procedure for the all brush rollers. All brushes should be adjusted to the
same settings.

Maintenance
5-12
Cleaning
Calibrating of the replenish pump

• Start up the HyperTerminal communication (see Part 3).
• Activate the service mode (see page 3-8).
• Place the suction tube from the
replenish pump into a measuring
cylinder containing 2 litres of
developer.
• Start the replenish pump calibrating
system by pushing . PUMP
• The pump runs for 1 minute.
• Compare the amount value with the
volume actually pumped from the
measuring cylinder (Y). X
Y
T 31943
• Change the original value in the

parameter “Dev replenish pump
capacity” by the actually pumped
value.

Trouble shooting
6-1
General
Part 6: 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. MMI alarm signals
D. PCU analyzing LED signals
For cleaning and maintenance subjects see the processor user manual and Part 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
6-2
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 6-6.
MACHINE WILL NOT • PCB defective. See PCU • Replace defective part.
START UP analyzing on page 6-6.
MACHINE DOES NOT • Input sensor(s) defective. • Replace defective sensor(s).

START WHEN A PLATE IS See PCU analyzing on page
INSERTED 6-6.
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
6-3
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 5.
• 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
6-4

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 5-11.
• 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 5-12.
• 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 5-6.
does not run.
• Brush misadjusted. • Adjust brush according to
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 5-11.
• Brush speed too high. • Reduce brush speed.

Trouble shooting
6-5
MMI alarm signals
MMI alarm signals
LED STATE ALARM CONDITION INDICATOR

CODE* FLASHING
POWER ON - Software is installed -
(YELLOW) and running.
FLASHING - Processor is in "Service -
Mode".
ALARM ON - Cover is open. -
(RED)
- Processor is in "Service -
Mode".
READY - ALARM FLASHING 0 Call manufacturer's
support center. ...
(GREEN - RED)
1 Developer temperature
unexpectedly too high ...
or too low.
2 Preheat temperature
unexpectedly too high ...
or too low.
3 Jam.
...
4 Fill up developer
manually. ...
5 Prewash/wash fill up
has not succeed. ...
6 Motor error (no tacho,

current alarm) ...
*) Alarm code is the number of Alarm (red) LED flashes between Ready (green) LED flashes.

Trouble shooting
6-6
PCU analyzing LED signals

• D1 = green
• D2 = yellow
• D3 = red
• D88 = green
LED STATUS CONDITION

D2 ON + MMI red ON Prewash or top panel not in place
(YELLOW)
+ MMI yellow ON OK
+ MMI yellow OFF Software not running
FLASHING + D3 ON Hardware error
+ D3 OFF Emergency signal disconnected
+ S2-4 ON Software missing
+ S2-4 OFF Set S2-4 ON
D88 ON CPU power supply OK

(GREEN)
OFF CPU power supply missing
T32012

Trouble shooting
6-7
• LEDs D5 - D12 = green

– show the status of level sensor inputs 0-7
• LEDs DI1 - DI8 = green
– show status of digital inputs
• LEDs DO1 - DO8
– show 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
Level sensor LEDs:
T32013
LED CONNECTOR COMPONENT IN USE

D5 X11, 15 (c) and 16 Pre-wash max. level sensor (polymer only)
D6 X9, 5 (c) and 6 Developer min. level sensor
D7 X10, 3 (c) and 4 Wash max. level sensor
LEDs D8 - D12 are not in use.

Trouble shooting
6-8
Digital input LEDs:
T32014

DI3 X114, 5 and 6 (-) Emergency stop
DI5 X114, 9 and 10 (-) Input sensor
DI6 X114, 11 and 12 (-) Output sensor
LEDs DI1, DI2, DI4, DI7 and DI8 are not in use.
Digital ouput LEDs:
T32015

DO1 X9, 7 and 8 (sink) Wash valve
DO2 X11, 3 and 4 (sink) Buzzer
DO6 X11, 11 and 12 (sink) Pre-wash valve (polymer only)
DO7 X36, 10 (source) Pre-wash brush motor (polymer only)
LEDs DO3, DO4, DO5 and DO8 are not in use.

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
230V AC, control devices
• Page 2 of 3:
Low voltage wiring
Sensors and control devices
• Page 3 of 3:
Motors and internal bus wiring
24V DC distribution

A-2
Primary wiring
Primary wiring
230V AC, 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
Non interrupted
Non interrupted
10057738
1 return 1
X6 RV17 RV13 RV18 RV14 RV27 RV21 RV19 RV20 RV22 RV26 RV31 RV32 RV15 RV16 ‘ ! RV30
BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
S14K460
R46 L1 Q36 Q28 Q44 Q30 Q55 Q45 Q42 Q43 Q46 Q53 Q64 Q66 Q34 Q35 Q54 Q61
150k
Cx
Cy Cy F6 F8 F9
Max 1A
Max 1A
Max 1A
Max 1A
4.7n 100n 4.7n
X102
X101
X109
X104
X103
X108
X105
X106
X107
1AT 1AT 1AT
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
POLYMER VERSION ONLY
POLYMER VERSION ONLY

L
PE
X26,3
X16,1
X17,2
X17,1
X46,2
X46,1
X14,2
X14,1
X20,3
X14,4
X14,3
X20,2
X21,1
X27,2
X27,1
X46,4
X46,3
X46,6
X46,5
X39,2; M32,2
X16,2
X16,3
X39,1; M32,1
X12,2
X12,1
X37,3
X37,1
X15,3
X15,2
X26,2
X26,1
10057740
Ground screw
in Electronics OPTIONAL
10055260 10055271
S1
ON/OFF 10052734
X104,5
X104,1
X104,7
X104,4
X102,6
X102,1
X46
15 14 13 12
PE
11 10 9 8 7 6 5 4 3 2 1
X21,2
X20,1
X106,4
X106,2
X107,5
X107,2
X108,2
X106,3
X106,1
X107,7
X107,3
X101,3
X101,1
X101,4
X101,2
X101,3
X101,1
X101,1
X105,6
X105,1
X105,6
X105,1
X105,5
X105,2
X105,4
X109,5
X109,1
X102,7
X102,4
N
L
16A L2
X12 X15 X26 X37 X14 X20 X21 X39 M32 X27 X17
3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1
R40
R
S13,P1
S13,P3
X29,4
X29,3
X29,2
X33,1
Blue
Black
Yl/grn
Brown
E10
E11
L3
IEC 60320 X16
L PE N 75 °C 75 °C 0.4 mH
750W
M M M M M M M
Appliance Inlet
4 3 2 1
Cy Cy
M 10010113
230V AC C1
M3 M4 M23 750W 750W M9 M34 M32 M10 2.2n 2.2n M5
X46,14
X46,1
1 W + N + PE E2 E3
X29,1
X46,2
X46,1
X33,2
X46,11
70 °C
X46,5
X46,6
X46,4
X46,3
or Motor Cooling Fan
PE
Dev. Repl. Gum Pump Dryer
L_reg.
N
250W
L_const
Motor Capacitor Cx
Dryer Heating, Elbox Cooling Fan 68n
230V AC Dev. Circ. Pump E1 Blower Dryer Blower Wash. Circ. X29 X33
E2 : basis PreWash. Circ. 4 3 2 1 3 2 1
2 W + PE Pump E3 : reg. Pump
Pump
Connection For
To PCU X114, 5 and 6
N
Dev. Heating
L
Chiller
See page 2
OPTIONAL S16
X22
Preheater
1 2 P4 P2 P2
Chassis M
10053846 C4
M7
U1 176 °C
CN5 303 2 221
CN1 X49 Preheat Motor Capacitor
1 1 To PCU X1,1
2
3
GND 2
3
blower Dryer Blower
1
4
5 To PCU X1,4 M11
+24 VDC 6
M
2
24 VDC SUPPLY, 125W 7

8
X52 For electronics and valves
4 3 2 1
Electronic fan
10054996
85630 U2
X109 Connections for cover switch(es) 24 VDC SUPPLY, 225W CN2
1
for Polymer versions For motors 2 E10 E11
+24 VDC 3 To PCU X1,5
1 2 3 4 4
5
800W 800W
X42 6 To PCU X1,2
7
GND 8
CN1 9
1 2 10
S14
10056402 1
2 +24 VDC
11
12
13
3
14
15 To PCU X1,6
Emergency Switch 16 Prewash
X42 GND
17
To PCU X1,3
Front X43 X42
18
19
20 800W E11
2 1
1 2 1 2 Plate travel
800W E10
10006411 85696 POLYMER VERSION ONLY
85696 Entry
11 12
11 12 11 12 Title: Number:
Date: Tuesday, September 28, 2010 Rev.:
Primary Wiring G
S8
Constructor: MLS
ELECTRONIC AND M ECHANICAL ENGINEERING
10052946
Function:
S3 S8 Cover Switch
Doc. No.:
Approval:
230 VAC Control Devices
This drawing belongs to Glunz & Jensen A/S
Cover Switch Cover Switch Dev Section and must not be used or handed over to any
Prewash Section Dev Section unauthorized person without our specific permission.
Page: 1 Of: 3 OrCAD
A-4
Low voltage wiring
Low voltage wiring
Sensors and control devices

Valve supply select
PIM in 1 cathode
PIM in 0 cathode
PIM in 1 anode
PIM in 0 anode
PIM out 1 emit
24 VDC motor
PIM out 0 emit

PIM out 1 coll.
PIM out 0 coll.

Power Control Unit, temp and digital input
Val7 source
Val6 source
Thermo +
C sense+
IR out + 0
IR out + 1
DIG IN 0
DIG IN 1
Thermo-
C sense-
Spare2+
IR out - 0
IR out - 1
A/D IN 0
A/D IN 1
Spare2-
OUT 0
OUT 1
OUT 2
OUT 3
PTin+
DEV+
PTin-
DEV-
GND
GND
"Vcc"
FIX+
FIX-
IN 0
IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
X114 X118 X36 X119 X204 X205
X113
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 1 2 3 4 5 6 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
R1,1
R1,2
R7,1
R7,2
X13,2
X13,1
X13,3
X13,5
X13,6
X50,1
X50,2
S1,1
S1,2
S2,1
S2,2
X13,8
10053841
X22
10053492
X204,10
X114,9
X114,11
X204,5
X204,3
X204,7
1 2
X114,10
X114,12
X204,8
X204,1
X118,5
X118,6
X118,7
X118,8
10058590
1 1 X13
1
To emergency stop X52
1 1 2 3 4 5 6 7 8
S1 S2 Keyboard with
GND
S10
S11
H1
H2
H3
R7
X205,5
X205,3
R1
See page 1
diodes.
Rntc 10K 10K
NC NC
2 1
GND
GND
GND
GND
GND
3 4 6 7 8
2 2 S10 S11 H1 H2 H3
2 2
X50
150R
150R
150R
Input Output
MINUS
PLUS
sensor sensor Dev temp Preheat temp NO6 NO7
sensor sensor
(Only Polymer version)
Ready Power On Error
Plate Eject Man. Replenish
LED LED LED
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
-
+
-
IN 1
IN 0
X116 X117 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
X44,2
X44,1
B1,2
B1,1
K8,1
K8,2
K1,1
K1,2
K6,1
K6,2
K6,2
K6,1
10053843 10056070 10055255
X11,4
X11,3
X11,16
X9,8
X11,12
X9,6
X9,5
X9,7
X11,11
X11,15
X44
4b
4c
1 2
1 1
1 1 1
Black
Red
15k
15k
15k
K8 24V B2 K6 24V B16

B1 2 2
2
H1 2
2
Wash valve Buzzer PreWash valve

Dev tank Wash tank Prewash tank
min sensor max sensor max sensor
Only Polymer Version
OPTIONAL
Title: Number: Rev.:
Date: Tuesday, September 28, 2010
Low Voltage Wiring
Constructor: MLS
ELECTRONIC AND MECHANICAL ENGINEERING
10052946 G
Function:
Doc. No.:
Sensors And Control Devices Approval: This drawing belongs to Glunz & Jens en A/S
and m us t not be us ed or handed over to any
unauthorized pers on without our s pecific perm is s ion.
Page: 2 Of: 3 OrCAD
A-6
24V DC distribution

Part of Power Control Unit, PCU P1
DC F27 2.5 AT
+ 3.3 Vdc
4
DC (mikrocontroller circuitry) TX
F28 4AT 8
+ 24 Vdc TX
X1 3 2
U37 (DC output supply) 2

F24 RX
CN5, 5 4 LM78L05
.
+ 5 Vdc Q411 7
8 1
RX
GND
24 VDC from CN 5 on PSU 1 +
IN OUT
CN5, 1 1 0.6 AT 3
0V GND
3
100 R 1
+ 24 Vdc 6
5 Dual Motor Controller 5

CN2, 3 F26
BTN7930 9
+
CN2, 6 2 10AF
BTN7930
24 VDC from CN 2 on PSU 2
(interrupted by E-stop CN2, 15 6 F25 P1
and cover switch) +
CN2, 18 3 10AF 4
TX
8
TX
2
BTN7930
BTN7930
BTN7930
BTN7930
RX
7
RX
3
IN 6
IN 7
GND
100 R 1
6
5
390 R
390 R
signal
signal
9
X5 X4
X36 1 2 3 4 5 6 7 8 9 10
+ +
1 4 2 6 3 5 1 4 2 6 3 5
X18,1; X19,1
M2,1
M2,2
M1,1
M1,2
X19,4
X18,4
3
5
4
5
4
10056352
10053887
X36,9
X36,8
X36,9
X36,10
10053913
4 1 6 5 3 2 4 1 6 5 3 2
X18 X19
10056401
X4,1
X4,4
X5,4
X5,1
X5,2
X5,5
X5,3
X4,2
X4,5
X4,3
F18 F17 F19

4AT 4AT 4AT
2 1 6 3 4 5 2 1 6 3 4 5 2 1 6 3 4 5
Brown
Brown
Brown
Green
Green
Green
White
White
White
Blue
Blue
Blue
Red
Red
Red
1nF 1nF 1nF 1nF 1nF 1nF
6.5uH 6.5uH 6.5uH 6.5uH 6.5uH 6.5uH

M
Dev Brush motor M2 Encoder S31 Transport motor M1 Encoder S30 Prewash Brush Motor M8 Encoder S30
Title: Number:
Date: Tuesday, September 28, 2010 Rev.:
Motors and Internal Bus Wiring

Constructor: MLS 10052946 G
Function: ELECTRONIC AND M ECHANICAL ENGINEERING
Doc. No.:
Approval:
24 Vdc distribution
This drawing belongs to Glunz & Jensen A/S
and must not be used or handed over to any
unauthorized person without our specific permission.

Page: 3 Of: 3 OrCAD

Service Manual: Plate Processor 85

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Service Manual: Plate Processor 85

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Service Manual

Edition AE, February 2011

This manual is for Service Technicians only.

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

Copyright © 2010 by GLUNZ & JENSEN A/S.

Service Manual - Plate Processor 85 1008

Part 0: General information

Notes, cautions, and warnings !

# 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 personal injury.

1008 Service Manual - Plate Processor 85

Unintended use of the equipment

Intended use of the equipment

"End of lifetime" disposal

Service Manual - Plate Processor 85 1008

1008 Service Manual - Plate Processor 85

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

Service Manual - Plate Processor 85 1017

Electrical specifications (polymer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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

1017 Service Manual - Plate Processor 85

Finishing installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Part 3: Gecko setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Part 4: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Part 5: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Service Manual - Plate Processor 85 1050

Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Part 6: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

1050 Service Manual - Plate Processor 85

Processor Spare Parts Manual (1)

Processor Service Manual (2)

Service Manual - Plate Processor 85 1008

CE Declaration Of Conformity (3)

Safety Instruction Manual (4)

User's Manual, Plate Processor (5)

1008 Service Manual - Plate Processor 85

Service Manual - Plate Processor 85 1008

Part 1: Technical specifications

General environmental information

The processor does not contain

1017 Service Manual - Plate Processor 85

Plate types Single sided

Plate width 200 - 850 mm

Plate length 290 - 1100 mm

Plate thickness 0.15 - 0.30 mm

Plate speed 50 - 140 cm/min

Brush speed 100 rpm

Pre-wash (optional with

Wash (optional with

Service Manual - Plate Processor 85 1050

Operation 16 l/min 16 l/min

Stand-by 0.0 l/min 0.0 l/min

*) w.o. tables, w. 3 brushes)

Capacity Max. 30 plates

1050 Service Manual - Plate Processor 85

40 cm (15.8") 110.2 cm (43.4")

Service Manual - Plate Processor 85 1017

40 cm (15.8") 30 cm (11.8") 110.2 cm (43.4")

1017 Service Manual - Plate Processor 85