Ip 85HDX 2010

Service Manual
InterPlater 85/125 HDX

Service manual
InterPlater 85/125 HDX
Edition DA, August 2010

This manual has part No 51579
General Information
0-1
This manual
Part 0: General information
This manual
Products covered
This manual is valid for:
IP 85 Thermal from serial nos. 95507-0001
95558-0001
95560-0001
IP 125 Thermal from serial nos. 95525-0001
95559-0001
95561-0001
The serial number is specified on the processor name plate located on the rear end of
the tank on the left side.
#
This manual is for Service Technicians only.
The directions given must not be followed by unauthorized personnel.
Always read the Safety Instruction Manual part No 21741 before installing the
equipment.
This manual is published by: GLUNZ & JENSEN A/S

Haslevvej 13,
DK-4100 Ringsted
Denmark
Phone:+45 57 68 81 81
E-mail: gjhq@glunz-jensen.com
Internet: www.glunz-jensen.com
Other manuals
Please see description of “Manuals available for the plate processor” later in this
chapter.
Copyright© 2008 by GLUNZ & JENSEN A/S.
1034 Service Manual - Plate Processors 85/125

General Information
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The processor
Reservations
• This manual was written and illustrated using the best possible information avail-
able at the time of publication.
• Any differences between this manual and the equipment reflect improvements intro-
duced after the publication of the manual.
• Changes, technical inaccuracies and typographic errors will be corrected in subse-
quent editions.
• As a part of our policy of continuous improvement, we reserve the right to alter de-
sign and specifications without further notice.
Notes, Cautions, and Warnings

Throughout the manual notes, cautions, and warnings are written in bold like the ex-
ample 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.
The processor
Approvals
• Approvals will appear from the labels attached to the name plate or the frame part
of 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 war-
ranty will no longer apply and the certification labels for UL, C-UL, and
Service Manual - Plate Processors 85/125 1034

General Information
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The processor
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 of 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 installa-
tion is made in accordance with local regulations, and by engineers authorized to
carry out plumbing and electrical installations.
• Installation, service and repair must be performed only by service technicians who
are trained in servicing the equipment. The installation procedure is described in the
separate “Installation manual”.
• The manufacturer cannot be held responsible for any damage caused by incorrect in-
stallation of this processor.
Technical data
• Observe technical data from the processor name plate and from Part 1 in this man-
ual.
Chemicals
• It is the responsibility of the owner of this equipment that data is available concern-
ing 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 ma-
chine must be made according to local regulations with special regards to following
parts:
• For recycling purposes significant components are marked with material specifica-
tion according to the ISO 11469 standard.
• PVC, tank etc., must be sent to a waste deposit with recycling in view. Alternatively
the PVC can be incinerated at a suitable incinerating plant.
• PCB's and other electric equipment must be sent to a suitable waste deposit.
Service assistance
• If help is needed to correct any problem with the equipment, please contact your lo-
cal supplier.
1034 Service Manual -Plate Processors 85/125

General Information
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The processor

Table of Contents
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Table of Contents
Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1

This manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Products covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1
Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
Notes, Cautions, and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
Unintended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
Intended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
“End of lifetime” disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
Service assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3
Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9
Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9
User manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10
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
Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
End of life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Noise emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Chemical emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Mechanical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Tank capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Water requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Installation requirements for power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

Table of Contents
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Part 2: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Processor sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Temperature/level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Replenishment/antioxidation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Plate size replenishment (standard): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Developer filling/topping-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Fill/top-up pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Replenishment/top-up: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
Gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Gum-rinse program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Gum open system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Gum closed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Master input/output unit (MIO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Power control unit (PCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Man machine interface unit (MMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Touch screen control panel (MMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
Part 3: Cleaning and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
PCB fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
PCB PCU fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Motor fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4
Mounting of r-clips for gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
NEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
ALWAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
1/4-yearly service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Adjusting the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Tools: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Developer/wash/gum/dryer transport rollers (A) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Adjusting the brush support rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Tools: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Adjusting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

Table of Contents
0-7
Adjusting the brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Tools: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Processor conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Adjustment (see top illustration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Alternative adjustment procedure (see bottom illustration). . . . . . . . . . . . . . . . . . 3.10
Adjustment of wash section spray tube valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
Cleaning the pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Developer and wash (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Cleaning of valves in the oscillation pump (B) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Cleaning of valves in the replenish pumps (C) . . . . . . . . . . . . . . . . . . . . . . . . . . 3.14
Part 4: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Before starting troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Part 5: Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Spare parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
How to read the spare parts list correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
PCB's and software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Stand closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
Feed / exit tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
Group tank base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13
Circulation and drain: Tap water. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15
Circulation and drain: Water saving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.19
Hoses and clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.23
Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25
Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29
Gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.33
Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.35
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.39
Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.41
Cables (not illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.42

Table of Contents
0-8
Appendix A: Additional spareparts

Appendix B: Electrical diagrams
Main power distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2
Fuse panel and interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.2
Motors and internal bus wiringI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
24V DC distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.4
Primary wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6
230V AC control devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.6
Primary wiring, preheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8
230V AC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.8
Low Voltage Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10
Sensors and control devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B.10

0-9
Manuals
Manuals
1 2 3 4 5
Manua
l
Manua
l ual ructio
ns
tion e e Man Inst
Installa Servic Softw
ar
Safety
6 6 7 o
1/2
51436D
.
8
Intr
ual s Gui
de ick
s Man User’
Qu
User’
on )
Power
(Example
ep
y/Sle
Read
save
Screen X min.
)
er save
(pow
Sleep
)
y (Example
Read
1 sec.
)
(Example
view
Over
1
2
3
(Example)
T31525
7
6
5
4
Service manuals
Service manuals available for the plate processor:
The manuals listed below are for service technicians only. In addition the service tech-
nicians will need the manuals listed later as “User Manuals”.
Processor Installation Manual (1)

Language: English
Contents: Installation of the processor
Processor Service Manual (2)

Language: English
Contents: Technical Specifications
Functional Description
Service Information
Service Maintenance
Trouble Shooting
Spare Parts
Electrical Diagrams

0-10
Manuals
Software Service Information (3)

Language: English
Contents: Menu structure (service menus)
Control Panel, Service Information
Calibration Procedures
User manuals
User manuals available for the plate processor:
CE Declaration of Conformity (4)

Language: Various
Contents: Survey of the directives to which the products conform
Safety Instruction Manual (5)

Language: Various
Contents: General Safety Information
Processor User Manual (6)

Language: 4 (English, German, Spanish, French)
Contents: Operating and cleaning procedures in cartoon version.
Control Panel (user manual) (7)

Contents: Functional description
Menu structure (user available)
Operation and programming
Alarm list
Quick Guide (8)

Language: English
Contents: Survey of Control Panel User Functions
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
The processor complies with the RoHS directive (2002/95/EC).
Plastic parts
Significant plastic parts are marked according to ISO 11469.
Batteries
No batteries in this equipment.
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.
End of life
Estimated product life: 10 years
Spare parts and service period: 7 years after last sales.
Packaging
Plastic packaging materials are marked according to ISO 11469.
Noise emission
Acoustic noise according to ISO 11201:1996

1-2
Mechanical specifications
Sound pressure level

Operational mode: 60 dB
Stand-by mode: < 50 dB
Chemical emissions
Ozone: 0 mg/m3
Dust: 0 mg/m3
Styrene: 0 mg/m3
Performance
Performance 85 125
Plate types Presensitized single-sided positive or negative offset plates.

CTP plates.
For information on chemicals and processing materials please contact your
supplier.
Plate width 200 - 850 mm 200 - 1250 mm

min.- max. (7.9 - 33.5") (7.9" - 49.2")
Plate length 285 mm 285 mm

min.- max. (11.2") (11.2")
Plate thickness 0.15 - 0.40 mm 0.15 - 0.40 mm

min.- max. (0.006 - 0.016”) (0.006 - 0.016”)
Plate speed 40 - 220 cm/min. 40 - 180 cm/min.

(15.7 - 86.6 "/min.) (15.7 - 70.9 "/min.)
Brush speed
Developer 40 - 130 rpm
Wash 40 - 130 rpm
Tank capacities
85 125
Developer 54 l (14 US gal.) 79 l (20.9 US gal.)
Wash 14 l (3.7 US gal.) 20.5 l (5.4 US gal.)
Gum (optional 3.5 l (0.9 US gal.) 4.2 l (1.1 US gal.)

double-gum)

1-3
Temperatures
85 125
Developer
18 - 35 °C (64 - 95 °F)
(min. - max.)
Dryer, process
30 - 55 °C (86 - 131 °F)
(min. - max.)
Water requirements
85 125
Pressure 1 - 6 bar (15 - 87 psi)
Min. - max. Min.recommended water pressure with tap water installation
= 2.75 bar (40 psi) + 19 l/min (5 gal./min.)
Dimensions
L1 W
L4 L3 L2 L5 L6
H1
H2 H3
T31739
Processor 85 125
Width, total (W) 133 cm (52.4") 173 cm (68.1")
Length, total (L1) 340.6 cm (134,1") 425.6 cm (167,6")
Length, processor (L2) 157.6 cm (62.1") 157.6 cm (62.1")
Length, feed table (L3) 60 cm (23.6") 60 cm (23.6")
Length, feed extension (L4) 23.5 cm (9.3") 40.5 cm (15.9")
Length, exit table (L5) 72.5 cm (28.9") 123.5 cm (48.6")
Length, exit extension (L6) 27 cm (10.6") 44 cm (17.3")
116 - 131 cm 116 - 131 cm

Height, total (H1)
(45.7 - 51.6") (45.7 - 51.6")
87.5 - 102.5 cm 87.5 - 102.5 cm
Height, feed (H2)
(34.4 - 40.4") (34.4 - 40.4")

1-4
Processor 85 125
86.5 - 101.5 cm 86.5 - 101.5 cm
Height, exit (H3)
(34.1 - 40.0") (34.1 - 40.0")
Weights
Processor 85 125
Weight, crated (+/- 5%) 580 kg 750 kg
(1278.7 lb) (1653.5 lb)
Weight, without crate 350 kg 490 kg

(771.6 lb) (1080.3 lb)

1-5
Electrical specifications
Installation requirements for power supply
Supply/Fuse Recom. cable type 85 125

1W + N + PE, 230 VAC, 1 x 25 A, Min. 3 x 2.5 mm²,
50/60 Hz. type H07RNF
• •
EUR
•
•
2W + PE, 230 VAC, Min. 3 x 12 AWG,
2 x 25 A, 50/60 Hz. type SJO
• •
3W + PE, 230 VAC, Min. 4 x 14 AWG,
US
3 x 15 A, 50/60 Hz. type SJO
•
3W + PE, 230 VAC, Min. 4 x 12 AWG,
3 x 20 A, 50/60 Hz. type SJO
•
2W + PE, 200 VAC, Min. 3 x 12 AWG,
2 x 20 A, 50/60 Hz. type SJO
•
2W + PE, 200 VAC, Min. 3 x 12 AWG,
2 x 25 A, 50/60 Hz. type SJO
•
JAP
3W + PE, 200 VAC, Min. 4 x 14 AWG,
3 x 15 A, 50/60 Hz. type SJO
•
3W + PE, 200 VAC, Min. 4 x 12 AWG,
3 x 20 A, 50/60 Hz. type SJO
•
*) Power cord must be in accordance with local regulations.
#
Please be aware of double pole/neutral fusing.

1-6
Power consumption
Max. power consumption 85 125

230/400 V AC operation: 4,700 Watt /16,000 BTU/hour •
EUR/
US
230/400 V AC operation: 5,100 Watt /17,400 BTU/hour •
Stand-by: 500 Watt /1710 BTU/hour • •
200 VAC operation: 3,600 Watt /16,000 BTU/hour •

JAP 200 VAC operation: 3,900 Watt / 17,400 BTU/hour •
Stand-by: 500 Watt /1710 BTU/hour • •
All Voltage tolerance ± 10% • •
Noise level
See “General environmental information” on page 1-1.

Functional description
2-1
General
Part 2: Functional description
General
Processor sections
The processor contains four major sections, each performing a basic function to change
the exposed plate into a fully developed and dry plate, ready for handling (see illustra-
tion below).
1 2 3 4
T31741
Developing of the plate and removal of the remaining unexposed emulsion

1 Developer
by means of the brush rollers.
2 Wash Washing off the developer chemicals from the developed plate.
Gum Application of a thin layer of gum onto the developed and washed plate to
3
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.

2-2
Developer section
Developer section
In the developer section the plate is developed and the remaining unexposed emulsion
is removed from the plate by the built-in brush rollers.
Circulation
A circulation pump (M4) recirculates the developer through two spray tubes. A filter
in the circulation system keeps the solution clean.
Temperature/level Control
The developer bath is equipped with a heater and a thermostat to keep the tempera-
ture in range, and a min./max. level detector circuit.
Replenishment/antioxidation system
General
The replenishment system automatically adds fresh developer to the developer section
to compensate for chemicals expended during processing and for lost activity caused
by plate development.
The antioxidation system adds fresh developer to the section on an hourly basis to
compensate for lost activity caused by oxidation.
The replenishment/antioxidation developer is added to the section by means of a sin-
gle pump (M18).
The antioxidation system parameters can be set differently for antioxidation in Sleep
mode and in Ready mode.
The various replenishment/antioxidation parameters are set in the Data menu (see the
Control Panel manual).
The replenishment system can run with three different settings:
• Plate Size Replenishment (standard, based on programmed plate sizes as entered
from the plate table)
• Plate Size Replenishment with conductivity measuring *
• Conductivity Control*
*)Only for processors equipped with the Conductivity Control System. See description
of the Conductivity Control System in the separate instruction delivered with the sys-
tem.

1034
OVERFLOW
SPRAY-TUBES
DEV. HEATING DEV TANK

MAX.SENSOR
DEV.TEMP.SENSOR
CHILLER-TUBE DEV TANK
X6 MIN.SENSOR
CHILLER
(OPTIONAL) (K17) K16

DEV. WATER DEV. WATER
MIX. VALVE MIX. VALVE
M4
FILTER DEV. CIRC. WASTE
PUMP CONTAINER
DEV
(OPTIONAL)
M11 M18 (M19)

DEV. FILL DEV. REPL. DEV. WATER MIX
PUMP PUMP PUMP
DEV. WASTE CONT. (OPTIONAL)
MAX. SENSOR
(OPTIONAL)
DEV. FILL CONT. DEV. REPL.CONT. DEV. MIX WATER
MIN. SENSOR MIN.SENSOR CONT. MIN.
(OPTIONAL) SENSOR
DEV. WASTE FILL (OPTIONAL) DEV. MIX WATER
CONTAINER DEVELOPER REPLENISH CONTAINER
(OPTIONAL) DEVELOPER
(OPTIONAL)
Developer section
Service Manual - Plate Processors 85/125

T 31644
2-3
2-4
Wash section
Plate size replenishment (standard):

The processor measures the size of each plate and on the basis of a set replenishment
2
value (ml/m ) it calculates the correct amount of replenisher for each plate.
Developer filling/topping-up
Fill/top-up pump
Some models are equipped with a pump (M11) to top-up at low level and to fill the de-
veloper section with fresh solution when it is empty.
Replenishment/top-up:
Some developing processes require different developer concentrates for replenishment
and for topping-up. When replenishing, the system uses concentrate from the Replen-
ish Developer Container and mixes it with water from the Dev. Mix Water Container.
When topping up (at low level) the system uses concentrate from the Fill/Top-Up De-
veloper Container and mixes it with water from the Dev. Mix Water Container.
Wash section
See illustration opposite.
In the WASH section the developer chemicals are washed and brushed off the plate.
Water is applied to the plate through two spray tubes, one above and one below the
plate.
The processor’s consumption of fresh water is reduced as the WASH section is filled
with water.
A pump (M10) continuously recycles the water through the spray tubes.
A solenoid valve (K11) adds fresh water to the section from the water tap when neces-
sary.

2-5
Wash section
WASH
OVERFLOW
WASH TANK
SPRAY-TUBES MAX. SENSOR
M10
WASH CIRC. WASTE CONTAINER
PUMP OR
K11 DRAIN
WASH FILL/
FLUSH VALVE
WASTE CONT.
MAX. SENSOR
T 31207
WASTE
CONTAINER

2-6
Gum section
Gum section
See upper illustration opposite.
In the Gum section a thin layer of gum solution is applied to the developed and
washed plate to protect it from oxidation, dirt, fingerprints etc.
Later, when the plate is fixed in the printing machine, the layer will be rinsed off.
If the plate has been corrected or if it has to be used again on a later occasion you
should rewash and refinish the plate.
Please refer to your User Manual delivered with this processor.
Circulation
An oscillation pump (K4) pumps the gum from the gum container into a distributing
tube and onto the plate. The gum section, pump and container are connected in a
closed system, so the gum runs back from the section into the container and keeps re-
cycling.
On some models the gum section will be filled with gum. These models will be
equipped with a solenoid valve (K15) and a max. level sensor.
The oscillating pump (K4) will maintain the appropriate gum level and during pro-
cessing the excess gum will run back into the container through the overflow opening.
Gum-rinse program
Gum open system

The rinse program works by means of a solenoid valve (K13) which lets in fresh water
through a spray tube. When rinsing, the solenoid valve (K14) will be closed so the wa-
ter runs via the overflow into the drain
Gum closed system

The rinse program works by means of a solenoid valve (K13) which lets in fresh water
through a spray tube. When rinsing, the solenoid valve (K14) will be closed and the
gum rinse solenoid valve (K15) will be open allowing the rinse water to run into the
drain.
"
The rinse program should be performed once a day. See how to run the rinse
program in the User Manual delivered with this processor.
#
After cleaning of the gum section release roller lock and pull off the lay-on
roller to the rest position to release the gum roller pressure.
See lower illustration opposite.

2-7
Gum section
GUM
SPRAY TUBES
K4
GUM CIRC. PUMP
K15
K13 GUM RINSE
GUM RINSE DRAIN VALVE
VALVE
WASTE CONTAINER
OR
DRAIN
(CLOSED GUM ONLY)
K14
GUM DRAIN
VALVE
GUM CONT.
MIN. SENSOR
GUM
T 31884

2-8
Dryer section
Dryer section
See illustration below.
In the dryer section the plate is dried, so further handling of the plate is possible imme-
diately after it exits the processor.
Fan (M5) blows hot air through air tubes and dry the plate on both sides.
DRYER
OUTPUT SENSOR
LEFT + RIGHT
AIR-TUBES
DRYER TEMP.
SENSOR
E3/E4 E5/E6
HEATER HEATER
LEFT RIGHT
M M5
DRYER FAN
AIR
T31963

2-9
Transport system
Transport system
See illustration below.
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.
The rubber rollers (1) at the developer section entrance always run dry to ensure a ho-
mogeneous development. The rollers (2) ensure that the plate is transported correctly
underneath the brushes (3) and the rollers (4) ensure proper contact between brushes
and plate.
The rollers (5) at the developer tank exit squeeze any residual chemicals off the plate.
In the wash section the plate is washed on both sides by means of the spray tubes (6)
and brushed on the upper side by means of the brush (7) (optional). The stop roller (8)
on top of the entrance rollers (9) prevents the wash water from flowing back into the
developer section, and water is squeezed off the plate by the section exit rollers (10).
The gum section contains one roller pair (11) and a smaller roller (12) situated close to
the upper roller. The gum solution from the application tube (13) forms a small reser-
voir between these two rollers and a thin layer of finisher is applied to the plate while
the extra finisher is forced backwards.
The exit roller pair (14) receives the plate when dry and transports it out of the proces-
sor.
1 2 3 5 8 10
J 13 11 14
4 9 6 12 T31742

2-10
Electronic control
Electronic control
See illustration opposite. The electrical control system consists of:
Master input/output unit (MIO)

The electrical control system is controlled by the MIO board via the SOM (System on
Module).
There are two separate communication lines (buses):
• GNUIB for all internal communication in the processor (RS485).
• ETHERNET for Remote Enabling System.
The MIO-board is equipped with a platesetter interface for communication between

the processor and platesetter.
Power control unit (PCU)

The PCU-board holds all the high voltage in- and outputs for the control of heaters,
motors etc.
Man machine interface unit (MMU)

The MMU-board is the Control Panel board from which the user operates the proces-
sor.
Touch screen control panel (MMI)

A graphical user interface colour display. The processor is operated on the touch
screen display. Control panel service information is described in the Software Manual.
T2636

2-11
Electronic control
REMOTE
ENABLING
(Optional)
ETHERNET
MMU
USB
INTERFACE
(Online installations only)
MASTER
I/O BOARD MIO SETTER
SOM
GNUIB (RS485)
T31649
SLAVE
I/O BOARD PCU

2-12
Electronic control

Cleaning and maintenance
3-1
General
Part 3: Cleaning and maintenance
General
This section contains special service information such as fuse list and roller adjusting
procedures etc.
For software related service information please refer to the separate “Software Service
Information” manual.
WARNING! DANGER
Please note that where this label
ELECTRICAL SHOCK HAZARD
appears on the processor electrical DISCONNECT ALL EXTERNAL POWER
SUPPLY BEFORE SERVICING
shock hazard still exists when main
TO BE SERVICED BY AUTHORIZED PERSONNEL ONLY
switch is turned off.
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 may still be active making the drive system run idle at
intervals.
Also be aware that the processor's heaters and motors will be in operation
during the initial startup if you have overridden the machine's safety
functions.

3-2
Safety check
Safety check
"
Below described safety check should be performed at least once a year.
Electrical
Refer to the electrical diagrams at the back of this manual).
• Check proper function of:
– Interlock switches S42, 43, and 44.
– Emergency switch S41, S47, S48, S49.
– Main switch S21.
– Dryer overload switches E3 + 4 + 10 + 11.
– GFCI relay 10F.
Mechanical
• Check proper function/location of:
– Side fenders, left/right.
– Top covers, front/rear.
– Covers, electronics boxes.
– Lower side panels, left/right

3-3
Safety check
Fuses
The fuses for the various functions are located in the electrical cabinet.
#
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.
$
The unit has double pole fusing!
See the table on the following page for a description of the fuses.
Standard
Motor fuse
Motor fuse
Heavy duty
Motor fuse
(mounted on cable) Fuses
T31914

3-4
Safety check
PCB fuses
Fuse Fuse for Type/Part no.

Gum, circulation pump K4
20AT, 35.8 x 10.3 mm
F1 & F2 Dev. heating E1
10053673
Dev. replenish pump M18
Dryer heater E3 + E11
20AT, 35.8 x 10.3 mm
F3 & F4 Dryer heater E4 + E10
10053673
Wash circ. pump M10
Ventilation fan electronics M14
Compressor in cooler X6
20AT, 35.8 x 10.3 mm
F5 & F6 Circ. pump in cooler X6
10053673
Dev. circulation pump M4
Dev. fill-up pump M11
2AT, 6.3 x 32 mm
F10 Stacker
6716
6.3AT, 5 mm round
F8 Power supply U1 + U2
10049272
PCB PCU fuses

1AT, 5 mm round
F6 Gum circulation pump K4
10011284
1AT, 5 mm round
F9 Dev. fill-up pump M11
10011284
Motor fuses

8AT, 6.3 x 32 mm
F17 Transport motor M1
16038
6AT, 6.3 32 mm
F18 Brush motor M2
16090

3-5
Mounting of r-clips for gears
Mounting of r-clips for gears
$
Following the instructions below is very important for the correct function of
the processor.
(See illustrations below).
NEVER
mount R-clips as shown in the upper illustration.
ALWAYS
mount R-clips as shown in the lower illustration.
Q
T 31427
R
1/4-yearly service
"
The following service procedures should be performed every 3 months:
• Dismount and clean:

– Circulation pumps
– Spray tubes

3-6
Adjusting the 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:
Developer/wash/gum/dryer transport rollers (A)

• 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.

3-7
2 1
A A A A A A A
Developer Wash Gum Dryer

section section section section
T31744

3-8
Adjusting the brush support rollers
General
The following describes the standard adjustment for the brush support rollers.
(See illustration opposite).
Tools:
– 5 mm hex T-key
Adjusting
• Remove the brush (1) and support roller (2).
• Adjust the screws (3) on both sides to the following:
– (A) Developer: X = 10 mm
– (B) Wash: X = 19 mm

3-9
A B
3 X
T31743

3-10
Adjusting the brushes
General
The following describes a standard adjustment for the brushes in the prewash*, devel-
oper and wash* sections (* = not all models). 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
The processor must be running and ready to process.
Recommended brush speed setting: 120 rpm
Preparations
• Open the processor top cover.
• Activate the interlock switch.
• Start the “Eject Plate” function.
Adjustment (see top illustration)

• While the brush (1) runs use the test plate (2) to test the brush pressure on both sides
and in the middle.
• Adjust the brush pressure on the screws (3) (clockwise = tighten) until you feel a
slight resistance when pulling the test plate backwards. Make sure that you obtain a
uniform pressure on both sides and in the middle.
• From this point turn the screws (3) half a turn clockwise in each side.
Alternative adjustment procedure (see bottom illustration)

Use a strip of film and a spring balance and proceed as follows:
• Fill the tank with water.
• Insert a strip of polyester film (10 cm wide, approximately 50 cm long, 0.19 mm
thick/4 x 20 x 1/128”) between a brush roller and a lower roller (or pressure plate)
• Activate the brush drive (120 rpm) 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
plate width.
• Repeat the procedure for the other developer brush roller and the brush rollers in
the prewash and rinse section. All brushes should be adjusted to the same settings.

3-11
400
300
200
100
T31710

3-12
Adjustment of wash section spray tube valves

The valves for the wash section spray tubes must be adjusted to obtain the best possi-
ble application of water to the plate.
(See illustration opposite).
• Adjust the valve for the upper spray tube (1) so that water is applied to the whole
roller width but without splashing.
• Adjust the valve for the lower spray tube (2) so that water is sprayed onto the upper
exit roller.

3-13
1 2
T31915

3-14
Cleaning the pumps
Cleaning the pumps

If the circulation pump ceases to function correctly, clean the pump as follows.
The illustrations opposite show two different types of circulation pumps for:
Developer and wash (A)

• Cut off the power to the unit by removing the top cover.
• 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.
• Remove 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, checking 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) or cover (4) whatever applies to the specific pump.
Cleaning of valves in the oscillation pump (B)

If a gumming pump ceases to function properly, run it with some lukewarm water in
order to clear the pump of chemicals or gum.
If this does not help, take the pump apart and clean both the small valves with hot wa -
ter.
Reinstall the valves and make sure they are placed correctly to allow free unobstructed
flow.
Cleaning of valves in the replenish pumps (C)

If a replenishment pump ceases to function properly, run it with some lukewarm wa-
ter in order to clear the pump of chemicals.
If this does not help, take the pump apart and clean both the small valves with hot wa -
ter.

3-15
Cleaning the pumps
B
1
2
3
4
VALVE
VALVE
T31712

3-16
Cleaning the pumps

Troubleshooting
4-1
General
Part 4: Troubleshooting
General
If the processor does not work properly, refer to the following pages to find the para-
graph that comes closest to your problem.
The troubleshooting guide is divided into two sections:
a. Problems with the processor
b. Problems with the processed material
For information about alarm messages see the “Control Panel” manual. For cleaning
and maintenance subjects see the processor user manual. For information about fuses
see page 3-3.
Use the “Test functions” parameters on the control panel to test individual compo-
nents. See the “Software Service Information” manual.
The electrical diagrams are located in Appendix A.
"
To change a fuse, switch off all power to the machine first. Always ensure that
the new fuse is of the correct rating according to the diagram.
WARNING!
When performing any service, maintenance, calibration, or trouble shooting
etc. it may be necessary to override the function of the processor’s
interlock switches.
In these cases please be aware, that the processor’s JOG-function is still
active, making the drive system run idle at intervals.
There will be NO advice when the JOG function starts.
Also be aware that the processor's heaters and motors will be in operation
during the initial startup if you have overridden the machine's safety
functions.

Troubleshooting
4-2
Before starting troubleshooting
Before starting troubleshooting
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 • Fuse(s) blown • Replace fuse
• Mains switch turned off or • Connect cable to main
power cable not connected power outlet and/or turn
to main power outlet main switch on
Processor cannot • Configuration error • Reload software
initialize • Defective PCB • Replace PCB
• Cables not properly • Check cables and make
connected proper connections
Machine will not start • Fuse defective • .Replace the fuse
• Power to PCU not ok • Measure power connection
to PCU
• MIO/MMU-PCB defective • Replace defective part
Machine does not start • GUM-RINSE program • Wait until program has
when a plate is inserted running finished
• Input sensor(s) defective • Control the signal from the
sensor via test program at
MMU
• Replace defective sensor
No wash water although • Water tap closed • Open water tap
machine is in “process” • Water solenoid valve
mode. defective • Replace valve.
• Water filter in valve • Clean water filter
clogged
• Water flow adjusting • Open valves and adjust
valves closed flow
• Electronics defective • Control the signal to the
valve via test program at
MMU
• Replace defective
electronics

Troubleshooting
4-3

Dryer blower working • Fuse(s) blown • Replace fuse.
heater is not • Temperature sensor • Control the actual
defective temperature at the heating
element via the test
program at MMU
• Control the signal to the
heating element via test
program at MMUReplace
temperature sensor
• Heating element defective • Replace heating element
• Electronics defective • Replace defective
electronics
Dryer blower not working. • Fuse(s) blown • Replace fuse
• Blower defective • Control the signal to the
blower via test program at
MMU
• Replace blower
electronics
No gum although machine • Gum container empty • Refill container
is in “process” mode. • Gum hose blocked • Clean hose
• Gum filter clogged • Clean filter
• Pump valves blocked or • Clean or replace valve
defective
• Pump defective • Control the signal to pump
via test program at MMU
• Replace pump
• Fuse(s) blown • Replace fuse
electronics
Gum/finisher pump runs • Gum hose blocked • Clean hose
but no finisher. (no • Pump valves blocked or • Clean or replace valve
alarms) defective
Developer replenishment • Fuse(s) blown • Replace fuse

pump does not work. • Pump defective • Control the signal to pump
• Replace pump
electronics
Developer replenishment • Replenishment hose • Clean hose
pump runs but no blocked
replenishment. • Pump valves blocked or • Clean or replace valves
defective
• Replenish container empty • Refill container

Troubleshooting
4-4

Replenishment system • Replenishment parameters • Make correct settings
does not work although settings not correct • Control the calibrating of
the machine is in the pump via the test
“process” mode. program at MMU
electronics
Developer fill pump does • Fuse(s) blown • Replace fuse
not work. • Configuration error • Make correct configuration
• Pump defective • Control the signal to pump
• Replace pump
electronics
No developer circulation • Fuse(s) blown. • Replace fuse
• Developer circulation • Control the signal to pump
pump defective via test program at MMU
• Replace pump
• Developer filter clogged • Control that the
configuration is made
correct
• Replace filter element
• Developer spray tubes • Clean spray tubes
clogged
No water circulation. • Fuse(s) blown. • Replace fuse
• Water circulation pump • Control the signal to the
defective pump via test program at
MMU
• Control that the level
sensor is working via the
test program at MMU
• Replace pump
• Water filter clogged • Clean filter
• Water spray tubes clogged • Clean spray tubes
Brush roller motor • Drive gears or worms • Check all worms and
running, but brushes do defective gears, and that they move
not turn freely. Replace any
defective part
Roller drive motor • Drive gears, worms, or • Check all worms and
running, but no plate couplings defective gears, and that they move
transport freely. Check couplings.
Replace any defective part

Troubleshooting
4-5
Problems with processed material

Plate is not dry • Dryer temperature is set • Set dryer temperature a
too low little higher
• Dryer section is
malfunctioning • Adjust rollers according to
• Gum rollers misadjusted description on page 3-7
Plate has stripes • Defective or dirty rollers or • Take rollers and/or guides
lengthwise or crosswise guides out, inspect and wash them.
Rollers with dents or other
marks must be changed
• Brush(es) misadjusted • Adjust brushes according

to description on page 3-10
• Brush(es) defective • Replace defective brush

Plate is underdeveloped • Developer exhausted • Change developer
(exposure is correct and • Machine runs too fast • Reduce the transport speed
plate not too old) slightly
• Developer temperature too • Increase developer
low temperature slightly
• Developer circulation • Check function of
insufficient circulation pump and
spray tubes and if filter is
clogged
• Replenishment insufficient • Increase replenishment
rate slightly
• Brush(es) out of • Adjust brush(es) according
adjustment to description on page 3-10
Plate is overdeveloped. • Machine runs too slow. • Increase the transport
(exposure is correct and speed slightly
plate not too old) • Developer temperature too • Reduce developer
high. temperature slightly
• Replenishment setting too • Reduce replenishment rate
high. slightly
Washing not sufficient • Water tap closed. • Open water tap
• Water solenoid valve • Check valve and filter
defective or water filter
clogged
• Spray-tubes clogged or • Clean or adjust whatever
misadjusted. is necessary
• Water circulation pump • See page 3-14
does not run
• Brush misadjusted • Adjust brush according to
description on page 3-10

Troubleshooting
4-6

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 is • Brushes mistakenly • Switch brushes to their
bent switched between original locations
developer and wash
sections
• Brush pressure too high • Adjust brush according to
description on page 3-10
• Brush speed too high • Reduce brush speed

Spare parts
5-1
General
Part 5: Spare parts
General
Spare parts kit

A small kit consisting of the most needed spare parts is delivered with the processor.
For further need of spare parts please refer to the spare part lists in this chapter with
isometric drawings, descriptions and part numbers.
Ordering spare parts

When ordering spare parts:
"
Please state carefully the spare part number, the specification and the number
of items wanted.
How to read the spare parts list correctly

Please note that this spare parts chapter in general covers all possible processor config-
urations. This means that the chapter includes descriptions of parts that may not be in-
stalled on your actual processor.
$
If you want to add extra components or change from one component type to
another (e. g. add a replenish container sensor/pipe or change of pump type)
you will in most cases need a conversion kit. Please contact your local Service
Technician for information of available conversion kits and kit order
numbers.
Some of the spare parts (covers, panels etc.) are dedicated to your actual processor.
These types of parts are listed in the Appendix A “Additional spare parts”.
PCB's and software
IMPORTANT!
"
All spare part PCB's with software proms will be delivered without software
installed.
The Service Technician must download the software and the upgrade
instruction from the manufacturers web site www.glunz-jensen.com/support.

Spare parts
5-2
8 10
2 7 26 24
25
8 27 3
17
18
16
15
19
1 22
T8642
PANELS

Spare parts
5-3
Panels
Panels
Pos. 85 125 Specification
1 SEE APPENDIX A
2 SPRING, GAS 100N L146.5/226.5 082414
3 SEE APPENDIX A
4 SEE APPENDIX A
5 SEE APPENDIX A
6
7 35825 SPRING, GAS 250N 405/160 094773
8 35362 35362 HANDLE, SOUTHCO TP. P2-44
9 SEE APPENDIX A
10 SEE APPENDIX A
11 35368 35368 GITTER, BLOWER, PAPST, LZ30-5-A2
12 26054 26054 FAN, SUNON DP200A 2123XBT
13 25235 25235 GROMMET D20/28X2
14 10042427 10042427 SLEEVE 1/2" BLACK TP.VERSAFIT
15 10044210 10044210 SENSOR, INPUT, COMPLETE
16 0180202 0180202 GUIDE, SILICONE D25 INCL.BUSHING
17 54334 54334 PIPE, DISTANCE, GUIDE, ENTRANCE
18 54373 54373 BEARING, RIGHT, GUIDE, ENTRANCE
19 45736 45736 PUSHBUTON, EMERGENCY, STOP
20 74161 74161 LABEL, EMERGENCY, STOP
21 45737 45737 NUT, STOP, EMERGENCY
22 36498 36498 CONTACT, BLOCK, EMERGENCY-STOP
23 10019245 10019245 GUARD, METAL, FAN, (FG-12), 120X120
24 SEE APPENDIX A
25 26545 26545 BUTTON, EMERGENCY-STOP, RAFIX
26 74161 74161 LABEL, EMERGENCY, STOP
27 36498 36498 CONTACT, BLOCK, EMERGENCY-STOP, RAFIX 2NC
28
29
30

Spare parts
5-4
12
13
2
7
5 6
4
4 8
10 14
15
15
1
9
3
11
T8641
STAND

Spare parts
5-5
Stand
Stand
1 SEE APPENDIX A
2 SEE APPENDIX A
3 35359 35359 LEG, TRAPEZOID, D40, METAL REAR LEGS ONLY
4 10009615 10009615 GASKET, D41/33/2
5 54212 54212 STAY, LOCK, PANEL D11.6/D4.1x18
6 SEE APPENDIX A
7 SEE APPENDIX A
8 10051089 10051089 NUT, TRM 26X5,NV30 FRONT LEGS ONLY
9 10050915 10050915 LEG, ADJUSTABLE, TRAPEZOID FRONT LEGS ONLY
10 15324 15324 SCR M4X25 CR P 4 7985
11 10035503 10035499 TRAY, DRIP, LONG NOT ALL MODELS
12 10054278 10054278 DRAIN
13 10054767 10054767 CLAMP (1R.ST2.500.00,BLACK)
14 35360 35360 NUT, LEG, ADJ.TRAPEZOID 36-KM 1 REAR LEGS ONLY
15 35358 35358 BUSHING, TRAPEZOID, D40X2
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-6
1 3
T8640
STAND CLOSED

Spare parts
5-7
Stand closed
Stand closed
1 SEE APPENDIX A
2 SEE APPENDIX A
3 35367 35367 HANDLE, LOCK, SOUTHCO TP.19-91-10
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-8
1
5
4
3
6
7 2
2 3
4 10
6
7 10
T8618
FEED/EXIT TABLES

Spare parts
5-9
Feed / exit tables
Feed / exit tables

1 10032630 10032636 TABLE, FEED

2 50025 50023 BOW, TABLE, FEED/EXIT
3 25110 25110 PIN, SPLIT D3X54
4 35865 35865 BEARING, BUSHING, SNAP, TP.22MPO-1050
5 54381 54381 PIN, GUIDE, TABLE, FEED
6 43546 43546 BEARING, BLOCK, BOW
7 35365 35365 SCR. FINGER M5X18 TP.GN421-M5-18
8 10023931 10032764 SUPPORT, TABLE, EXIT
9 10023904 10032744 TABLE, EXIT
10 10032767 10032767 BRACKET, PANEL, REAR, UPPER
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-10
4
13
12
14
16
9
1
3 10
15
11 2
8
7
6
4
5
T8791
GROUP TANK BASE

Spare parts
5-11
Group tank base
Group tank base

1 54563 CAPACITOR, 2MF, CA-250

73014 CAPACITOR, 4UF, W.PLUG
2 10034474 10034474 CABLE, COVER SWITCH, PT MK.II, S43
3 10034473 10034473 CABLE, COVER SWITCH, PT MK.II, S42
4 10030891 10030891 SWITCH, LEVEL, (7037)
5 26446 26446 CONN.RECEPT.MINIFIT, MOLEX 5557-2R
6 10037727 10037727 NUT, M12, POLYAMID, 6.6
7 35386 35386 O-RING D16.3X2.4 FPM
8 10039929 10039929 SENSOR, LEVEL, 2-PIN, 90 DEGREE, SHORT
9 10009459 10009459 BEARING, ROLLER, GUIDE
10 26545 26545 BUTTON, EMERGENCY-STOP, RAFIX
11 36498 36498 CONTACT, BLOCK, EMERGENCY-STOP, RAFIX 2NC
12 43724 43724 SENSOR, TEMP, NTC (90mm CABLE)
13 35355 35355 O-RING D5.0X2.5 EPDM
14 44968 44968 FITTING, BUSHING, «"RG-D6
15 36484 HEATER, 1500W, 75C+84C, D20x543
36360 HEATER, 2200W, 230V
16 25302 25302 O-RING D19X4
17
18
19
20
21
22
23
24
25
26
27
28

Spare parts
5-12
6
3
5 7
4
3
1
28 25
26 11
24 9
1
23
22 1 11 7
29 6
1 3
8 5
10 4
1
12 27 3
1 2
14 21
13
18
19
20
16
15
17 12
2 14
26 25 22 16
29 T8790
HEAVY DUTY
DRIVE

Spare parts
5-13
Drive
Drive
1 10052578 10052778 GEAR, Z16, M3, RIGHT

2 44912 44912 CLIPS, R-SHAPE, D4.0
3 22887 10052807 BEARING, SHAFT, LEAD-IN
4 44909 44909 SHAFT, LEAD-IN
5 35482 35482 O-RING, ?68x2.0, NBR
6 35483 35483 V-RING, VA20, NBR
7 43221 43221 GEAR, Z23, M3
8 10052561 10052561 GEAR, Z16, M3, LEFT
9 53746 53746 BUSHING, GEAR, INTER, ECCENTRIC
10 63123 63123 BUSHING, GEAR, INTER
11 45371 45371 CIRCLIP D15X1,5 A4 6799
12 44913 44913 BEARING, AXIAL, DRIVE
13 42223 42223 BEARING, SHAFT, DRIVE
14 88961 88961 BEARING, THRUST, AXIAL
15 43235 43235 WORM, GEAR, Z3, M3, RIGHT
16 43236 43236 WORM, GEAR, Z3, M3, LEFT
17 10033460 10033460 CABLE, GROUND, BEARING, DRIVE, BASE
18 73707 73707 GEAR, Z42, M2
19 74559 74559 BUSHING, GEAR
20 73282 73282 HOUSE, BEARING, DRIVE, SHAFT
21 10054199 10054658 SHAFT, DRIVE, BASIS
22 SEE APPENDIX A
23 10031609 10031609 PCB, MOTOR, FILTER, CHOKE, W.WIRES
24 16090 16090 FUSE, 6A 6,3X32 S/B UL
25 SEE APPENDIX A
26 SEE APPENDIX A
27 10047286 10054201 SHAFT, DRIVE, BASIS
28 14452 14452 CLIP, WORM D2X15.5
29 SEE APPENDIX A
30

Spare parts
5-14
54
20 34
27
18 56
14
29
4 23
40 D
15 49 37
50
47
10 48
39 46
5 25
26 4 C
3
53
52
43
16
24
E
19
28 T8788
12
13
36 C D
42
44 8 8
12
35
REPL. TUBE REPL. TUBE

17
B C D
11
51 51 9
32 38 7
51
12 45
B 45 33 45
22 33
DEV. FILL-UP DEV. REPL. FINISHER REPL.
SENSOR/PIPE SENSOR/PIPE SENSOR/PIPE
CIRCULATION & DRAIN: TAP WATER

Spare parts
5-15
Circulation and drain: Tap water

1 10047788 10047788 FITTING, 1/2, D20, VALVE

2 36105 36105 VALVE, SOLENOID, D132A22, Z130A 24V DC
3 54328 54328 FIT, GUM, CAN, UPPER
4 45000 45000 O-RING D20, GBO
5 10035199 10035199 FITTING, GUM, RINSE, LOWER
6 10058870 10058870 FITTING, DEV, DRAIN
7 10035172 10035172 SUCTION, 2-PIN SENSOR NOT ALL MODELS
8 4030 4030 REPL TUBE - GREY FOR FIX
10 SEE APPENDIX A
11 67885 67885 SHOWER, HAND, HOSE NOT ALL MODELS
12 45911 45911 GASKET, FIBER,1/2", D18x12.5x2 NOT ALL MODELS
13 10055841 10055841 FITTING, HANDSHOWER NOT ALL MODELS
14 10052862 10052862 TUBE, DEV, SPRAY 1 + 2
15 10052863 10052863 FITTING, PUMP, CIRCULATION
16 42224 42224 HOUSING, FILTER, VIH, 10, MODIFIED
17 73431 73431 HOSE, SPIRAL, 4 METER NOT ALL MODELS
18 35929 35929 CAP 3/4"
19 74388 74388 GASKET, EPDM, SHORE70, 24X17X2 NOT ALL MODELS
20 45929 45929 FITTING, PLUG,3/4", 1R.TA2.250.00
21 10002552 10002552 VALVE, SOLENOID, 24VDC, 6115-NC
22 35488 35488 HAND, SHOWER, ORAS, BEDETTA NOT ALL MODELS
23 10052865 10052865 FITTING, SPRAY, WASH, CIRC.PUMP
24 0012153 00012153 O-RING
25 73305 73305 PUMP, BELLOW, KBR-3X, W.PLUG
26 10055381 10055381 MANIFOLD, DRAIN, EXTENSION
27 25467 25467 FITTING, NIPPLE NI2 3/4"
28 10055839 10055839 FITTING, INLET, WATER NOT ALL MODELS
29 10052788 10052788 PUMP, OSC., GUM
30

Spare parts
5-16
54
20 34
27
18 56
14
29
4 23
40 D
15 49 37
50
47
10 48
39 46
5 25
26 4 C
3
53
52
43
16
24
E
19
28 T8788
12
13
36 C D
42
44 8 8
12
35

17
B C D
11
51 51 9
32 38 7
51
12 45
B 45 33 45
22 33
CIRCULATION & DRAIN: TAP WATER

Spare parts
5-17

31
32 10035796 10035796 TUBE, SUCTION, CHECK-VALVE
33 15827 15827 VALVE, CHECK 1/4" NOT ALL MODELS
34 22085594 22085594 FITTING, ELBOW, NUT, 3/4"X20, HOSE
35 10054299 10054299 PUMP, QUICK-FILL, AD550
36 22085594 22085594 FITTING, ELBOW, NUT, 3/4"X20 NOT ALL MODELS
37 36340 36340 HEAD, PUMP, IWAKI, KBR
39 10055383 10055383 MANIFOLD, WASTE
40 6388 6388 HOLDER, PIPE D25
41 26388 26388 VALVE, SOLENOID, 4-WAY, IMQ R-G 90, 13L/MIN
42 7288 7288 FITTING, CONN., 1/2"x1/2", A210 NOT ALL MODELS
43 SEE APPENDIX A
44 0011361 0011361 FIT. VALVE, BALL 1/2" MA/FE NOT ALL MODELS
45 35742 35742 CIRCLIP, D10/D16x3.6 POMC RED NOT ALL MODELS
46 36341 36341 FITTING, INLET, PUMP, KBR
47 10003917 10003917 VALVE, POPPET, ASSEMBLY, PUMP, BELLOW, IWAKI
48 36343 36343 FITTING, NUT, PUMP, KBR
49 36342 36342 FITTING, OUTLET, PUMP, KBR
50 10004402 10004402 O-RING, ASSEMBLY, PUMP, BELLOW, IWAKI
51 10002830 10002830 SENSOR, LEVEL, 2-PIN
52 10004710 10004710 FITTING, ELBOW, SWIVEL, 3/4"
53 25380 25380 O-RING D24.99X3.53
54 25700_3 25700_3 VALVE, SOLENOID, ES 90/88, 3.3L/MIN
55
56
57
58
59
60

Spare parts
5-18
41
E
14
29
23
4
6
21
26
40 D
15 49 37
50
47
10 48
39 46
5 25
18 4 C
3
20
23
43
16
24
E
19
28 T8789
12
13
36 C D
42
44 8 8
12
35

17
B C D
11
27 27 9
32 38 7
27
12 45
B 45 33 45
22 33
CIRCULATION & DRAIN: WATER SAVING

Spare parts
5-19
Circulation and drain: Water saving

1 10047788 10047788 FITTING, 1/2, D20, VALVE

2 36105 36105 VALVE, SOLENOID, D132A22, Z130A 24V DC
3 54328 54328 FIT, GUM, CAN, UPPER
4 45000 45000 O-RING D20, GBO
5 10035199 10035199 FITTING, GUM, RINSE, LOWER
6 10058870 10058870 FITTING, DEV, DRAIN
8 4030 4030 REPL TUBE - GREY FOR FIX
10 SEE APPENDIX A
11 67885 67885 SHOWER, HAND, HOSE NOT ALL MODELS
12 45911 45911 GASKET, FIBER,1/2", D18x12.5x2 NOT ALL MODELS
13 10055841 10055841 FITTING, HANDSHOWER NOT ALL MODELS
14 10052862 10052862 TUBE, DEV, SPRAY 1 + 2
15 10052863 10052863 FITTING, PUMP, CIRCULATION
16 42224 42224 HOUSING, FILTER, VIH, 10, MODIFIED
17 73431 73431 HOSE, SPIRAL, 4 METER NOT ALL MODELS
18 10055381 10055381 MANIFOLD, DRAIN, EXTENSION
19 74388 74388 GASKET, EPDM, SHORE70, 24X17X2 NOT ALL MODELS
20 25380 25380 O-RING D24.99X3.53
21 24675 24675 HOSE, ELBOW 90 , D19/23
22 35488 35488 HAND, SHOWER, ORAS, BEDETTA NOT ALL MODELS
23 10004710 10004710 FITTING, ELBOW, SWIVEL, 3/4"
24 0012153 00012153 O-RING
25 73305 73305 PUMP, BELLOW, KBR-3X, W.PLUG
26 10052793 10052793 PUMP, PREWASH
27 10002830 10002830 SENSOR, LEVEL, 2-PIN
28 10055839 10055839 FITTING, INLET, WATER NOT ALL MODELS
29 10052788 10052788 PUMP, OSC., GUM
30 10052720 10052720 VALVE, BALL, 3/4",1V.321.250.00H

Spare parts
5-20
41
E
14
29
23
4
6
21
26
40 D
15 49 37
50
47
10 48
39 46
5 25
18 4 C
3
20
23
43
16
24
E
19
28 T8789
12
13
36 C D
42
44 8 8
12
35

17
B C D
11
27 27 9
32 38 7
27
12 45
B 45 33 45
22 33
CIRCULATION & DRAIN: WATER SAVING

Spare parts
5-21

31 10003279 10003279 FIT, NIPPLE, 20X25X3/4", AM3

32 10035796 10035796 TUBE, SUCTION, CHECK-VALVE
33 15827 15827 VALVE, CHECK 1/4" NOT ALL MODELS
34
35 10054299 10054299 PUMP, QUICK-FILL, AD550
36 22085594 22085594 FITTING, ELBOW, NUT, 3/4"X20 NOT ALL MODELS
37 36340 36340 HEAD, PUMP, IWAKI, KBR
39 10055383 10055383 MANIFOLD, WASTE
40 6388 6388 HOLDER, PIPE D25
41 26388 26388 VALVE, SOLENOID, 4-WAY, IMQ R-G 90, 13L/MIN
42 7288 7288 FITTING, CONN., 1/2"x1/2", A210 NOT ALL MODELS
43 SEE APPENDIX A
44 0011361 0011361 FIT. VALVE, BALL 1/2" MA/FE NOT ALL MODELS
45 35742 35742 CIRCLIP, D10/D16x3.6 POMC RED NOT ALL MODELS
46 36341 36341 FITTING, INLET, PUMP, KBR
47 10003917 10003917 VALVE, POPPET, ASSEMBLY, PUMP, BELLOW, IWAKI
48 36343 36343 FITTING, NUT, PUMP, KBR
49 36342 36342 FITTING, OUTLET, PUMP, KBR
50 10004402 10004402 O-RING, ASSEMBLY, PUMP, BELLOW, IWAKI
51
52
53
54
55
56
57
58
59
60

Spare parts
5-22
1 BLACK EPDM 2 3 4 5 6 7
BLACK EPDM
BLACK EPDM
BLACK EPDM
BLUE PVC
RED PVC
SILICON
Ø 35 Ø 28 Ø 24 Ø 17 Ø 14 Ø 14 Ø 17
8 9 10 11 11 11 12
T8806
HOSES AND CLAMPS

Spare parts
5-23
Hoses and clamps
Hoses and clamps

1 10054249 10054249 HOSE, RUBBER, D25X5MM, EPDM, BLACK

2 10008509 10008509 HOSE, RUBBER, 19X4.5MM, EPDM, BLACK
3 10056809 10056809 HOSE, RUBBER, D16X4MM, EPDM, BLACK
4 10056952 10056952 HOSE, RUBBER, D10X3.5MM, EPDM, BLACK
5 6342 6342 HOSE, D10/D14, PVC, BLUE, PER METER
6 6341 6341 HOSE, D10/D14, PVC, RED, PER METER
7 10034866 10034866 HOSE, SILICONE, D10/D17
8 6062 6062 CLAMP, HOSE D18-38 MAH016
9 6042 6042 CLAMP, HOSE, D20-32
10 6323 6323 CLAMP, HOSE D13-27
11 15510 15510 CLAMP, HOSE D11-18mm
12 6079 6079 CLAMP, HOSE D15-16.8 PL SNP10
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-24
53 30 26 22 54
12
23
21 16 56 7
19
24 17
2 4
3
18 6
20
BRUSH 31
ROLLER
11 10
15
42 44 PUR
43 ROLLER
40 41 44 45 ROLLER
8
39 46
47 13
48
49 9 9 31
50
51
45
52
37
36
35
33
29 27
34
55 28
38
32
25
T8807
14
37
25 33
35
36
55
1
DEVELOPER HEAVY DUTY

Spare parts
5-25
Developer
Developer
1 43264 43264 CLAMP,WASH,LOWER,TUBE

2 88992 88992 STOPPER, TUBE, SPRAY, D20, COMPLETE
3 10042785 10042785 GUIDE, DEV, FRONT, LEFT
4 10041269 10041269 GUIDE, DEV, FRONT
5 35350 53550 PIN, CYLINDER D4X30 A4 DIN7
6 35895 35895 O-RING, D14X1.78, VITON
7 10023292 10032701 GUIDE, DEV, FRONT, COMPLETE
8 43220 GEAR, Z18, M3
43221 GEAR Z23, M3
9 10046059 MILLED, BEARING, ROLLER, D54
10046055 MILLED, BEARING, ROLLER, D69
10 44912 44912 CLIPS, R-SHAPE, D4.0
11 10014227 10014227 GEAR,Z 23, M2
12 63453 ROLLER, EPDM, D54, SH40, BULGED, BLACK
10025953 ROLLER, EPDM, D69, SH40, BULGED, BLACK
13 44910 44910 SPRING, SPACER, BRUSH D12X30
14 85004 85004 AJUSTMENT, ROLLER, LEFT
15 10014025 10014025 BEARING, D20, L15
16 43584 10026017 ROLLER, PUR, D54
17 315FJ0055 315FJ0055 CIRCLIP, STAINLESS
18 10004646 10004646 GUIDE, SILICONE, D25
19 10023277 10032714 TUBE, SPRAY, DEV, REAR, COMPLETE
20 0061432 0061432 CIRCLIP, A12-411, DIN471 A2
21 10023260 10032707 GUIDE, DEV, REAR, COMPLETE
22 63450 ROLLER, EPDM, D54, SH30, STRAIGHT, GREY
10054516 ROLLER, D54X1270, EPDM, SHORE A 30
24 10009355 10010009355 GUIDE, DEV, REAR
25 85005 85005 AJUSTMENT, ROLLER, RIGHT
26 10037403 10040663 LID, DEV, ANTIOX

Spare parts
5-26
53 30 26 22 54
12
23
21 16 56 7
19
24 17
2 4
3
18 6
20
BRUSH 31
ROLLER
11 10
15
42 44 PUR
43 ROLLER
40 41 44 45 ROLLER
8
39 46
47 13
48
49 9 9 31
50
51
45
52
37
36
35
33
29 27
34
55 28
38
32
25
T8807
14
37
25 33
35
36
55
1
DEVELOPER HEAVY DUTY

Spare parts
5-27
Developer
Developer
Pos. 85 Specification
27 35386 35386 O-RING D16.3X2.4 FPM

28 10052745 10052847 TUBE, COOLING, BENDED
29 3230Z000401 3230Z000401 NUT, UNION, MALE, INSIDE, D16.3
30 SEE APPENDIX A
31 10040421 10040421 KIT, UPDATE, RING, ROLLER, ID, POLYMER
32 10050946 10050946 BEARING, RIGHT, BRUSH, DEV
33 SEE APPENDIX A
34 10017448 10017448 LOCK, BRUSH
35 53322 53322 BRACKET, MOTOR, BRUSH
36 14452 14452 CLIP, WORM D2X15.5
37 63400 63400 SHAFT, MOTOR, DEV, WASH
38 44911 44911 SPRING, LOCK, BRUSH D7.7X20
39 45661 45661 O-RING, D31.47X1.78, FPM
40 35976 35976 BUSHING, D20XD23X20, SKF PPM 202320
41 35483 35483 V-RING, VA20, NBR
42 73191 73191 BRACKET, SEAL, BEARING, BRUSH, DEV.
43 53323 53323 GEAR, Z17, M2
44 45371 45371 CIRCLIP D15X1,5 A4
45 10014026 10014026 GEAR, Z31, M2
46 10014025 10014025 BEARING, D20, L15
47 44991 44991 SHAFT, GEAR, INTERMEDIATE
48 10003357 10003357 SPRING, SILICONE, SPRAY
49 10009485 10009485 BUSHING, SPRING
50 74226 74226 SPRING, D12.5, T1.6, L19, K12.3
51 10031542 10031542 BRACKET, TUBE, SPRAY
52 10050947 10050947 BEARING, LEFT, BRUSH, DEV
53 SEE APPENDIX A
54 SEE APPENDIX A
55 SEE APPENDIX A
10054517 ROLLER,D54X1270,EPDM,SHORE A 40,BULGED

Spare parts
5-28
21
25
17 17
38
37
16 15 12 16
ROLLER 37
1
20
ROLLER
19 37
12
1
18 33
37
36
29
BRUSH 34
1 25
7 2 PUR 33
ROLLER
31 35
18 27
28
10 13
9 2
24 14
26
11 9
32
10
23
22
6
5 T8808
3 4
6
30 3 4 5
WASH
30
HEAVY DUTY

Spare parts
5-29
Wash
Wash

2 45371 45371 CIRCLIP D15X1,5 A4
3 SEE APPENDIX A
4 53322 533322 BRACKET, MOTOR, BRUSH
5 14452 14452 CLIP, WORM D2X15.5
6 63400 63400 SHAFT, MOTOR, DEV, WASH
7 10014228 10014228 GEAR, Z23, M2
8 43264 43264 CLAMP, WASH, LOWER, TUBE
9 35976 35976 BUSHING, D20XD23X20, SKF PPM 202320
10 63269 63269 BEARING, BRUSH, WASH
11 53323 53323 GEAR, Z17, M2
12 10057669 10057670 GUIDE, WASH, BRUSH, COMPLETE
13 10017448 10017448 LOCK, BRUSH
14 44911 44911 SPRING, LOCK, BRUSH D7.7X20
15 43584 10026017 ROLLER, PUR, D54
10025951 ROLLER, EPDM, D69, SH30, STRAIGHT, GREY
19 44912 44912 CLIPS, R-SHAPE, D4.0
20 43220 GEAR Z18 M3
43221 GEAR Z23 M3
21 43569 10030012 BRUSH, D55/D20, PPN0.08
24 0011924 0011924 RUBBER PLUG D25MM
25 10055273 10055275 TUBE, SPRAY, PRE/WASH, UPPER, COMPLETE
26 35513 35513 O-RING, VITON, 34.0 x 2.0MM

Spare parts
5-30
21
25
17 17
38
37
16 15 12 16
ROLLER 37
1
20
ROLLER
19 37
12
1
18 33
37
36
29
BRUSH 34
1 25
7 2 PUR 33
ROLLER
31 35
18 27
28
10 13
9 2
24 14
26
11 9
32
10
23
22
6
5 T8808
3 4
6
30 3 4 5
WASH
30
HEAVY DUTY

Spare parts
5-31
Wash
Wash
27 88874 88874 FILTER, WASH, AMIAD, 500, MICRON

28 35083 35083 FILTER, INSERT, AMIAD, 500 MICRON
29 35350 35350 PIN, CYLINDER D4X30 A4 DIN7
30 SEE APPENDIX A
31 44910 44910 SPRING, SPACER, BRUSH D12X30
32 1554 1554 PIN, \4X20
33 88992 88992 STOPPER, TUBE, SPRAY, D20
34 15499 15499 SNAP RING M20X1, 2 4 471
35 10030672 10030672 BRACKET, ROLLER, WASH
36 10024234 10030261 ROLLER, PUR, SMOOTH, STEEL TAP, 13/13
37 35895 35895 O-RING, D14X1.78, VITON
38 32323 32323 GUIDE, WASH, BRUSH
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56

Spare parts
5-32
5
13
6
15
14
11 1
5 12
16 11
17
18
8
10 1
7
9 11
12
11
19
10
3
4
1
19
20
T8810
GUM

Spare parts
5-33
Gum
Gum
1 10046059 BEARING, ROLLER, D54

10046055 BEARING, ROLLER, D69
3 43220 GEAR, Z18, M3
43221 GEAR, Z23, M3
4 44912 44912 CLIPS, R-SHAPE, D4.0
5 10052265 10052265 LIP, GUMTUBE
6 10052649 10052649 LIP, WATER, GUMTUBE
7 10052124 10052124 BEARING, SLICK, ROLLER
8 10052452 10052479 ROLLER, PUR, D30
9 10046130 ROLLER, EPDM, D54, SH25, STRAIGHT, BLACK
10057837 ROLLER, EPDM, D69, SH25, STRAIGHT, BLACK
11 35266 35266 WASHER D21/37X3
12 44944 44944 SPRING, AXIAL, ROLLER
13 45766 45766 O-RING, D6.75X1.78, FPM
14 10052670 10052666 GUMTUBE, COMPLETE
15 0068650 0068650 O-RING D11,11 x 1,78 VITRON
16 10006668 10006668 NUT, M22 MOULDED
17 35434 35434 O-RING 13.3x2.4 EPDM
18 10006670 10006670 VALVE, TUBE, SPRAY
21
22
23
24
25
26

Spare parts
5-34
5
3
21
3
4
6
12
29
22 4 24
29
20
19 28
27
19 25
18 26
17
16
17 2
1 11
1
2
15
14
11
7
9
10
T8809
23
8
13 DRYER

Spare parts
5-35
Dryer
Dryer
1 43523 10030165 DUCT, AIR, UPPER

2 43250 10030202 DUCT, AIR, LOWER
3 10046130 ROLLER, EPDM, D54, SH25, STRAIGHT, BLACK
10057837 ROLLER, EPDM, D69, SH25, STRAIGHT, BLACK
5 6293 6293 HANDLE, BLACK
6 44912 44912 CLIPS, R-SHAPE, D4.0
7 10056265 10056265 GUARDS, FINGER
8 10010015 10010015 FAN, 2DTRU45 180x32
9 10056163 10056163 BRACKET, HEATER, FAN
10 10057104 10057104 INLET, DRYER
11 10053042 10053042 BOX, END, FAN
12 43220 GEAR, Z18, M3
43221 GEAR, Z23, M3
13 10056233 10056233 COVER, MOTOR, FAN
16 10030406 10030406 GUIDE, DRYER
17 16787 16787 SWITCH, ASSY 10-59220-010
18 26385 26385 SENSOR, TEMP THERMISTOR, PLASTIC
19 10035591 74500 BRUSH, ANTISTATIC
20 32332 10031981 GUIDE, DRYER
21 10023350 10032030 COVER, DRYER, COMPLETE
23 10057107 10057107 VIBRATIONDAMPER, 20-25-1, M6x12, SH57
24 98151 10032664 ROLLER, GUIDE, DRYER, COMPLETE
25 35598 35598 CIRCLIP, D14, A2, DIN 471
26 54572 54572 SPRING, D16/D13.6X22.8
27 0180202 0180202 GUIDE, SILICONE D25 INCL.BUSHING

Spare parts
5-36
5
3
21
3
4
6
12
29
22 4 24
29
20
19 28
27
19 25
18 26
17
16
17 2
1 11
1
2
15
14
11
7
9
10
T8809
23
8
13 DRYER

Spare parts
5-37
Dryer
Dryer
28 54334 54334 PIPE, DISTANCE, GUIDE, ENTRANCE

30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56

Spare parts
5-38
29
M E
ST
SY
7
G
N I
BL
RE
MO
A
TE
EN
EN
AB
LIN
G
TE
SYSTE
O
M
TEM
M
G SYS
RE
9 082
ABLIN
Beta2-
E EN
REMOT
6
30
8 9
5
10
4 27
17
11
12 13
28
19
18 16
15
24 14
25
26 31
T8793
22 21
23
20
ELECTRICAL

Spare parts
5-39
Electrical
Electrical
1 64979 64979 BRACKET, CABINET, EL

2 10055968 10055968 BRACKET, FAN
3 10001640 10001640 FAN, TYPE RL90-18/50 R
4 10054510 10054510 PLATE, END, ELBOX, LEFT
5 50932 50932 TOP, BOX EL
6 36227 36227 PROFILE, EDGE TP.DX 2P
7 10054303 10054303 PLATE, END, ELBOX, RIGHT, HPU/HCU
8 10051945 10051945 PSU, AC>DC, 230-24, 125W, OPEN
9 10053174 10053174 SPACER, M3x5+35, BN 3318.1384864
10 10053159 10053159 SHIELD, PLASTIC
11 10053237 10053237 COVER, PANEL, FUSE
12 10051950 10051950 PSU, AC>DC, 230-24, 225W, OPEN
13 60082 60082 PLATE, END, ELBOX RIGHT MPU
14 10054541 10054541 PLATE, END, ELBOX, GNUC II
15 10019350 10019350 PCB, GNUC-II, MIO, SPARES
16 10039871 10039871 PCB, SoM, SPARE
17 10053238 10053238 SPACER, M4x6+25
18 10049000 10049000 PCB, POWER, CONTROL UNIT
19 50931 50931 BOTTOM,BOX EL
20 10053471 10053471 BOX, TOP
21 10053672 10053672 SWITCH, DISCONNECT, 4-CIRCUIT, 32A
22 4121Z000201 4121Z000201 PLASTIC SHIELD
23 36500 36500 GLAND, CABLE, ST-M 32x1.5
24 10053248 10053248 BOTTOM, BOX, FWB
25 10053472 10053472 BRACKET, RELAY,L=135
26 16418 16418 RELAY, HPFI 40A/30mA 400V 4-POL
27 10052560 10052560 PCB, FUSE, PANEL
28 10013597 10013597 LID, CABINET, EL, GNUC II
29 10034929 10034929 REMOTE ENABLING, W SW, GNUCII NOT ALL MODELS
30 10039870 10039870 DISPLAY, SPARE NOT ALL MODELS
31 10030570 10030570 USB MEMORY STICK NOT ALL MODELS

Spare parts
5-40
T8595
COOLER, MAGNUM

Spare parts
5-41
Cooler
Cooler
PLEASE REFER TO THE COOLER MANUALS FOR COOLER SPARE PARTS
1 94224 94224 COOLING UNIT 50 HZ, HIGH CAPACITY

51545 51545 MANUAL, SERVICE, CHILLER KA134A-2
1 94225 94225 COOLING UNIT 60 HZ, HIGH CAPACITY
51054 51054 MANUAL, SERVICE, CHILLER KA134A-2
2 29636 29636 COOLING UNIT, STANDARD CAPACITY 50/60 HZ
51269 51269 MANUAL, SERVICE, STANDARD CAP. COOLER
3 10011476 10011476 CABLE, SUPPLY, STANDARD COOLER
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

Spare parts
5-42
Cables (not illustrated)

10024119 10024119 WIRING HARNESS, HIGH VOLTAGE, PT MK.II

10036504 10036504 WIRING HARNESS, LOW VOLTAGE,
10036208 10036208 CABLE, SUPPLY, MFU
10035978 10035978 CABLE, GNUIB, HPU/MFU-MFU
10024242 10024242 CABLE HARNESS, EMERGENCY STOP
10024427 10024427 CABLE, CLAMP, EMERGENCY STOP
10024428 10024428 CABLE, COVER SWITCH, PT MK.II, S42
10032739 10032739 CABLE, INPUT SENSOR, S11/S12
10030229 10030229 CABLE, EMERGENCY-STOP, X106/X107
10030230 10030230 CABLE, EMERGENCY-STOP, X108
88062 88062 CABLE, TERMINAL->FUSE PRINT
10024781 10024781 CABLE, MOTOR-MFU
98515 98515 CABLE, GNUIB, MPU-MMU, 3.2M
10004721 10004721 CABLE, GNUIB, HPU-MMU/HCU, 1.6M
10033952 10033952 CABLE, FUSE PCB TO HPU
10033953 10033953 CABLE, FUSEPANEL-TRANSFORMER FILTER PCB
10033951 10033951 CABLE, MAIN SWITCH-FUSEPANEL/GFCI
10030637 10030637 CABLE, HPU-TRAFO
10001547 10001547 CABLE, SHORTCUT, 2POLE, MINIFIT
10015205 10015205 CABLE, GROUND
85913 85913 CABLE, GROUND, AWG18, D4-D4,L=150
10015166 10015166 CABLE, BLOWER
85998 85998 CABLE, GROUND, AWG10, D4-D6
10019965 10019965 CABLE, SCSI2, SHIELDED, 4M
10033507 10033507 CABLE, GROUND, INTERF. FRONT
10033460 10033460 CABLE, GROUND, BEARING, DRIVE, BASE
10033461 10033461 CABLE, GROUND, BEARING, DRIVE, PREWASH

Spare parts
5-43

10033462 10033462 CABLE, GROUND, GUIDE, DRYER SEC

10033463 10033463 CABLE, GROUND, LID, ELBOX
10033464 10033464 CABLE, GROUND, ELBOX, GNUC
10033465 10033465 CABLE, GROUND, GNUC-LID
10036104 10036104 CABLE, LPM TO WATER REPLENISH PUMPS
10036618 10036618 CABLE, HPFI TO X7

Spare parts
5-44

Appendix A:
A-1
Additional spareparts
Appendix A: Additional spareparts
Some of the spareparts shown on the ISO-metric drawings in Part 5 have no sparepart
number and specification. The sparepart numbers and specification for those parts are
listed below. The page and position numbers refer to the page and position numbers
used in Part 5.
Please also refer to the ISO-metric drawings in Part 5.
When ordering spareparts please state carefully the sparepart number, the
specification and the number of items wanted before you send your order.
Page 5-2 (Panels):

1 10023590 10023590 FENDER, SHORT, LEFT
3 10023580 10023580 FENDER, SHORT, RIGHT
4 10031132 10032495 PANEL, INTERFACE, COMPLETE
5 10023380 10031878 PANEL, REAR, UPPER
9 10023372 10031871 PANEL, DRYER, HINGED
10 10023060 10031868 PANEL, TOP, HINGED
Page 5-4 (Stand):

1 10031595 10032044 PANEL, FRONT, STAND
2 50014 10032047 PANEL, REAR, STAND
6 10052484 10052484 LEG, LEFT, REINFORCE, STAND
7 10052483 10052483 LEG, RIGHT, REINFORCE, STAND
Page 5-6 (Stand closed):

1 10032990 10032990 PANEL, SIDE, LEFT, STAND
2 10032992 10032992 PANEL, SIDE, RIGHT, STAND

Appendix A:
A-2
Page 5-12 (Drive):

22 10024652 10024652 MOTOR, DRIVE KSV5035/702
10056830 10056830 MOTOR, DRIVE, 125RPM, 8.8NM
25 32969 32969 BRACKET, MOTOR, DRIVE
10050951 10050951 BRACKET, MOTOR, DRIVE
26 63401 63401 GEAR, Z16, M2
10049516 10049516 GEAR, Z20, M2
29 10031570 10031570 MOTOR, DRIVE, Z16, KSV, COMPLETE
10052435 10052435 MOTOR, DRIVE, Z20, BODINE, COMPLETE
Page 5-14 (Circulation and drain: Tap water):

10 10025521 10025521 PUMP, DEVELOPER, MD-20R
10050649 10050649 PUMP, DEV, MD40
Page 5-16 (Circulation and drain: Tap water):

43 15770 15770 INSERT, FILTER TP. F40/CP509.7, COTTON
57727 57727 FILTER, INSERT, 9 7/8", 150 MIC, REUSE, BROWN
57728 57728 FILTER, INSERT, 9 7/8", 350 MIC, REUSE, GREY
Page 5-18 (Circulation and drain: Water saving):

10 10025521 10025521 PUMP, DEVELOPER, MD-20R
10050649 PUMP, DEV, MD40
Page 5-20 (Circulation and drain: Water saving):

43 15770 15770 INSERT, FILTER TP. F40/CP509.7, COTTON
57727 57727 FILTER, INSERT, 9 7/8", 150 MIC, REUSE, BROWN
57728 57728 FILTER, INSERT, 9 7/8", 350 MIC, REUSE, GREY
Page 5-26 (Developer):

30 43570 10030010 BRUSH, PPN 0.10, D55, WHITE
43569 10030012 BRUSH, PPN 0.08, D55, BLACK
43574 BRUSH, PA6/12 0.075, D55, BLACK
10030011 BRUSH, PA6/12 0.075, D55, BLACK
33 10004309 10004309 MOTOR, KSV 5053/711 24 V DC
10050560 10050560 MOTOR, BRUSH, BODINE, 60800610-2

Appendix A:
A-3
Page 5-26 (Developer):

63455 ROLLER, SILICONE, D54, SHORE 40, STRAIGHT, RED
63455 ROLLER, SILICONE, D54, SHORE 40, STRAIGHT, RED
55 10031075 10031075 MOTOR, BRUSH, KSV, COMPLETE
10054471 10054471 MOTOR, BRUSH, BODINE, COMPLETE
Page 5-28 (Wash):

3 10004309 10004309 MOTOR,KSV 5053/711 24 V DC
10050560 10050560 MOTOR, BRUSH, BODINE, 60800610-2

Appendix A:
A-4

Appendix B:
B-1
Electrical diagrams
Appendix B: Electrical diagrams

This chapter includes all electrical diagrams for the 85/125 processor.
The diagrams (5 pages) cover:
• Main power distribution, Fuse panel and interlocks

• Motors and internal bus wiring, 24V DC distribution
• Primary wiring, 230V AC control devices
• Primary wiring, preheat, 230V AC
• Low Voltage Wiring, Sensors and control devices)

Appendix B:
B-2
Electrical diagrams
Main power distribution
Fuse panel and interlocks

A B C D E
Three Phases Without Neutral, 230V, 3W + PE Return 1*

1
X7 Line 1*
X3 C1 C2 C3 2
PE 10nF 10nF 10nF Return 2*
Ground Fault F1 20 AT To PCU
Main switch Orange A 3
Circuit Interruptor Return 1 RV1 shown on
S21 Line 2* page 2
F10 C4 R1
220nF 470k
4
Brown B F2 20 AT Return 3*
4 Blue N N Blue Line 1 10052775
N N 5
F3 20 AT Line 3*
4 Blue C 4
3 Black 5/L3 6/T3 Black Return 2 6
L3 6 5
C5 R2 X11
In<0.03A 220nF 470k
2 White 3/L2 4/T2 White Yellow D F4 20 AT
L2 4 3 Line 2
1 Red 1/L1 2/T1 Red Black E F5 20 AT
L1 2 1 Return 3
10053871 10053872 C6 R3
220nF 470k
Field Wiring Box Red F F6 20 AT F13 N.M.
Line 3
10053862 C7 C8 C9
1
10nF 10nF 10nF F15 N.M.
2
F8 6.3 AT L1
Single Phase, 230V, 2W + PE or 1W + N + PE F12 F10 3
F11 N.M.
X7 Use only on thermal variants (without preheater) N.M. 4
2 AT
X3
PE E-stop Cover Cover Cover Cover Follow E-stop + cover Follow E-stop F14 N.M. 5
Main switch Ground Fault Orange A
S21 Circuit Interruptor 6
F10
Brown B X12
C10
4 Blue N N Blue 1 2 3 4 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4
X2
X4
N N C11 C12
X52
X51
X50
X43
X42
X40
X41
X39
10nF 10nF
10nF
Blue C
3
3 Black 5/L3 6/T3 Black 3
L2 6 5
(N) In<0.03A
2 White 3/L2 4/T2 White Yellow D
4 3
Output for Stacker
1 Red 1/L1 2/T1 Red Black E
L1 2 1
10053871 10053872
10001547
CN1 CN5
Field Wiring Box Red F 1
AC/L - 1 To PCU, X1
10053862 2 24 Vdc, 4.2 A shown on
+ 5
Fold back limiter page 2
3
AC/N
10052748
Three Phases With Neutral, 400V, 3W + N + PE 10052747
CN1 CN5
X7
X3 1
10053875
AC/L 6
10053873
10053874
PE 2 -
Main switch Ground Fault Orange A 18
24 Vdc, 9.4 A To PCU, X1
S21 Circuit Interruptor 3 -
shown on
F10 AC/N Constant current 3
+ page 2
Brown B 10057523 15
4 Blue N N Blue +
10053863
N N N
Blue C
2
3 Black 5/L3 6/T3 Black 2
L3 6 5
In<0.03A D
2 White 3/L2 4/T2 White Yellow
L2 4 3
1 Red 1/L1 2/T1 Red Black E
L1 2 1
10053871 10053872
Field Wiring Box Red F
10053862
IMPORTANT
X109 X106 X107 X108
Check wiring at main terminal X7 and ground fault interruptor F10 before the power 11 12 11 12 11 12
supply is switched on. 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 S42 S43 S44
Rewire if necessary accordingly to table below.

Cover Switch Cover Switch Cover Switch
Line Voltage: Ground Fault Interruptor, F10: Wiring between Fuse PCB and Ground Fault Interruptor, F10: S47 S48 S49 S41 Rinse Section Developer Section Prewash Section
(Not on all Models)
Three Phases without Neutral, Jumper between Red: X3,F to F10,1 Yellow: X3,D to F10,3 Brown: X3,B to F10,5
1 1
230V, 3W + PE N and 2 Black: X3,E to F10,3 Blue: X3,C to F10,5 Orange: X3,A to F10,1 Emergency Stop Emergency Stop Emergency Stop Emergency Stop
(optional) (optional) (optional) (optional)
Single Phase without Neutral Jumper between Red: X3,F to F10,1 Yellow: X3,D to F10,1 Brown: X3,B to F10,1 Front right Front left
230V, 2W + PE N and 2 Black: X3,E to F10,5 Blue: X3,C to F10,5 Orange: X3,A to F10,5
Title: Number: Rev.:
Single Phase with Neutral Jumper between Red: X3,F to F10,1 Yellow: X3,D to F10,1 Brown: X3,B to F10,1 Date: Tuesday, August 31, 2010
230V, 1W + N + PE N and 2 Black: X3,E to F10,5 Blue: X3,C to F10,5 Orange: X3,A to F10,5 Main Power Distribution
Constructor: JW 10053615 C
Red: X3,F to F10,1 Yellow: X3,D to F10,3 Brown: X3,B to F10,5 Function: ELECTRONIC AND MECHANICAL ENGINEERING
Three Phases with Neutral, Doc. No.:
Black: X3,E to F10,N Blue: X3,C to F10,N Orange: X3,A to F10,N Approval: This drawing belongs to Glunz & Jens en A/S
400V, 3W + N + PE
Fuse Panel And Interlocks 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: 1 Of: 6 OrCAD
A B C D E
Appendix B:
B-4
Electrical diagrams
Motors and internal bus wiringI
24V DC distribution

Part of Power Control Unit, PCU P1
DC F27 2.5 AT
+ 3.3 Vdc
4 #4
DC (mikrocontroller circuitry) TX
F28 4AT 8 #8
3 2 + 24 Vdc TX
X1
U37 (DC output supply) 2 #2
F24 .
RX
4 LM78L05 98516
CN5, 5 8
IN OUT
1 + 5 Vdc Q411 7 #7
RX
GND
24 Vdc from CN 5 on +
#1
#2
#3
#4
#5
#6
#7
#8
#9
1 3 #3
3
PSU 1 CN5, 1 0.6 AT 0V GND
(interrupted by E-stop) 100 R 1 #1
+ 24 Vdc 6 #6
1
2
3
4
5
6
7
8
9
P3
5 #5
CN2,3 5 Dual Motor Controller F26
Part of MIO
9 #9
+ See page 3 for connection to
2 10AF
24 Vdc from CN 2 on CN2,6 input and temperature sensors
BTN7930
BTN7930
PSU 2 6 F25 P1
(interrupted by cover CN2,15
+ 50 ckt
switch) 3 10AF 4
CN2,18 TX
8
IN 6
IN 7
10052747 TX
2
RX
7
RX
BTN7930
BTN7930
BTN7930
BTN7930
X36 1 2 3 4 5 6 7 8 9 10 3
GND
100 R 1
2 x 25 pairs 1:1
6
5
10057540
9
signal
signal
X5 X4 X13 X12
+ + + + 50 ckt
1 4 2 6 3 5 1 4 2 6 3 5 1 4 2 6 3 5 1 4 2 6 3 5
Man Machine Interface, MMI
M2 +
M2 -
M2,1
M2,4
M2,3
M2 +
M2 -
M2,1
M2,4
M2,3
M2 +
M2 -
M2,1
M2,4
M2,3
M2 +
M2 -
M2,1
M2,4
M2,3
10043714 10043713 10053865 10053864
Alternate motors on High Speed variant
Part of Power Control Unit, PCU
X5 X4 X13 X12
+ +
1 4 2 6 3 5 1 4 2 6 3 5 1 4 2 6 3 5 1 4 2 6 3 5
X51,5
X51,1
X51,7
X51,2
X51,6
X50,1
X50,5
X50,7
X50,2
X50,6
X53,5
X53,7
X53,2
X53,6
X52,1
X52,5
X52,7
X52,2
X52,6
F19
10050874 10050875 4AT 10057139
X53,1
10057136
X13,4
X13,1
X13,3
X13,5
X13,2
X12,4
X12,1
X12,3
X12,5
X12,2
X5,4
X5,1
X5,3
X5,5
X5,2
X4,1
X4,4
X4,3
X4,5
X4,2
F18 F17
F20
4AT 8AT
4AT
X51 X50 X53 X52
1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8 1 5 2 6 3 7 4 8
X5,4
X5,1
X5,3
X5,5
X5,2
X4,1
X4,4
X4,3
X4,5
X4,2
X13,4
X13,1
X13,3
X13,5
X13,2
X12,4
X12,1
X12,3
X12,5
X12,2
4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1
1 2 1 2 1 2 1 2
F17 F19 F20
F18
6AT 6AT 6AT 6AT
Red
Red
Red
Red
Black
Black
Black
Black
White
White
White
White
2 X T filter 2 X T filter 2 X T filter1 2 X T filter2

Vcc
Vcc
Vcc
Vcc
Black
Red
Black
Red
Black
Red
Black
Red
Black
Black
Black
Black
White
White
White
White
M
M
M
M
M
M
M
M
X X X X
Brush motor, Dev, M2 Encoder S31 Transport motor M1 Encoder S30 Brush motor, Prewash M13 Encoder S33 Brush motor, M3 Encoder S32 Brush motor, Dev, M2 Transport motor, M1 Brush motor, Prewash, M13 Brush motor, Wash, M3
Encoder S31 Encoder S30 Encoder S33 Encoder S32

Date: Tuesday, August 31, 2010
Motors and Internal Bus Wiring
Function: ELECTRONIC AND M ECHANICAL ENGINEERING
Doc. No.:
Approval: This drawing belongs to Glunz & Jensen A/S
24 Vdc distribution and must not be used or handed over to any
unauthorized person without our specific permission.
Page: 5 Of: 6 OrCAD
Appendix B:
B-6
Electrical diagrams
Primary wiring
230V AC control devices

Power Control Unit, PCU
6 Line 3
5 Return 3
From X11, 4 Line 2
on Fuse PCB Return 2
3
2 Line 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 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
Q36 Q28 Q44 Q30 Q55 Q45 Q42 Q43 Q46 Q53 Q64 Q66 Q32 Q34 Q59 Q61
F6 F7 F8
1AT 1AT 1AT
Max 1A
Max 1A
Max 1A
Max 1A
X102
X101
X109
X104
X103
X108
X105
X106
X107
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
NOTE: NOTE: NOTE: NOTE:

Connectors contains other Connectors contains other Connections for Preheat in Connections for
wires for wires for this connector Preheat in this
other components in other components in See page 4 connector
processor processor (Optional) See page 4
See page 4 See page 4 (Optional)
(Optional) (Optional)
X33,3
X33,2
X33,1
X31,2
X31,1
X38,3
X38,2
X38,1
X40,2
X36,4
X40,1
X36,3
X40,4
X36,2
X36,1
X40,3
X37,2
X46,2
X46,1
X37,1
X30,2
X30,1
X91,2
X47,2
X91,3
X47,1
X91,1
X35,3
X35,2
X41,1
X34,3
X34,2
X34,1
Ground screw
in Electronics
10053876
10053877
X42,2
X35,1
X105,8
X105,4
X101,4
X101,2
X102,6
X102,1
X102,2
X108,5
X108,2
X108,5
X108,2
X107,5
X107,1
X107,2
X105,6
X105,1
X109,5
X109,1
X109,2
X103,4
X103,2
X103,3
X103,1
X103,3
X103,1
X103,4
X103,2
X107,8
X107,4
X107,4
X30 X31 X33 X37 X46 X34 X47 X38 X36 X40 X35 X42
3 2 1 3 2 1 4 3 2 1 3 2 1 3 2 1 4 3 2 1 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 3 2 1
X105,2
X105,6
X105,1
84°C
M 75 °C M M M M X6
Yl/grn
Blue
Black
Brown
M4 M18 M10 M12 M11 3 2 1 K4

75 °C 75 °C 75 °C 75 °C C1
E1
M M
620W 620W 620W 620W M5
Dev heating: Optional M14 E 12
Dev circ E 10 E3 E 11
2200W on 125 width Dev Wash Prewash
pump Dev fill up Motor capacitor,
1500W on 85 width replenish circulation circulation
Plug for Chiller Electronic Fan GUM circ pump Dryer Heating Dryer Heating Dryer Fan dryer fan
X31 Optional
3 2 1 Only on HDX High Speed
10049423
X15 X16
3 2 1 4 3 2 1
84°C
75 °C
250W
750W
70 °C
E1
Primary Wiring
Dev heating, E1 Dev heating, E2 Constructor: JW 10053615 C
1500W 250 + 750 W Doc. No.:
230 VAC Control Devices and must not be used or handed over to any

Page: 2 Of: 6 OrCAD
Appendix B:
B-8
Electrical diagrams
Primary wiring, preheat
230V AC

158 Line 3
135 Return 3
From X11, 142 Line 2
on Fuse PCB Return 2
157
159 Line 1
160 Return 1
Non interrupted
Non interrupted
X6 RV35 RV23 RV43 RV24 RV44 RV42 RV41 RV36 RV39 RV28 RV40 RV37 RV38 RV25 RV34 RV33
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
Q37 Q29 Q58 Q31 Q68 Q63 Q52 Q56 Q57 Q54 Q65 Q67 Q33 Q35 Q60 Q62
F9 F21 F22
1AT 1AT 1AT
Max 1A
Max 1A
Max 1A
Max 1A
X102
X101
X109
X104
X103
X108
X105
X106
X107
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
NOTE:
Connectors contains other wires for
other components in processor
See page 2
X90,4
X90,6
X90,2
X90,1
X90,11
X90,8
X90,9
X90,7
X90,5
X90,12
X90,13
X90,3
X90,14
X90,10
Ground screw
in Electronics
10053879
X101,1
X101,3
X104,1
X102,8
X106,1
X102,4
X106,3
X104,4
X104,5
X106,2
X102,4
X104,8
X104,4
X106,4
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
X90 OPTIONAL
E5,2
E6,2
S22,P1
X73,3
E9,2
X73,2
X33,1
E7,2
S22,P3
S13,P3
X72,1
X29,3
X29,2
S13,P1
10053880
X90,5
X90,7
X90,2
X90,1
X90,4
X90,6
X72,2
X73,1
X90,3
X90,9
X33,2
X29,1
X90,8
X90,11
X90,14
X90,10
X90,12
X90,13
S22 S13
P3 P2 P1 X73 X72 P3 P2 P1 X29 X33

4 3 2 1 3 2 1 4 3 2 1 3 2 1
Chassis
198 °C 198 °C
3 2 1 3 2 1
1350W E5
Preheat
1350W E9
2 1 1 2 2 1 1 2 1350W E6
Boost
1350W E7
M C3 M C4
E9 E5 E6 E7
M7
M8 Plate travel
Pre-heat Pre-heat Boost Motor capacitor Boost Boost Preheat Motor capacitor
1350W 1350W blower for M7 1350W 1350W blower for M8

Primary wiring, preheater
Doc. No.:
230 VAC and must not be used or handed over to any
Page: 4 Of: 6 OrCAD
Appendix B:
B-10
Electrical diagrams
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
R9,1
R9,2
R4,1
R4,2
R5,1
R5,2
X101,1
X101,2
X101,5
X101,6
R1,1
R2,2
X92,1
X92,2
X94,1
X94,2
X92,3
X92,4
S15,1
S15,2
S14,1
S14,2
Red
Blue
Green
Yellow
10053869
10053868
10053870
Optional
2
1
J10,1
J10,2
J10,3
J10,4
J10,9
J10,5
J10,6
J11,3
J11,4
J11,5
J11,6
J10,15
J10,16
J10,13
J10,14
J10,10
5
3
X92 X94 X101
1 2 3 4 1 2 1 2 3 4 5 6
1 1 1 1 1
J11,7
J11,8
J12,1
J12,2
J11,13
J11,14
1 1 1 Plate Setter
1 1 R4 1 R5 See Setter manual for actual
R1 R30 R31 R3 S14 S15 S11 S12 R9
pin connections, or contact your S27
Rntc Service Suplier.
Rntc 10K Rntc 50K Rntc 10K
15k
15k
15k
50K
NC NC NC NC Developer Conductivity
2 2 2 Sensor (If fitted)
2 2 2 2 2 2 2 2
Dev temp Preheat Preheat Dryer temp Output Output Input Input Dev tank Wash tank Prewash
sensor temp sensor temp sensor sensor sensor sensor sensor sensor min level max sensor max sensor
(optional)

0 Vdc +24Vdc +24Vdc
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
X9 X10 X11
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
R8,1
R8,2
R6,1
R6,2
X80,1
X80,2
B22,1
B22,2
K12,1
K12,2
K15,1
K15,2
K13,1
K13,2
K11,1
K11,2
R25,1
R25,2
R13,1
R13,2
X103,1
X103,2
K16/K17
K16/K17
10053866 10053867 10048696

X11,1
X11,2
X10,11
X10,12
X103 X80
X9,3
X9,4
X11,11
X11,12
X11,11
X11,12
X10,3
X10,4
X10,5
X10,6
X10,7
X10,8
X10,9
X10,10
1 2 1 2
1 2 1 2
1 1 1 1 1
X11,3
X11,4
X11,5
X11,6
X11,7
X11,8
X11,9
B22
X11,10
1
R8 R25 R6 R13 1 1 1 1 1 1 1
15k
15k
15k
15k
15k
R26
15k
2 2 2 2 2
24V 24V 24V 24V
K14 K12 K15 K13 K11 K16 K17
2
2 2 2 2 2 2 2
Water container
Dev fill container Waste container
min sensor, B22 Dev tank Gum container Dev replenish Gum Prewash water Gum double Gum rinse Wash fill
min sensor max sensor Reduction kit solenoids
(optional) max sensor min sensor container min sensor drain valve valve (optional) valve (optional) valve valve
(optional) (optional) (optional)

Low Voltage Wiring
Constructor: JW
ELECTRONIC AND MECHANICAL ENGINEERING
10053615 C
Function:
Doc. No.:
Approval: This drawing belongs to Glunz & Jens en A/S
Sensors And Control Devices 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: 3 Of: 6 OrCAD
Appendix B:
B-12
Electrical diagrams

Ip 85HDX 2010

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Service Manual

InterPlater 85/125 HDX

Edition DA, August 2010

Part 0: General information

The directions given must not be followed by unauthorized personnel.

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

Copyright© 2008 by GLUNZ & JENSEN A/S.

1034 Service Manual - Plate Processors 85/125

Notes, Cautions, and Warnings

Symbol Meaning Explanation

" Note information in order to obtain the best possible function

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.

Unintended use of the equipment

Service Manual - Plate Processors 85/125 1034

CE certification of the equipment shall be removed as the certification will no longer

Intended use of the equipment

“End of lifetime” disposal

1034 Service Manual -Plate Processors 85/125

Service Manual - Plate Processors 85/125 1034

Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1

Part 1: Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

1034 Service Manual - Plate Processors 85/125

Part 2: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

Part 3: Cleaning and maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

Service Manual - Plate Processors 85/125 1034

Adjusting the brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

Part 4: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

Part 5: Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

1034 Service Manual - Plate Processors 85/125

Appendix A: Additional spareparts

Service Manual - Plate Processors 85/125 1034

Processor Installation Manual (1)

Processor Service Manual (2)

1034 Service Manual - Plate Processors 85/125

Software Service Information (3)

CE Declaration of Conformity (4)

Safety Instruction Manual (5)

Processor User Manual (6)

Control Panel (user manual) (7)

Quick Guide (8)

Service Manual - Plate Processors 85/125 1034

Part 1: Technical specifications

General environmental information

The processor does not contain

The processor complies with the RoHS directive (2002/95/EC).

1034 Service Manual - Plate Processors 85/125

Sound pressure level

Plate types Presensitized single-sided positive or negative offset plates.

Plate width 200 - 850 mm 200 - 1250 mm

Plate length 285 mm 285 mm

Plate thickness 0.15 - 0.40 mm 0.15 - 0.40 mm

Plate speed 40 - 220 cm/min. 40 - 180 cm/min.

Developer 54 l (14 US gal.) 79 l (20.9 US gal.)

Wash 14 l (3.7 US gal.) 20.5 l (5.4 US gal.)

Gum (optional 3.5 l (0.9 US gal.) 4.2 l (1.1 US gal.)

Service Manual - Plate Processors 85/125 1034

Length, total (L1) 340.6 cm (134,1") 425.6 cm (167,6")

Length, processor (L2) 157.6 cm (62.1") 157.6 cm (62.1")

Length, feed table (L3) 60 cm (23.6") 60 cm (23.6")

Length, feed extension (L4) 23.5 cm (9.3") 40.5 cm (15.9")