Service Manual

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0323M380.3
SERVICE MANUAL

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Page 3
ENGINEERING SCREENS
SERVICE MANUAL

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Starting the Processor

1 HT PRO, 205 2
[Software Version]
[Date & Time]
Heater System
DC Drive System
3 ADC System 4
Read Clock - Done
Read PT Cal - OK

5 Any Key To Start 6

7 8

This Start up screen will be displayed when the mains power to the proces-
sor is switched on. This screen shows information on the software version
and self-checks of the system.
This series of processors uses a digital control system. The software
parameters are factory pre-set and can only be changed by approved per-
sonnel using a secure password.

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SERVICE MANUAL

1 Excercise Machine 2
2301

3 4

Any Key to Stop

5 30 6

7 8

Pressing any key will start the processor and bring up the Exercise
Machine Screen
The processor will go into an Auto run mode running for 30 seconds.
Pressing any button will stop this function.
Usually when the processor is first switched on Developer and Pre-heat
temperatures will be out of specification. In most cases the next screen will
show the active Alarms Menu.

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Alarms

1 Alarms 2
Return 1900

3 Dev Temp Low 4

Pre-Heat Temp Low

5 6

7 8

This screen shows the active alarms. (Typical Example)

In normal operation these alarms will be temperature related and will clear
as the processor warms up.
In other cases the e.g. Developer level. User intervention will be neces-
sary.
Pressing the Return button will take the operator to the Main Menu

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SERVICE MANUAL
Main Menu

Main Menu 2
1
Return Re-Enter
Plate

3 Operator Sleep 4
Settings

5 Change Menu Drive 6

System
Summary Engineering
7 8

1 Returns to Operator Display Manual Plate Re-Entry 2

3 Moves to the Operator Settings
Menu
Moves to Sleep Menu 4
5 Moves to the Change Menu Moves to Drive Menu 6
7 Moves to the System Summary
Menu
Moves to the Engineering Menu
(Passcode Protected) 8

As described in the Operator Manual this screen allows access to certain

functions. One of these functions is the Engineering Menu.
This allows a Service Engineer to:
1. Set Processing parameters eg. developer temperature, drive speed etc.
2. Configure the processor.
3. Calibrate temperature sensors and replenishment pumps.
4. Check component operation by manually activating them.
5. Check input signals from sensors to the control board.

Press Press Engineering to go to the Engineering Menu

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Enter Password Screen

Set Password
1 2
Return 0

3 1 2 4

5 3 4 6

5 6
7 8

1 Moves to the Main Menu / Active

Alarms (if any exist)
Push to key in number 2
3 Push to key in number Push to key in number 4
5 Push to key in number Push to key in number 6
7 Push to key in number Push to key in number 8
All adjustable settings on this processor are inputted via the display. As
there are no user adjustable settings in normal operation, all settings are
protected by 4-digit numeric passcode calculated using the table on the
next page.
This is changed six times per day, 365 days a year.
If unauthorised access is gained to the microprocessor serious damage
could be done to the machine as well as there being Health and Safety
Risk.

It is vital that the password calculation table or related infor-

mation is not given to customers/end users. This information
! is intended for use by trained technicians only. Unauthorised
access to the engineering section by untrained personnel
could result in the processor not functioning correctly, damge
to the processor and the warranty being made invalid.

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SERVICE MANUAL
Engineering Passcode Calculation Table

Note

L First check that the local time and date are correct on the
screen.

First Digit (Hour)

Hour Code
The hour of the day divided by four.
00:00 - 03:59 0
04:00 - 07:59 1
08:00 - 11:59 2
12:00 - 15:59 3
16:00 - 19:59 4
20:00 - 23:59 5
Second Digit (Day)
The remainder when the day of the month is divided by six.

Day Code 16th 4

1st 1 17th 5
2nd 2 18th 0
3rd 3 19th 1
4th 4 20th 2
5th 5 21st 3
6th 0 22nd 4
7th 1 23rd 5
8th 2 24th 0
9th 3 25th 1
10th 4 26th 2
11th 5 27th 3
12th 0 28th 4
13th 1 29th 5
14th 2 30th 0
15th 3 31st 1

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Third Digit (Day) Hour Code
The day of the month divided by six.
1, 2 , 3, 4, 5 0
6, 7, 8, 9, 10, 11 1
12, 13, 14, 15, 16, 17 2
18, 19, 20, 21, 22 ,23 3
24, 25, 26, 27, 28, 29 4
30, 31 5

Fourth Digit (Month)

Remainder of the month divided by six.

Hour Code July (07) 1

January (01) 1 August (08) 2
February (02) 2 September (09) 3
March (03) 3 October (10) 4
April (04) 4 November (11) 5
May (05) 5 December (12) 0
June (06) 0

The correct passcode is dependent on the time and date shown on the front
screen display.
On the installation check that the time has been entered - Main Menu -
Closedown - Set Clock.
Once the passcode has been entered successfully , this provides access to
all areas of the operator and utility settings, When the passcode-protected
area is exited and the machine reverts to normal operation mode, you can
re-enter the code.
Each time you re-enter within the 60 minutes, the 60 minutes is reset. After
the 60 minutes has elapsed, the code must then be re-entered

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SERVICE MANUAL

1 Set Password 2
Return 0

3 1 2 4

5 3 4 6

5 6
7 8

1 Moves to the Main Menu / Active

Alarms (if any exist)
Push to key in number 2
3 Push to key in number Push to key in number 4
5 Push to key in number Push to key in number 6
7 Push to key in number Push to key in number 8
Example
If the Time and Date are:
14:30 on the 17th August
Then the Passcode would be:
14:30 / 4 = 3
17th / 6 (remainder) = 5
17th / 6 = 2
August (8th month) / 6 (month) = 2

Passcode for this time and day = 3522

Enter Passcode digits - Return - Go to Engineering Main Menu

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Engineering Main Menu Screen

Engineering Main Menu

1 2
Exit

3 4

5 Process
Settings
Service
Utilities 6

7 8

1 Exits to EEPROM Update Screen No Selection Available 2

3 No Selection Available No Selection Available 4
5 Moves to Process Settings Moves to Service Utilities 6
7 No Selection Available No Selection Available 8
This Screen gives access the two functions:
1. Process Settings
Access to -
Developer Menu
Pre-Heat Menu
Prewash/Rinse/Gum Menu
Dryer Menu
2. Service Utilities
Access to -
Test
Machine Configuration and Settings
Watchdog Events and Settings
Settings Alarm Cancel Time
Pressing the Exit key will give the engineer the choice of saving any
changes made to the settings.

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SERVICE MANUAL
EEPROM Update Screen

EEPROM Update 2
1

3 Save Any Change 4

Made to EEPROM Memory

5 6

Quit Continue
7 8

1 No Selection Available No Selection Available 2

3 No Selection Available No Selection Available 4
5 No Selection Available No Selection Available 6
7 Quit Continue 8
Press Continue to exit and Save or Quit to Exit without saving.
Pressing Quit will return to the Main Menu Screen.
Pressing Continue will bring up a screen to confirm that the Updates have
been successful.
Pressing any key will then return to the Main Menu.
Return to Engineering Main Menu and Select - Process Settings

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Process Settings Screen

Processor Settings
1 2
Return

3 Developer Gum 4
Menu Replenish
Type

5 Preheat Menu 6

Dryer Menu Data Menu

7 8

1 Returns to Engineering Menu No Selection Available 2

3 Move to Developer Menu
Move to Prewash / Rinse / Gum
Menu 4
5 Move to Preheat Menu No Selection Available 6
7 Dryer Menu Save Settings 8
These menus allow all processors parameters to be chaecked and adjust-
ed.

Press - Developer Menu

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SERVICE MANUAL
Developer Menu Screen

Developer Menu 2
1
Return

3 Processor Dev Replen 4

Speed Type

5 Developer 6
Temperature

Brush Speed
7 8

1 Returns to Processor Settings No Selection Available 2

3 View and Change Processor Drive
Speed
Select the Type and Rate of
Developer Replenishment 4
5 View and Change
Temperature
Developer
No Selection Available 6
7 View and Change Processor Brush
Motor Speed
No Selection Available 8
This screen allows access to process parameters associated with the
Developer Section.
Processor Speed - Sets the time the plate is in the developer. Shown as
“Dwell Time” in seconds and as Speed in mm/min or inches/min.
Developer Temperature - Sets the temperature of the developer. Shown
as degrees C or F
Brush Speed - Sets the speed of the scrub rollers in the developer section
and prewash. Shown as RPM.
Developer Replenisher Type - Sets the replenisher type from None (Off)
to Per Area (Replenish by area or plate processed)
When Per Area, selected access to setting is allowed. Shown as mls/m2 of
fl oz/ft2.
As an example of how to make adjustments - Press Processor Speed

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Processor Speed Screen

Processor Speed
1 2
Enter Default

3 Increase Left Digit 4

5 Decrease Right Digit 6

19.0 seconds

7 1006 mm/min 8

1 Enters Settings and returns to

Developer Menu
Restores Default Settings 2
3 Increases Highlighted Figure Moves Highlight Cursor Left 4
5 Decreases Highlighted Figure Moves Highlight Cursor Right 6
7 No Selection Available
No Selection Available - Displays
speed setting. 8
This is an example the general layout of a Settings Screen.
By pressing the appropriate button(s) the cursor can be moved and the set-
ting changed.
Once set pressing enter returns to the previous menu. In this case the
developer menu.
Pressing the Default button can set default values (which are pre-pro-
grammed and cannot be changed).
In this case the Default value is 19.0 sec / 1006mm/min
All Setting screens use the same or similar format
Press - Enter - Return to go to Process Settings
Select Pre-Heat Menu

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SERVICE MANUAL
Preheat Menu Screen

Preheat Menu 2
1
Return

3 4
0.15mm 0.20mm

5 0.24mm 0.30mm 6

7 8

1 Enters Settings and returns to

Process Settings
No Selection Available 2
3 Moves to Setting Screens for
0.15mm plates
Moves to Setting Screens for
0.20mm plates 4
5 Moves to Setting Screens for
0.24mm plates
Moves to Setting Screens for
0.30mm plates 6
7 No Selection Available No Selection Available 8
This screen allows access to the setting screens for the different gauges of
plates being processed. The heaters are split into 2 zones (inner and outer)
and the temperatures monitored.
These temperatures can be adjusted to achieve an even pre-bake.
Factory Pre Sets are:
0.15mm = Inner 330 / Out 330 Deg C
0.20mm = Inner 350 / Out 350 Deg C
0.24mm = Inner 380 / Out 380 Deg C
0.30mm = Inner 460 / Out 460 Deg C
The heaters can also be switched off to ensure that the temperature is
maintained as the plate passes through the preheat section.
Refer to Set Back Temperature and Start Setback.
Other screens for the different gauges are the same.
Press - 0.15mm

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Setting Preheat Temperature

Preheat Out 1
1 2
Enter Default

3 Increase Left Digit 4

5 Decrease Right 6
330.0C

7 8

1. Sets Preheat Outer Zone Temperature - Enter

Preheat In 1
1 2
Enter Default

3 Increase Left Digit 4

5 Decrease Right 6
350.0C

7 8

2. Sets Preheat Inner Zone Temperature - Enter

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SERVICE MANUAL
Setting Preheat Temperature (Set Back / Set Back Start)

Set Back 2
1
Enter Default

3 Increase Left Digit 4

5 Decrease Right 6
20.0C

7 8

3. Sets the Temperature Drop as the Rear of the plate passes through the
heater - Enter

Set Back Start

1 2
Enter Default

3 Increase Left Digit 4

5 Decrease Right 6
24mm

7 8

2. Distance from the rear of the plate that the temperature starts to drop -
Enter - Return - Select Dryer Menu.

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Dryer Menu Screen

Dryer Menu
1 2
Return

3 Dryer Warm Up Dryer O/P 4

5 6

7 8

1 Enter Settings and Returns to

Process Settings
No Selection Available 2
3 Moves to Dryer Warm Up Menu Moves to Dryer Output Menu 4
5 No Selection Available No Selection Available 6
7 No Selection Available No Selection Available 8
This screen allows access to the setting screens to set parameters for the
Dryer.
Dryer Warm Up - Sets the start time for the dryer to start before the plate
reaches it. (Sec's)
Dryer Output - Sets the output of the dryer as a percentage (%)
Press - Enter to save settings and Return to Processor Settings -
Select Prewash / Rinse / Gum

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SERVICE MANUAL
Service Utilities Screen

Service Utilities 2
1
Exit

3 Test Settings 4

5 M/c Config Alarm 6

Cancel Time

Watchdog
7 Events 8

1 Exit and Returns to Engineering

Main Menu
No Selection Available 2
3 Moves to Test Menu Moves to Settings Menu 4
5
Moves to Machine Configuration
Menu
Moves to Alarm Cancel Time Menu 6
7 Moves to Watchdog Events Menu No Selection Available 8
This is the Service Utilities Screen. This screen gives access to various
functions and settings.
Test - Allows independent testing of various functions. A useful tool when
fault finding.
Machine Configuration - Allows setting of the basic operation of the
machine and display.
Watchdog Events - Displays date and time (in Reverse order) of a stored
log of exceptional events within the control system.
Settings - Allows for calibration and set up of the various machine systems.
Alarm cancel Time - Sets the time the alarm is temporarily cancelled by
the operation of the 'cancel alarm' function in the cancel alarm menu.
Press Test to move to Test Menu

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Test Screen

Test
1 2
Exit Debug
Displays

3 4
Set/Clear OP Heater Ctrl

5 Display IP Motor Ctrl 6

A to D Test Setter I/F

7 Test 8

1 Exit and Returns to Service Utilities

Screen
Moves to Debug Displays Menu 2
3 Moves to Set/Clear Outputs Menu Moves to Heater Control Menu 4
5 Moves to Display Inputs Menu Moves to Motor Control menu 6
7 Moves to A to D Display
Setter I/F - Only applicable to
interfaces other than “Boxer” 8
Set/Clear Outputs - Allows manual operation of all outputs on the Machine.
Display Inputs - Displays the status of inputs to the control board.
A to D Test - Displays the unmodified readings of the analogue inputs.
(Analogue to Digital)
Debug Displays - Allows the display of the plate length and allotted plate
size on the Operator Screen. Also allows error list, watchdog list, open error
list to be cleared and reset.
Heater Control - Allows the power of the Developer heater, Preheat, and
Dryer heaters to be manually set for testing (0 - 100%)
Motor Control - Allows manual testing of the Conveyor and Brush motors.
Also will display the current measured speed (conveyor speed)
Setter I/F Test - Not Applicable
Press Exit to Return to Service Utilities - Select M/c Config.

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SERVICE MANUAL
Machine Configuration Screen

M/c Configuration 2
1
Exit Change
& Fill

3 Offsets Language 4
and Units

Entry Drive Idle

5 Sensors State 6

Reentry Network Node

7 Present 8

1 Exit and returns Service Utilities

Screen
Moves to Change & Fill Menu 2
3 Moves to Dev Temp Offset Menu
Moves to Language and Units
Menu 4
5 Moves to Entry Sensor Menu Moves to Drive Idle State Menu 6
7 Moves to Reentry Present Menu Move to Network Node Menu 8
Offsets - Allows manual compensation for perceived errors in the display
temperature.
Entry Sensors - Enables or Disables jam sensors. Normal operation set to
1 plate jam sensor enabled. Disables plate jam sensors when set to 2.
Change & Fill - Allows access to the Change menu that sets the parame-
ters for warnings of developer life wash water life and filter life. Based on
either plate count or area processed. Also sets developer tank max fill time
and over fill time. (When bulk fill pump fitted).
Language and Units - Allows operation language to be changed. Also
Allows Plate speed, Temperatures and Replenisher rates to be displayed
in metric or imperial units
Network Node - Not Applicable
Press Exit to Return to Service Utilities - Select Watchdog Events

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Watchdog Events Display Screen

Watchdog Events
1 2

1. 02/11/17 07:24:30
Power On
3 4
2.02/11/16 18:34:02
Power Off

5 6

7 8

1 Exit and Returnsto Service Utilities

Screen
Scroll Screen 2
3 Scroll Screen Scroll Screen 4
5 Scroll Screen Scroll Screen 6
7 Scroll Screen Scroll Screen 8
This screen displays a stored log of exceptional events within the control
system.
Usually will display when the processor has been switched on and off at the
main power supply.
Press - Exit (1) to return to Service Utilities
Select - Settings

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SERVICE MANUAL
Settings Screen

Settings 2
1
Exit Autorun Menu

3 Motor Setup Set Heater 4

PI Constants

Plate Path Plate

5 Menu Setter Menu 6

Temperature Calibration
7 Limits Menu 8

1 Exit and Returns to Service Utilities

Screen
Moves to Autorun Menu 2
3 Moves to Motor Setup Menu
Moves to Set Heat PI Constants
Menu 4
5 Moves to Plate Path Menu Moves to Platesetter Menu 6
7 Moves to Temperature Limits Menu Moves to Calibration Menu 8
This screen allows access for calibration and set up of the various machine
systems.

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Motor Setup Menu Screen

Motor Setup
1 2
Exit Brush Setup
Scaling

3 Conveyor I Brush I 4
Limit Limit

Conveyor Brush
5 Smoothing Smoothing 6
Brush
Armature Res
7 8

1 Exit and Returns to Settings Screen

Moves to the Brush Motor Speed
Calibration Screen 2
3 Moves to Conveyor Motor Current
Limit Screen
Moves to Brush Current Limit
Screen 4
5 Moves to the Conveyor Smoothing
Screen
Moves to the Brush Smoothing
Screen 6
Moves to the Armature Resistance
7 Screen (Compensate for motor
losses)
8
This Screen allows access for calibration and setup for the conveyor (drive)
motor and the scrub brush motor.

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SERVICE MANUAL
Conveyor Current Limit Screen

Conveyor Current Limit 2

1
Exit Default

3 Increase Left Digit 4

5 Decrease Right Digit 6

3.0A

7 8

1 Exits and Returns to Settings Menu Restores Default Settings 2

3 Increases Highlighted Figure Moves Highlight Cursor Left 4
5 Decreases Highlighted Figure Moves Highlight Cursor Right 6
7 No Selection Available No Selection Available 8
This is an example the general layout of a Setup Screen.
By pressing the appropriate button(s) the cursor can be moved and the set-
ting changed.
Once set pressing enter returns to the previous menu. In this case the
developer menu.
Pressing the Default button can set default values (which are pre-pro-
grammed and cannot be changed).
In this case the Default value is 3.0 Amps
All Setup screens use the same or similar format
Press - Exit - Return to Motor Setup - then Exit to Settings Screen
Select Plate Path Menu

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Plate Path Menu

Plate Path Menu

1 2
Exit

3 4

5 Plate Path Length

Adjustment 6

Encoder Step
7 8

This screen allows access to setting the point the processor system switch-
es different functions on and off.
Plate Path - Information in the form of a measurement can be entered to
time the switching of different functions
e.g. Switch the prewash on when plate has travelled 200mm into the
processor. See next screen.
Length Adjustment - Allows the entry of an offset figure to compensate for
speed differences between the CTP bridge on the processor. This offset is
only required at installation where the plate size is displayed on the
Operator Screen.
Encoder step - The distance the plate travels point to point on the encoder.
All of the information in this section should be set to the default setting.
Press - Plate Path

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SERVICE MANUAL
Boxer Positions

Boxer Positions 2
1
Exit Input Roller
Re-Entry Sensor
Re-Entry Roller
Brush On
3 Brush Off 4
Prewash On
Prewash Off
- - - - - - -
- - - - - - -
5 Up Rinse On 6
Rinse Off
Gum On
Gum Off
Down Entry Blocked
7 8

1 Exits and Moves to Setting Screen No Selection Available 2

3 No Selection Available No Selection Available 4
5 Moves the Cursor Up No Selection Available 6
7 Moves the Cursor Down No Selection Available 8
Using Up or Down buttons move cursor to chosen function.

Press Exit to move to Prewash On Setting Screen

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Prewash On

Prewash On
1 2
Exit Default

3 Increase Left Digit 4

5 Decrease Right Digit 6

360mm
7 8

1 Returns to Exit or Change again

Screen.
Restores Default Settings 2
3 Increases Highlighted Figure Moves highlight Cursor Left 4
5 Decreases Highlighted Figure Moves highlight Cursor Right 6
7 No Selection Available No Selection Available 8
Using the Cursor buttons the measurement figure can be changed to alter
when the Prewash spraybars start.

Press Exit to return to Settings Screen then Select Temperature Limits

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SERVICE MANUAL
Temperature Limits

Temperature Limits 2
1
Exit Temp Limit
Check

3 Dev Temp Set Plate 4

Limits Change Delay

5 Preheat Preheat 6
Soak Times Sock Debug

Preheat
7 Temp Limits 8

1 Exits and Returns to Settings

Screen
Moves to Temperature Limit Check
Menu 2
3 Moves to Developer Temperature
Limit Menu
Moves to Plate Change Delay
Menu 4
5
Moves to Preheat Soak Times
Menu
Moves to Preheat Soak Debug
Menu 6
7 Moves to Preheat Cooling Menu
Moves to Preheat Temperature
Limit Menu 8
This screen allows access for calibration and set up relating to tempera-
tures for the developer and preheat sections.
Developer Temperature Limits - Sets the acceptable temperature range
for normal operation.
Preheat Soak Times - Sets the time required for the pre-heaters to stabilise
depending how long they have been switched off.
Preheat Cooling - Selects the temperature at which the preheat cooling
fans are switched on.
Temperature Limit Check - Temporarily disables all temperature limits.
Set Plate Change Delay - Sets the time required for the temperature to sta-
bilise when selecting a different plate gauge has changed it.

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Preheat Soak Debug - Allows preheat soak times to be displayed on the
Main Operator screen.
Preheat Temperature Limits - Sets the acceptable temperature range for
normal operation.
Press Exit to return to the Settings Menu
Select - Autorun Menu

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SERVICE MANUAL
Autorun Menu

Autorun Menu 2
1 0263
Exit

3 Autorun Time 4

5 Anti-Ox Type 6

Configure
7 Sleep 8

1 Return to Previous No Selection Available 2

3 Select Time between Autoruns No Selection Available 4
5 Select AntiOx Type No Selection Available 6
7 No Selection Available
Set System Operations during
Closedown 8

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Autorun TIme Menu

Autorun Time
1 2306 2
Exit Default

3 Increase Left Digit 4

5 Decrease Right Digit 6

15 min
^
7 8

1 Accepts figure and returns to

Previous
Restores Default Settings 2
3 Increases highlighted figure Moves highlight cursor left 4
5 Decreases highlighted figure Moves highlight cursor right 6
7 No Selection Available No Selection Available 8
Autorun Time - The time between machine exercise periods, starts from
the last plate to be processed.

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SERVICE MANUAL

Anti-Ox Type 2
1 3042
Exit

3 4
Averaging Anti-Ox
Timed Anti-Ox
5 Up 6

7 Down 8

1 Accepts selection and returns to

previous menu
No Selection Available 2
3 No Selection Available No Selection Available 4
5 Moves the highlighted option up No Selection Available 6
7 Moves the highlighted option down No Selection Available 8
Selects which Anti-Ox method to use

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 Averaging Anti-Ox
1 0008 2
Exit

3 Daily Repl Min Replen 4

Vol Vol

5 Averaging
Period
Samples/
Average 6

Replenish
7 Summary 8

1 Exits and returns to previous menu No selection available 2

3 Moves to Daily Replenishment
Volume menu
Moves to Minimum Replenish
Volume menu 4
5 Moves to Averaging Period menu
Moves to Samples and Averaging
Anti-Ox menu 6
7 Moves to Replenish Summary
menu
No selection available 8
This screen allows access for calibration and set up relating to the Autorun
Feature.
Daily Replenishment Volume - The volume which the Anti-ox system
attempts to replenish during a 24hr period.
Averaging Period - The time over which the Anti-ox replenish volume infor-
mation is managed.
Replenishment Summary - Allows information on the Anti-ox system
operation to be displayed at the end of the Consumable summary screen.
Minimum Replenisher Volume - The minimum volume of replenisher that
is added during any sample period.
Samples/ Average - the number of samples during the averaging period.

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SERVICE MANUAL
Configure Closedown - Sets features that will or will not be active during
closedown e.g Closedown exercise time, Closedown interval, developer cir-
culation.
Press Exit to return to the Settings Menu
Select - Set heater PI Constants

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Timed Anti-Ox Menu

Timed Anti-Ox
1 0009 2
Exit

3 Operational Close Down 4

Volume Volume

AntiOx Delay
5 Period AntiOx 6

7 8

1 Exits and returns to previous menu No selection available 2

3 Moves to Operational Volume menu
Moves to Close Down Volume
menu 4
5 Moves to Anti-Ox Period menu Moves to Delay Anti-Ox menu 6
7 No selection available No selection available 8
Operational Volume - Sets the dosing volume when the machine is in use
Close Down Volume - Sets the dosing volume when the machine goes into
sleep mode
Anti-Ox Period - Sets the dosing interval
Delay Anti-Ox - Selects if plate processing delays the timed Anti-Ox

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SERVICE MANUAL
Operational Volume Menu

Operational Volume 2
1
Exit Default

3 Increase Left Digit 4

5 Decrease Right Digit 6

80 ml
^
7 8

1 Accepts figure and returns to previ-

ous menu
Reverts operational volume to
default setting 2
3 Increases the highlighted figure Moves cursor to left digit 4
5 Decreases the highlighted figure Moves cursor to right digit 6
7 No selection available No selection available 8
Sets Anti-Ox volume when system is in normal operation.

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Anti-Ox Period Set Menu

AntiOx Period
1 3045 2
Exit

3 Increase Left Digit 4

5 Decrease Right Digit 6

60 min
^
7 8

1 Accepts figure and returns to previ-

ous menu
No selection available 2
3 Increases the highlighted figure Moves cursor to left digit 4
5 Decreases the highlighted figure Moves cursor to right digit 6
7 No selection available No selection available 8
Set the time between Anti-Ox doses

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SERVICE MANUAL
Closedown Volume Menu

Closedown Volume 2
1 3028
Exit Default

3 Increase Left Digit 4

5 Decrease Right Digit 6

40 ml
^
7 8

1 Accepts figure and returns to previ-

ous menu
No selection available 2
3 Increases the highlighted figure Moves cursor to left digit 4
5 Decreases the highlighted figure Moves cursor to right digit 6
7 No selection available No selection available 8
Sets Anti-Ox volume when machine is closed down.

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Delay Anti-Ox Menu

Delay Anti-Ox
1 3044 2
Exit

3 4
Always
Delayed by Plate
5 Up 6

Down
7 8

1 Accepts selection and returns to

previous menu
No Selection Available 2
3 No Selection Available No Selection Available 4
5 Moves the highlighted option up No Selection Available 6
7 Moves the highlighted option down No Selection Available 8
Selects whether the processing of a plate delays the anti-ox dose by a full
anti-ox period, or whether it has no effect on the anti-ox cycle.

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SERVICE MANUAL
From Configure Sleep Option

Closedown Excercise Time 2

1
Exit

3 Increase Left Digit 4

5 Decrease Right Digit 6

20 sec
^
7 8

1 Accepts figure and returns to previ-

ous menu
No selection available 2
3 Increases the highlighted figure Moves cursor to left digit 4
5 Decreases the highlighted figure Moves cursor to right digit 6
7 No selection available No selection available 8
Sets the period for which the machine exercises when closed down.

Next Screen is Closedown Excercise Interval if the excercise time is greater

than zero.

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Closedown Exercise Interval Menu

Closedown Exercise Interval

1 2308 2
Exit

3 Increase Left Digit 4

5 Decrease Right Digit 6

2 min
^
7 8

1 Accepts figure and returns to previ-

ous menu
No selection available 2
3 Increases the highlighted figure Moves cursor to left digit 4
5 Decreases the highlighted figure Moves cursor to right digit 6
7 No selection available No selection available 8
This menu sets the time between excercises when the machine is closed
down.

This screen will not be shown if Closedown Excercise Time is set to zero
seconds.

Next screen is the Close Down Circulation Screen.

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SERVICE MANUAL
Closedown Circulation Menu

Closedown Circulation
1 2302 2
Exit

3 Off 4
Continuous ON
On During Excercise
5 Up 6

Down
7 8

1 Accepts selection and returns to

previous menu
No Selection Available 2
3 No Selection Available No Selection Available 4
5 Moves the highlighted option up No Selection Available 6
7 Moves the highlighted option down No Selection Available 8
This menu selects what developer circulation there is during excercises.

Off - No Circulation
Continuous On - Always circulates
On During Excercise - Only circulate during excercise

If Closedown Excercise Time is set to zero seconds then only the first two
options are shown to the user.

Next is the Rinse / Wash Spraybars

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 Rinse / Wash Spraybars
1 2303 2

3 4
Off
On During Excercise
5 Up 6

7 Down 8

1 Accepts selection and returns to

previous menu
No Selection Available 2
3 No Selection Available No Selection Available 4
5 Moves the highlighted option up No Selection Available 6
7 Moves the highlighted option down No Selection Available 8
This menu is provided to preserve water in direct to drain machines.

Next is the Close Down Anti-Ox

Not shown if Closedown Excercise Time is set to zero.

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SERVICE MANUAL

Closedown Anti-Ox 2
1 2305
Exit

3 4
Off
Off
On
5 Up 6

Down
7 8

1 Accepts selection and returns to

previous menu
No Selection Available 2
3 No Selection Available No Selection Available 4
5 Moves the highlighted option up No Selection Available 6
7 Moves the highlighted option down No Selection Available 8
Selects whether anti-ox takes place when closed down.

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Set Heater PI Constants

Set Heater PI Constants

1 2
Exit

3 Dev Chiller 4

5 Preheat
Outer
Preheat
Inner 6

Configure
7 Closedown 8

1 Exits and returns to Settings Screen No Selection Available 2

3 Moves to Developer Set Heater
Setup Menu
Moves to Chiller Setup Menu 4
5
Moves to Preheat Outer Setup
Menu
Moves to Preheat Inner Setup
Menu 6
7 No Selection Available
Moves to Configure Closedown
Menu 8
This screen allows access for calibration and set up relating to the
Developer, Preheat Heaters and the Chiller.
Press Exit to return to the Settings Menu
Select - Plate Setter Menu

If adjustment of these settings is required, advice from your

technical service contact must be sought prior to making the
! changes.

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SERVICE MANUAL
Platesetter Menu

Platesetter Menu 2
1
Exit

3 4

5 Select Configure 6
Setter I/F Error Levels

7 8

1 Exits and Returns to Settings

Screen
No Selection Available 2
3 No Selection Available No Selection Available 4
5 Moves to Select Setter Interface
Menu
Moves to Configure Error Levels
Menu 6
7 No Selection Available No Selection Available 8
This screen allows access for calibration and set up relating to the Plate
Setter Interface.
Select Setter Interface - Allows the manual selection of the appropriate
setter interface.
Configure Error Levels - Allows the individual allocation of levels to each
machine error. e.g. Developer low level is a level 1 fault and will stop the
processor and the imagesetter, operator intervention is required. Whereas
a temperature error, level 2, will stop the imagesetter from sending a plate
but will clear when the temperature comes back into spec. Change devel-
oper is level 3 and will give a warning on the processor but will not stop
plate production.
Configure User Setter - Allows the operation of the setter interface to be
defined by the user from the display.
Press Exit to return to the Settings Menu.
Select - Calibration Menu.

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Calibration Menu

Calibration
1 2
Exit

3 Cal. PT100 Preheat 4

Dev Calibration

5 Replenish
Calibration 6

Read System
7 Data 8

1 Exits and Returns to Settings

Screen
No Selection Available 2
3 Moves to Calbration of PT100
Temperature Probe Menu
Moves to Preheat Calibration Menu 4
5
Moves to
Calibration Menu
Replenishment
No Selection Available 6
7 No Selection Available
Allows data previously stored in
non-volatile memory to be restored 8
This screen allows access for calibration relating to the following -
Calibrate PT100 Developer probe - Step by step procedure for calibrating
the PT100 temperature probe. Using a connector to link out points on the
control board, instructions are displayed on the screen to calibrate the
board.
Replenisher Pump Calibration - Step by step instructions on how to cali-
brate Developer wash and gum replenisher pumps. Once again instructions
are displayed on the screen
Preheat Calibration - Step by Step guide to calibrate both the inner and
outer banks of heaters on the preheat section. A hand held simulator will be
needed for this function.
Read System Data - Allows data previously stored in non-volatile memory
to be restored
Press Exit to return to the Settings Menu
Select - Calibration Menu
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SERVICE MANUAL

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Page 53
SETTING INSTRUCTIONS
SERVICE MANUAL
2.1 Checking the Pre-Heat Temperature
Specification
The preheating temperature of a one sided Photopolymer laser plate,
measured on the underside of a new plate with thermostrip, should be
99°C -104°C.

Procedure
1. Ensure that all covers are on the processor
2. Switch on the processor and check that the Temperature Controller(s) are
set to the relevant “Area” number for the plate thickness that is being
checked. All ow the pre-heat station to warm up and stabilise at the set point
for approximately 10-15 minutes.
3. Check the processor throughput speed is set to 1006mm/min.
4. Using a new (full width if available), fully coated plate that has been
exposed to daylight, stick a number of thermo strips on the underside of
the plate in the posistions shown below.
5. Feed the plate through the processor and record the results.

Note

L In order to prevent misreading, please ensure that the ther-

mo strips are firmly adhered to the plate and a new plate is
used on each test.

25mm (1" TYP)

25mm (1" TYP)

Minimum recommended
thermo strip positions

Position of higher scale

thermo strips if required
Direction of Travel

Additional thermo strip

positions recommended
for full temperature
check

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2.2 Positions of Drains and Overflows

1 3 6 8

2 4 5 7

Position Description
1 Gum Overflow
2 Gum Drain
3 Rinse Overflow
4 Rinse Drain
5 Developer Drain
6 Developer Drain
7 Prewash Drain
8 Prewash Overflow

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SERVICE MANUAL
2.3 Setting the Prewash, Rinse and Gum Flow Rates
The output volume/pressure of the spray bars is regulated by the inline taps
situated on the operation/non drive side of the machine.
Adjust these valves to provide the desired flow rate.
The valves are highlighted in the pictures below.

Prewash Inline Taps

Rinse Inline Taps

Gum Inline Tap

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2.4 Setting the PT100 temperature Probes
Part No. 0285B215 - Calibration Lead

2 x Molex 0.1” (2.54mm) KK female plugs

3 x 0.5mm2 cable, 100mm long (approx)

Calibration
Select:
Engineering-Service Utilities-Settings-CalibrationMenu-Cal PT100
Dev.
1. Follow the on screen instructions
2. Disconnect the Developer Temperature Sensor plug in PL5
3. Plug in end “B” if the calibration lead into PL5
4. Plug in end “A” of the calibration lead into PL8 for the 105? setting as shown
below (Number indicated should be @270+)

PL8

5. Follow the on-screen instructions for the 110? setting as shown below

PL8

6. Update the EPROM.

7. Replace the PL5 plug.
8. Exit to main menu

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SERVICE MANUAL
2.5 Replacing the Main Control Board

Attention

1 Please follow the standard electrostatic discharge procedure

when handling the PCB.

If the board needs changing, before you unplug anything, save the settings
in the Operator Menu.

1. Remove the board.

2. Swap over the fuse holders (if required). Make sure that the jumpers are in
the same position as the old board.
3. Remove IC12 E2ROM. This is near the main EEPROM (IC7) from the old
board. This chip carries the usage data, error log and other history/informa-
tion to the new board. This information is correct from the point that the data
was last saved.
4. Fit the IC12 E2ROM. Locate the board to the back plate and re-connect all
wiring harnesses/cables.
5. Turn the power on and start up the machine.
6. Select the machine identity (if required).
7. For the computer to access the data from IC12, you must go into Restore
Settings for it to take effect.
8. Go to Data Menu in the Operator Menu.
9. Select Restore Settings and follow the instructions on the screen.

Attention

1 Do not attempt to copy data between software with different

major version numbers, as these versions are not compatible.
The major version number is indicated by the first two digits of
the software version (eg. V02.05.13 - 02 is the major version)

10. Select Restores Cons data. This restores the consumable data such as the
number of plates the machine had processed.
11. Enter the Engineering Menu, go to Settings, Calibration Menu and then
select Read System Data. This reads back the calibration data for the
replenishment in the EEPROM.
The Machine is Now Ready to be used

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2.6 Replacing the Board / Clearing the Memory
To wipe the memory, there are two methods
1. Switch the machine OFF and isolate at the wall.
2. Remove the jumper J1 from the normal position to the memory discharge
position. wait about 30-45 minutes for the memory to be wiped. Replace J1
back to the normal position. Turn the Machine Back on
OR
Self Test Procedure
1. To use the self test software in the EPROM first turn OFF the machine and
isolate.
2. Move the jumper J4 to the self-test position. When the machine is then pow-
ered up, the software automatically starts to test itself and the board. The
test interrogates the memory allocation and checks the EEPROM (IC7),
EEPROM (IC4) and E2ROM (IC12) are working correctly. Any failure will be
reported on the screen.

Attention

1 The machine is completely unusable during the self-test proce-

dure, it also loops continuously until the machine is turned off
and J4 is returned to its normal position. The number of suc-
cessful tests is displayed on the screen

Note

L Please remember that this procedure completely clears the

machine memory.

This software is applicable from version 01.17 onwards

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SERVICE MANUAL
2.5 Main Control Board - Fuse Listing
Stage Description Rating (A) Rating (B)
F01 Chiller / Compressor 6.3AT 6.3AT
F02 Drier Fan (M3A & M3B) 630mAT 630mAT
F03 Prewash Recirculation Pump or Solenoid (P1) 1AT 1AT
F04 Rinse Replenish Pump (P10) 2AT 2AT
F04 Pre Wash Replenish Pump (P2) 2AT 2AT
F05 Gum Recirculation Pump (P7) 1AT 1AT
F06 Dev Recirculation Pump (P3) 1AT 1AT
F07 Gum Replenish Pump (P8) 500mAT 500mAT
F08 Not Used
F09 Developer Fill Pump (P4) 600mAT 600mAT
F10 Not Used
F11 Rinse Recirculation Pump or Solenoid (P6) 1AT 1AT
F12 Not Used
F13 Developer Concentrate Replenishment Pump (P9) 200mAT 200mAT
F14 Not Used
F15 Cooling Fans (M4 & M5) 500mAT
F16 Not Used
F17 Not Used
F18 PCB Main AC Power Supply 1AT 1AT
F19 Not Available
F20 Not Available
F21 65V DC Motor Power Supply 6.3AT
F22 Not Available
F23 TR1 Power Supply 6.3AT 6.3AT
CB1 Main Power Supply (Single Phase Option L1+L2/N+E) 32A/220V +/-10% (Type C)
CB1 Main Power Supply (Three Phase Option 3P+N+E) 16A/400V +/-10% (Type C)
CB2 Pre Heat 10A (Type C)
CB3 Developer Heaters 6A (Type C)
CB4 Dryer Heaters 16A (Type C)
CB5 Board Output Supplies 10A (Type C)
CB6 Chiller 6A (Type C)
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2.8 PCB Jumper Positions and Test Points
Jumper Positions J1 - J7 as seen with the board in normal ori-
entation, fuses to the top.

Jumper No. Illustration Function

J1 Normal Position - Memory OK
J1 Memory Discharge Position
J2 Normal Position
J3 Normal Position
J4 Normal Position
J4 Self Test
J5 Normal Position
J6 Normal Position - RS232 Interface Setting
J6 RS485 Interface Setting
J7 Normal Position

Test Points TP1 - TP7

Test Point No. Output

TP1 0V DC
TP2 +24V DC Unregulated (13-26V DC)
TP3 -24V DC Unregulated (13-26V DC)
TP4 +12V DC Regulated
TP5 +5V DC Regulated
TP6 -9V DC Regulated
TP7 +65V DC Unregulated
TP8 +15V DC Regulated for Motor Control Circuits

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SERVICE MANUAL
2.9 EEPROM Chip Exchange
Upgrading Software
If only the minor version number has changed, the upgrade should be
straight forward; the EEPROM will require changing, and then any setting s
for functions which have been added will need to be adjusted.
If a major change has taken place (eg. from V01.01.xx to V01.02.yy) a util-
ity will normally be provided to convert stored settings from the old format
to the new, and to set any new settings to their default value.
In extreme cases, however, it may be necessary to clear down the existing
settings and start again. The upgrade will make it clear if this approach is
required.

Inca Upgrade
There have been no major version changes for this processor. The proces-
sor software was introduced at software version V1.02.04, and the current
software in the field is V1.02.30. The latest pre-release version is V1.02.31.
Since the introduction of the software, various additional functions have
been provided. When the EEPROM has been changed it will be necessary
to modify the settings for the following items (they will be using previously
virgin memory, so the values stored will be undefined):
1. Initially a PDI menu may be displayed. To exit from this and ensure it is not
displayed again on machine start-up, move the cursor down to the last
option (End PDI) and press Exit.
2. Set the Length Adjustment field to 0. This variable allows fixed errors in
plate length measurement, which sometimes occur with odd in-feed sensor
arrangements to be compensated for. (Selected from Engineering -
Service Utilities - Settings - Plate Path Menu - Length Adjustment).
3. Set up the required options for automatic runs and circulation during close-
down. These settings allow the user to choose how the machine operates
in ‘Closedown’. First the Exercise Time must be set in seconds. If the
Exercise time is greater than zero, then the interval between exercises, the
operation of the developer circulation pump and the operation of spray-bars
during exercises can be selected. If no exercise time is set, then the oper-
ation of the developer circulation pump can be selected. Whether or not an
exercise time is set, operation of the anti-ox system can be enabled or dis-
abled. (Selected from Engineering - Service Utilities - Settings - Autorun
- Configure Closedown).

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4. Set the Date Style flag as required. This selects whether the date is dis-
played as 15 Jan 03 or Jan 15 03. (Selected from Engineering - Service
Utilities - Machine Configuration - Languages and Units - Date Style).
5. Set the Conveyor Motion flag as required. This selects the state of the con-
veyor drive when the machine is not processing a plate. Normally this would
be ‘Rolling’ for the Inca 70P / 80P. (Selected from Engineering - Service
Utilities - Machine Configuration - Conveyor Idle State).
6. (For upgrade to V1.02.31 only) Before the first use of the Manual Replenish
option, the volume to replenish must be set via the option on the manual
replenish screen

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SERVICE MANUAL
2.10 Replenisher Pump Calibration
Developer and Gum Replenishment Calibration
1. Use an accurate measuring jug (10ml graduations) and place the replenish-
ment / fill spears into the jug filled with liquid.
2. Note the amount of developer in the jug.
3. Go to the Calibration Menu in the Engineering Section.
4. Follow the on-screen instructions.
5. Enter the quantity of developer that was pumped out of the jug in the 30-
second test period.
6. Save the setting,
7. Follow the same instructions for the Gum section replenishment pump as
required.

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2.11 Developer Guide Roller Setting
Measurements are taken from the top of the tank wall to the top of the black
support brackets.

A = 82mm
B = 131mm
C = 70mm

Measurement of height for guide roller bracket in rinse section is taken from
the bottom lip of the black support bracket to the top of the tank wall.

A B C

81 70
130
FRONT OF
MACHINE

PREWASH

DEV
SECTION

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SERVICE MANUAL
2.12 Drive Motor Sensor and Cam Setting
To ensure the correct operation of the drive motor, the sensor must count
consistently. The sensor is situated on the internal facing end of the drive
motor drive shaft.
The setting distance between the sensor and the cam is 0.5 - 1.0mm.
Confirm operation by using Conveyor Menu in Engineering to see the set
speed. Set an output value and then compare this with the actual output
rotational speed.

1.25 - 1.5mm

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2.13 Setting Scrub Roller Nip Pressure

C C

A Scrub Rollers

Fixed Bracket

B Pressure Plate
Pivot Point

1. Place a section of plate between the scrub roller (A) and pressure plate (B).
The plate material should be 0.3 mm gauge and approximately 100 x 400
mm in size.
2. Adjust bolts (C) so that the plate can be pulled with moderate force from
between the rollers and pressure plate (A & B). If the plate shudders when
pulled out, this would indicate that the pressure was excessive.
3. Ensure that equal pressure is applied to both the bolts (C).
4. Carry out the same procedure on the other end of the rollers. When this has
been completed, re check that the pressure is even across the full length of
the rollers and pressure plates (A & B).

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SERVICE MANUAL

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Page 69
OPERATOR MAINTENANCE
SERVICE MANUAL
3.1 Operator Maintenance - Daily / Weekly

Warning
Before handling or using any graphic arts material be sure to
! read the Material SafetyData Sheet for health hazard data,
precautionary information, suggested first aid and recom-
mended waste disposal.

Attention

1 Any maintenance must only be carried out by suitably skilled or

properly instructed/supervised personnel.

1. Check the chemistry levels in the processor, developer replenishment bot-

tle and finisher replenishment bottles. Ensure all tanks are full.
2. Keep the processor free from dust and dirt.
3. Weekly, check the scrub roller covers for wear and replace if necessary.
4. Check the developer pH level with a pH Meter.
5. Check level and cleanliness of the prewash bath, clean as required if PVA
has accumulated.
6. Check the developer exit rollers for build-up of coating and clean as
required.
7. Clean / check overflows.

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3.2 Chiller Service and Maintenance
Major Components and Functions
In the unlikely event of the chiller under performing, the following steps
should be undertaken.
1. Check the information displayed on the controller.
2. Check the water circuit for leaks, blockages, sufficient water and pump
operation.
3. Check the refrigeration circuit - check the major components as outlined
below.

Compressor (Hermetic, reciprocating type)

The compressor motor is protected by an internal device fitted within the
windings. This is an auto-reset device that monitors temperature and is non-
serviceable.
In the unlikely vent of a compressor failure, the start compressor start elec-
tric's should be checked. These are serviceable and located under the com-
pressor electric's cover.

Condenser
A fan assisted finned coil design. The flow of air across the condenser
causes heat transfer, enabling the vapour refrigerant to condense. The fan
should operate whenever the compressor operates.

Sight Glass / Moisture Indicators

Gives an indication to the state of the refrigerant charge.
Clear (full) System fully charged
Bubble (continuous) System undercharged
Core Green No moisture present
Core Yellow Moisture present

Note

L An undercharged system may provide some cooling, but will

not perform at it's optimum. Moisture can affect cooling per-
formance an compressor reliability. Moisture can freeze and
block capillary tubing. It can also form acids that attack com-
pressor windings.

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SERVICE MANUAL
If moisture is present, then:
1. The refrigeration system should be fully evacuated
2. A new drier should be fitted - taking care not to insert the capillary too far as
this would foul on the internal mesh.
3. The unit should be re-charged.

Water Pump
The pump is magnetically coupled to an integral motor. The motor is inter-
nally protected in a similar way to the compressor.

High Pressure Switch

In the event of high pressures it will stop the compressor from running. This
is a manual reset control. Pressing the reset button will reset the control.
Excessively high pressures can result from:
Condenser fan failure
Condenser fins blocked or dirty
Moisture and/or non-condensable gases in the refrigerant
Ambient operating temperature too high
Excessive refrigerant charge
Inadequate ventilation or poor installation promoting hot air re-circu-
lation

Chilled Water Flow Switch

'Sail' or 'Paddle' type switch situated in the chilled water circuit, which
responds to water flow. The flow switch opens its contacts (to stop the com-
pressor and pump), before flow is reduced to where evaporator 'freeze up'
would be possible.
This item does not require field adjustment.

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Inca 70/MR700P &
80/MR800P- Service
Page 72
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0323M380.3
Planned Maintenance Schedule
External checks and inspection required for signs of deterioration:
Control Panels
Fixing Fasteners
Labelling etc
Check water/fluid levels and top-up where necessary
Check for undue noise and vibration

Note

L All controls should be checked during routine maintenance

and adjustments made if necessary.
frquency of cleaning and maintenance will need to be re-
evaluated if the chiller is running in a contaminated atmos-
phere or has extreme or long operating conditions etc.

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Inca 70/MR700P &
80/MR800P- Service
Page 73
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0323M380.3
SERVICE MANUAL
3.3 Changing the Filter Elements
Changing the Developer Filter Element
1. Place an empty container under the filter housing.
2. Close the valve on the head of the filter unit.
3. Open the valve on the bottom of the filter unit.
4. When the contents have drained, unscrew the filter housing and discard the
old element.
5. Clean filter housing and install a new filter element.
6. Inspect the 'O' ring and replace if necessary. Ensure the 'O' ring is properly
seated.
7. Refit the filter housing.
8. Close the valve on the bottom of filter unit.
9. Open the valves on the head of the filter unit.

Changing the Pre Wash / Rinse Filter Element

1. Place an empty container under the filter housing.
2. Close the valve on the head of the filter unit.
3. Open the valve on the bottom of the filter unit.
4. When the contents have drained, unscrew the filter housing and discard the
old element.
5. Clean filter housing and install a new filter element.
6. Inspect the 'O' ring and replace if necessary. Ensure the 'O' ring is properly
seated.
7. Refit the filter housing.
8. Close the valve on the bottom of filter unit.
9. Open the valves on the head of the filter unit.

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Inca 70/MR700P &
80/MR800P- Service
Page 74
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0323M380.3
3.4 Changing the Scrub Roller Cover
1. Remove the scrub rollers from the tank.
2. Remove the gearbox and bearing block.
3. Cut the tie wraps securing the cover to the roller and remove the old cover.
4. Clean the roller with warm water.
5. Wet the new cover and slide on to the roller.
6. Fix one end with the tie wrap.
7. Pull cover tight over roller and ensure it is smooth and wrinkle free.
8. Fix other end with tie wrap.
9. Cut off the excess cover and both the tie wrap ends.
10. Scrub Rollers will need checking for nip pressure (Ref.: Setting Scrub Roller
Nip Pressure)

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Inca 70/MR700P &
80/MR800P- Service
Page 75
Revision
0323M380.3
SERVICE MANUAL

Document
Inca 70/MR700P &
80/MR800P- Service
Page 76
Revision
0323M380.3
Page 77
FAULT FINDING
SERVICE MANUAL

Document
Inca 70/MR700P &
80/MR800P- Service
Page 78
Revision
0323M380.3
Stage Problem Cause Action

Incorrect developer Check the replenisher

replenisher ratio (too setting and check
much) operation

Check temp setting

and temp on display,
(28ºC / 82ºF) adjust if
necessary
Developer temperature
Check temperature
too high
Check developer flow
Check developer filter
Check heater opera-
tion

Check the speed set-

ting and adjust if nec-
Dot Shrinkage essary (19 sec
Platemaking dwell/1250mm/min)
(Highlights drop out)
Check roller drive sys-
Development time too
tem
long
Check roller nip pres-
sure
Adjust to correct
Check speed sensor
on drive motor

Check settings and

temp on display, adjust
if necessary
Check plate tempera-
Preheat temperature
ture with thermal strips
too low
(100ºC / 212ºF)
Check preheat opera-
tion
Check heater tiles

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Inca 70/MR700P &
80/MR800P- Service
Page 79
Revision
0323M380.3
SERVICE MANUAL
Stage Problem Cause Action
Check if water from
prewash or rinse is
Incorrect developer dilu- going into developer
tion (must be too strong section.
or too weak) Check drain connec-
tions, blocked or
kinked pipes

Check the replenisher

Incorrect replenishment setting and check
operation

Exhausted developer Replace developer

Check temp setting

and temp on display,
(28ºC / 82ºF) adjust if
necessary
Developer temperature
Check temperature.
is too low
Check developer flow
Dot Gain Check developer filter
Check heater opera-
(shadows fill in) tion
Platemaking
Residual colour, Check water supply is
emulsion in non- turned on
image areas Insufficient rinse
Check spraybars,
unblock if needed

Adjust spraybar pres-

sure if needed
Incorrect brush pres-
Check scrub pressure,
sure
reset or replace the
molleton cover

Check setings and

temp on display if nec-
essary
Check plate tempera-
Incorrect pre-heat tem- ture with thermal strips
perature (100ºC / 212ºF)
Check preheat opera-
tion
Check all heater tiles
are working

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Inca 70/MR700P &
80/MR800P- Service
Page 80
Revision
0323M380.3
Stage Problem Cause Action
Check scrub pressure,
Incorrect developer
reset or replace the
scrub pressure
molleton cover

Check settings and

temp on display, adjust
if necessary
Check plate tempera-
Un-even temperature in
ture with thermal strips
the Pre-Heat section
(100ºC / 212ºF)
Non-Uniform tints
Check preheat opera-
tion
Lines in tints
Check heater tiles

Clean rollers and

Dirty disc rollers check condition
replace if needed

Check the pH of the

Developer is too weak,
developer, replace as
low pH
necessary

Check scrub pressure,

Platemaking Incorrect developer
reset or replace the
scrub pressure
molleton cover

Check temp setting

and temp on display
(28ºC / 212ºF)
Developer temperature Check temp
too high Check developer flow
Check developer filter
Check heater opera-
Scratches, pinholes tion
in image area
Check the speed set-
ting and adjust if nec-
essary (19sec
dwell/1250mm/min)
Check roller drive sys-
Development time too
tem
long
Check roller nip pres-
sure
Adjust to correct
Check speed senosr
on drive motor

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Inca 70/MR700P &
80/MR800P- Service
Page 81
Revision
0323M380.3
SERVICE MANUAL
Stage Problem Cause Action
Check settings and
temp on display, and
adjust if necessary
Check plate tempera-
Preheat temperature
ture with thermal
too low
strips (100ºC / 212ºF)
Check preheat opera-
tion
Scratches, pin- Check heater tiles
holes in image
area Check rollers in drier
Plate output is incorrect
section

Ensure prewash
spraybars are facing
Prewash splashing the prewash scrub
back toward preheat roller / reduce the pre-
wash spraybar pres-
sure

Clen the processor

Developer processing
and refill with fresh
capacity exceeded
developer
Platemaking Contaminated rinse
water (If circulation Replace water
used)

Checking settings and

temp on display,
adjust if necessary
Scum / Sludge in Check plate tempera-
Developer Section Incorrect pre-heat OC-
ture with thermal
(Blue/Green layer baked
strips (100ºC / 212ºF)
sludge) Check preheat opera-
tion
Check heater tiles

Check water supply is

turned on
Check spraybars,
unblock if needed
Too low water pressure
Adjust spraybar pres-
or brush pressure in the
sure if needed
prewash section
Check water solenoid
Check water filter and
pump (where fitted)
Check brush condition

Document
Inca 70/MR700P &
80/MR800P- Service
Page 82
Revision
0323M380.3
Stage Problem Cause Action
Check the replenisher
Incorrect developer
setting and check
replenishment
operation.

Exhausted developer Replace developer.

Check temp setting

and temp on,
(28ºC/212ºF) adjust if
necessary.
Scumming of non- Check temperature.
image areas Developer temperature
Check developer flow
too low
Check developer filter.
Shadows filling in Check heater opera-
tion.
Check chiller opera-
tion.

Check water supply is

turned on.
Check spray bars,
Insufficient rinse
unblock if needed.
Printing Adjust spraybar pres-
sure if needed.

Incorrect developer Check the replenisher

Replenishment (too setting and check
much). operation.

Check temp setting

Dot sharpening and temp on,
(28ºC/212ºF) adjust if
Run length necessary.
Check temperature.
Developer temperature
Check developer flow
too high
Check developer filter.
Check heater opera-
tion.
Check chiller opera-
tion.

Document
Inca 70/MR700P &
80/MR800P- Service
Page 83
Revision
0323M380.3
SERVICE MANUAL
Stage Problem Cause Action

Check the speed set-

ting and adjust if nec-
essary (19sec
dwell/1250mm/min)
Check roller drive sys-
Development time too
tem
long
Check roller nip pres-
sure
Adjust to correct
Check speed sensor
Dot Sharpening on drive motor
Printing (cont.)
Run length
Check settings and
temp on display,
adjusting if necessary
Check plate tempera-
Pre-Heat temperature
ture with thermal strips
too low
(100ºC / 212ºF)
Check preheat opera-
tion
Check heater tiles

Clean covers with

Grit particle in developer
fresh machine devel-
scrub cover(s)
oper

Seized final drive

Free wheel(s)
wheel(s)
Scratched or dam-
aged plate
Damaged surface on
Replace roller(s)
drive roller(s)

General Hold down roller mis- Re-align hold down

aligned roller

Excessive brush pres- Check and reset brush

sure pressure

Plate not feeding

correctly
Insufficient roller pres- Check and adjust
sure pressure

Document
Inca 70/MR700P &
80/MR800P- Service
Page 84
Revision
0323M380.3
Stage Problem Cause Action

Use drive inch reverse

Plate not feeding Check plate path function to free plate.
correctly through rollers Adjust roller as
required.

Damaged applicator Replace applicator

blade blade

Hardened finsher Clean roller(s) with

deposits on roller(s) warm water

Damaged squeegee
Replace rollers
rollers

General (cont.)

Inconsistent
Finishing Replenisher bottle
Fill replenisher bottle
empty

Drain clean and

Contaminated finisher replace with fresh fin-
isher

Realign blade to con-

Spreader blade mis-
tact entire width of fin-
aligned
isher applicator roller

Finisher viscosity too

Change finisher
high or low

Document
Inca 70/MR700P &
80/MR800P- Service
Page 85
Revision
0323M380.3
SERVICE MANUAL
Stage Problem Cause Action

Isolator switch OFF Switch isolator ON

Machine will not

start when Power
On switch is acti-
vated.
Fuse blown or circuit
Replace fuse / reset
breaker tripped in power
Display Off cicuit breaker
supply distribution box

Emergency stop switch Reset emergency stop

activated switch

Plate not seen - Check

Sensor Fault
sensors

General (cont.)

Developer level Check developer level

Machine will not

start when Power
On switch is acti-
vated Top covers open Close covers

Display On -
No Processing
MCB tripped in proces-
Reset circuit breaker
sor

Faulty power on switch Replace switch

Loose electrical connec- Contact your service

tions Representative

Document
Inca 70/MR700P &
80/MR800P- Service
Page 86
Revision
0323M380.3
Stage Problem Cause Action

Sensor requires adjust- Contact your Service

Brush Drive, Pump, ment Representative
Water Sprays, and
Heaters do not
come into operation
when plate is insert-
ed
Contact your Service
Sensor unit faulty
Representative

General(cont.)

Contact your Service

Heat control set too low
Representative

Insufficient Pre-
Heat

Damaged Infrared Contact your Service

heater(s) Representative

Document
Inca 70/MR700P &
80/MR800P- Service
Page 87
Revision
0323M380.3
 Website
www.heights.com

Original Manufacturer
Office
Heights (UK) Ltd.
Wainstalls
Halifax
HX2 7TJ
UK

Telephone
+44 (0) 1422 240914
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