BL Dwez 01

Service Manual
Plate Processors
85-125 Supreme
Service manual
Plate Processors
85-125 Supreme
T11041
Edition CA, February 2009

This book has part No. 51518
General information
0-2
This manual
Part 0: General information
This manual
Products covered
This manual is valid for:
Plate Processor 85 from serial no 94273-0001.
Plate Processor 125 from serial no 94274-0015.
The serial number is specified on the processor name plate located on the rear end of
the tank on the left side.
#
This manual is for Service Technicians only.
The directions given must not be followed by unauthorized personnel.
Always read the Safety Instruction Manual part No 21741 before installing the
equipment.
This manual is published by: GLUNZ & JENSEN A/S

Haslevvej 13,
DK-4100 Ringsted
Denmark
Phone:+45 57 68 81 81
E-mail: 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 © 2009 by GLUNZ & JENSEN A/S.
Service Manual - Plate Processors 85-125 0906

General Information
0-3
The processor
Reservations
• This manual was written and illustrated using the best possible information
available at the time of publication.
• Any differences between this manual and the equipment reflect improvements
introduced after the publication of the manual.
• Changes, technical inaccuracies and typographic errors will be corrected in
subsequent editions.
• As a part of our policy of continuous improvement, we reserve the right to alter
design and specifications without further notice.
Notes, Cautions, and Warnings !

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

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 personnel injury.
The processor
Approvals
• Approvals will appear from the labels attached to the name plate or the frame part
of the processor.
Intended use of the equipment

• Development of photographic materials as specified in “Technical specifications” in
Part 1 in this manual.
0906 Service Manual, Plate Processors 85-125

General Information
0-4
The processor
Installation
• Never install the processor in explosive environments.
• It is the responsibility of the owner and operator/s of this processor that the
installation is made in accordance with local regulations, and by engineers
authorized to carry out plumbing and electrical installations.
• Installation, service and repair must be performed only by service technicians who
are trained in servicing the equipment. The installation procedure is described in the
separate “Installation manual”.
• The manufacturer cannot be held responsible for any damage caused by incorrect
installation of this processor.
Technical data
• Observe technical data from the processor name plate and from Part 1 in this
manual.
Chemicals
• It is the responsibility of the owner of this equipment that data is available
concerning possible health risk from the chemicals used with the equipment.
"End of lifetime" disposal

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

Table of contents
0-5
Table of contents
Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2

This manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Products covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Notes, Cautions, and Warnings ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
The processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Intended use of the equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
"End of lifetime" disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Service assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
Service manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10
User manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11
Part 1: Technical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

Table of contents
0-6
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Part 2: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Processor sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Level control/temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Replenishment/anti-oxidation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Gum distribution roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Master Input/Output Unit (MIO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
High Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Motor Filter Unit (MFU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Touch Screen Control Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Part 3: Cleaning and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Standard recommendations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Special recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Hand shower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Container contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing rollers from block bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Removing rollers from clutch bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Major cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Gum section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Daily cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning of valves in the replenish pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Cleaning of the circulation pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Table of contents
0-7
Changing developer filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Adjustment of gum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Changing the brush roller cloth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Setting rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Installation of rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Drive/scrub chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Roller pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Adjusting gap between the rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Drive rollers pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Scrub roller in wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Roller reassembling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Chain maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
After processing 400 hours/6,500 m2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
After processing 2,500 hours/80,000 m2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Lubrication:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Idler sleeve bearings maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Chain adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
How to check for potential chain wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Measurement point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Measure between two given numbers of pitches . . . . . . . . . . . . . . . . . . . . . . 3-19
Control the length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Chain Kit Scrub drives 85
Chain Kit Scrub drives 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Chain Kit Roller drives 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Chain Kit Roller drives 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Changing roller bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Roller bearing kit 85 - 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Part 4: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Before starting trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Problems with the processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Problems with processed material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Part 5: Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Spare parts kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Special spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
PCB's and software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Feed, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Delivery, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Drive plate (CD 125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Chain drive plate (CD 125) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

0-8
Drive plate (double scrub 85). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Chain drive plate (double scrub 85) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Group filter dev ac-5c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Pump / circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Tank base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Group roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Group dev kit cd twin scrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Group dev kit double scrub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Group tube spray water gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Cables (not illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Appendix A: Additional spareparts . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B: Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Main Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Fuse panel and Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
High Voltage Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
230V AC, Control Devices, HPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Low Voltage Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Sensors and Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Motors and Internal Bus Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
8, 24 and 35 VAC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8

0-9

General Information
0-10
Manuals
Manuals
Manuals available for the plate processor:
1 2 3 4 5
Manual Manual Manual ruct ions
lation rvice Software ty Inst
Instal Se Safe
6 6 7 o
1/2
51436D
.
8
Intr
ual s Gui
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Qu
User’
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Power
(Example
ep
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Read
save
Screen X min.
)
er save
(pow
Sleep
)
y (Example
Read
1 sec.
)
(Example
view
Over
1
2
3
(Example)
8
7
4
5
6
T31525
Service manuals
Service manuals available for the plate processor:
The manuals listed below are for service technicians only. In addition the service
technicians will need the manuals listed opposite as "User's Manuals".
Processor Installation Manual (1)

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

Language: English
Contents: Technical Specifications
Functional Description
Service Information
Service Maintenance
Trouble Shooting
Spare Parts
Electrical Diagrams
Software Service Information (3)

Language: English
Contents: Menu structure (service menus)
Control Panel, Service Information
Calibration Procedures

General Information
0-11
Manuals
User manuals
User manuals available for the plate processor:
CE Declaration Of Conformity (4)

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

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

Language: 4
Contents: Operating and cleaning procedures.
User's Guide, Control Panel (7)

Language: 4
Contents: Functional description
Menu structure (user available)
Operation and programming
Alarm list
Quick Intro (8)

Language: 4
Contents: Quick intro to Control Panel user functions
Keep the manuals with the machine for reference at all times.

0-12

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.
End of life
Estimated product life: 10 years
Spare parts and service period: 7 years after last sales.
Recycling
The processor should be disposed at a certified appliance recycling centre or
processing centre.
Recycling Passport with specifications of components and materials used in this
processor is available on www.glunz-jensen.com/support.
Packaging
Plastic packaging materials are marked according to ISO 11469.
Noise emission
Acoustical noise according to ISO 11201:1996
Sound pressure level

Operational mode: 64 dB
Stand-by mode: < 64 dB

1-2
Mechanical specifications
Chemical emissions
Ozone: 0 mg/m3
Dust: 0 mg/m3
Styrene: 0 mg/m3
Heat emission
See "Power consumption" at page 1-7.
Performance
85 125
Plate types Single sided

thermal offset plates
Plate width 200-850 mm 200-1250 mm

min.- max. (7.9-33.5”) (7.9-49.2”)
Plate length 285-1100 mm 350-1500 mm

min.- max. (11.2”-(43.3") (13.8”-(43.3")
Plate thickness 0.15-0.50 mm

min.- max. (0.006-0.02”)
Plate speed 40-150 cm/min 70-230 cm/min

(15.7-59.1“/min) (27.6-90.6 “/min)
Brush speed
at 50 Hz 80 rpm (revolutions per min.)
at 60 Hz 96 rpm
Tank capacities
85 125
Developer, total
ex. filter, pumps etc. 28.5 l 71.0 l
(7.5 US gal.) (18.8 US gal.)
Gum 3.5 l 6.0 l

ex. filter, pumps etc. (0.9 US gal.) (1.6 US gal.)

1-3
Temperatures
85 125
Developer 18 - 35 °C
Min. - Max. (64.4 - 95 °F)
Dryer, process Fixed
Water requirements
85 125
Pressure
Min. - max. 2 - 6 bar (29 - 87 psi)
Water consumption
85 125
Operation 8 l/min 12 l/min

(if no wash recirc.) (2.1 US gal/min) (3.2 US gal/min)
Stand-by 0.0 l/min

(if no wash recirc.) (0.0 US gal/min)
Hose connections
85 125
Water supply 10 mm
inside diameter (0.39")
Drain connections
85 125
Dev 20 mm (0.79")
Wash 20 mm (0.79")
Gum 20 mm (0.79")

1-4
Dimensions
L1
L2 L3 L4
W
H1
H2
T31619
Processor type 85 125

152.5 cm 195.0 cm
Width (W)
(60.0") (76.8")
243.8 cm (96.0"), or 326.8 cm (128.7"), or
Length (L1)
253.8 cm (99.9") 386.8 cm (152.3")
30.0 cm (11.8"), or 40.0 cm (15.7"), or
Length (L2)
40.0 cm (15.7") 100.0 cm (39.4")
107.0 cm 141.0 cm
Length (L3)
(42.1") (55.5")
106.8 cm 145.8 cm
Length (L4)
(42.0") (57.4")
108.5 cm* 114.5 cm*
Height (H1) *
(42.7")* (45.1")*
79.8 cm* 80.6 cm*
Height (H2) *
(31.4")* (31.7)*
*) Height is adjustable up to approx. 6 cm (2.4") upwards from measurements listed above.
Some processors have foot extentions. Heights will in those cases increase accordingly.
Weights
Processor type 85 125

Weight, empty 324 kg 610 kg
(714 lbs) (1345 lbs)

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

1W + N + PE, 230V AC, Min. 3 x 1.5 mm2,
1x20 Amps, 50/60 Hz type H07 RNF
•
1W + N + PE, 230V AC, Min. 3 x 4 mm2,
•
EUR
3W + N + PE, 400V AC, Min. 5 x 1.5 mm2,
•
3W + N + PE, 400V AC, Min. 5 x 1.5 mm2,
•
2W + PE, 230V AC, Min. 3 x 12 AWG,
2x20 Amps, 50/60 Hz type SJO
•
2W + PE, 230V AC, Min. 3 x 10 AWG,
•
US
3W + PE, 230V AC, Min. 4 x 14 AWG,
•
3W + PE, 230V AC, Min. 4 x 12 AWG,
•
All Voltage tolerance

+10%/-10%
• •
*) Power cord must be in accordance with local regulations.
#
Please be aware of double pole/neutral fusing.
See also specifications of actual power consumption below.
Power consumption
Max power consumption at … 85 125

230/400 V AC operation: 3400 Watt / 11600 BTU/hour •
EUR/
US
230/400 V AC operation: 5700 Watt / 19400 BTU/hour •
Stand-by: 500 Watt / 1710 BTU/hour • •
Noise level
See "General environmental information" on page 1-1.

1-6

Functional description
2-1
General
Part 2: Functional description
General
Processor sections
The basis processor contains four major sections:
1 2 3 4
T11025
Fig.: Processor for short plates with front drive
Developing of the plate and removing of the remaining unexposed/-

1 Developer
exposed emulsion.
2 Wash Washing off the developer chemicals from the developed plate.
Application of a thin layer of gum onto the developed and washed plate to
3 Gum
protect it from oxidation, dirt, fingerprints etc.
4 Dryer Drying of the plate to ensure immediate handling of the plate.
The processor sections are described in detail on the following pages.
Control panel
Processor functions, settings and alarms are controlled from the control panel.
The control panel functions are described in the Control Panel.

2-2
Developer section
Developer section
(Detailed plumbing configuration schematics are shown later in this chapter.)
In the developer section the plate is developed.
Configuration
Roller configuration will vary depending on processor model. See also the description
of "Transport" later in this chapter and schematics with configurations for flow and
drains.
Circulation
A circulation pump recirculates the developer in the section. The solution passes
through a filter to clean it from impurities and make the solution last longer.
Level control/temperature
The developer bath is equipped with a min. level detector circuit, and to keep the
temperature in range, a heater, a thermostat and for some models an external chiller
unit. The chiller unit is a closed system in which water is cooled and circulated
through the developer bath.
Replenishment/anti-oxidation system
The replenishment system automatically adds fresh developer to the developer section
to compensate for chemicals expended during processing and for lost activity caused
by plate development.
The processor measures the plate size to determine the correct amount of replenisher
for each plate.
$
Plate sizes must be entered in the "PLATE SIZES" menu in order to obtain
exact calculation of replenishment.
The time replenish system adds fresh developer or replenish concentrate to the
developer section to compensate for lost activity caused by oxidation and evaporation.
The replenish amounts can be set individually for stand-by mode (heated bath) and off
mode (unheated bath).
The replenishment system also features an

"off replenishment" function which adds an amount of developer into the developer
bath when the processor is turned on after being turned off for a long period.
The replenishment/anti-oxidation developer is added to the section by means of a

pump.

2-3
Wash section
Wash section
In the wash section the developer solution is washed off the developed plate.
When the plates passes through the section, water is applied onto both sides of the
plate through 3 spray tubes, 2 above and 1 underneath the plate.
Gum
In the gum section a thin layer of gum is applied to the developed and washed plate to
protect it from oxydation, dirt, fingerprints etc.
Later, when the plate is fixed in the printing machine, the layer will be rinsed off.
If the plate has been corrected or if it has to be used again on a later occasion it should
be rewashed and regummed (optional feature for some processors).
Circulation
The gum solution is pumped from the gum container into a distributing tube and onto
the plate. The gum section, pump and container are connected in a closed system. The
gum returns to the section into the container and keeps recycling.
The gum circulation system is equipped with a bypass valve for adjustment of the
circulation flow. Adjustment of the gum circulation bypass valve is described in Part 3
"Cleaning and maintenance".
Gum distribution roller

The gum distribution roller ensures a uniform distribution of gum. The roller must be
lifted to upper position and cleaned at each shut-down and again lowered to process
position at each start-up. See Part 3 "Cleaning and maintenance".

2-4
Dryer section
Dryer section
In the dryer section the plate is dried, and so further handling of the plate is possible
immediately after it exits the processor.
A fan blows hot air through a pair of air tubes and dries the plate on both sides.
Transport system
The plate is transported through the processor by a series of rollers and roller guides.
The rollers are driven by a drive motor and a sprocket/chain drive system.
The plate is transported through the processor by a series of rollers and guides.
The rollers are driven by a drive motor and a worm gear drive system.
The rollers at the developer section entrance always run dry to ensure a homogeneous
development. The guide and rollers ensure that the plate is transported correctly
through the developer solution and underneath the brush roller and the guide
underneath the brush roller leads the plate to the rollers at the developer tank exit.
In the wash section the residual emulsion is washed off the plate by means of a brush
roller and spray bars. The wash section entrance rollers prevent that the wash water
runs back into the developer section. Water is squeezed off the plate by the wash
section exit rollers.
The gum section contains one roller pair and a smaller roller situated close to the upper
roller. The gum solution from the application tube forms a small bath between these
two rollers and a thin layer of gum is applied to the plate. The extra gum returns to the
main replenisher container and recirculates.
In the dryer section the plate is dried which makes it ready for immediate handling
afterwards. The exit roller pair takes the plate when dry and leads it out of the
processor.
The processor will be equipped with one of the two transport systems illustrated
opposite:

2-5
SP 85
DEVELOPER WASH GUM DRY
T11046
CD 125
DEVELOPER WASH GUM DRY
T11047

2-6
SP 85 Processor

DEVELOPER WASH GUM DRY SOLENOID
OPERATED
0906
VALVE
NOTE:
All spray bars have
MAINS
individual spray control
WATER SUPPLY
FLOW
CONTROL
VALVE
DEVELOPER
FILTER
REPL. PUMP
DEVELOPER
CIRCULATION GUM
PUMP RECIRCULATION
PUMP
DEV
FILL
PUMP
EMERGENCY
FOR COLLECTION OVERFLOW
FROM DEVELOPER UNIVERSAL
COOLER
CIRCULATION PUMP
DEVELOPER GUM
REPLENISHMENT CONTAINER
CONTAINER TO MAIN WATER DRAIN
Service Manual, Plate Processors 85-125

Processor 85 T11042
2-7
2-8
CD 125 Processor

DEVELOPER WASH GUM DRY SOLENOID
OPERATED
0906
VALVE
NOTE:
All spray bars have
MAINS
individual spray control
WATER SUPPLY
FLOW
CONTROL
VALVE
DEVELOPER
FILTER
REPL. PUMP
DEVELOPER
CIRCULATION GUM
PUMP RECIRCULATION
PUMP
DEV
FILL
PUMP
EMERGENCY
FOR COLLECTION OVERFLOW
FROM DEVELOPER UNIVERSAL
CIRCULATION PUMP COOLER
DEVELOPER GUM
REPLENISHMENT CONTAINER
CONTAINER TO MAIN WATER DRAIN
Service Manual, Plate Processors 85-125

Processor 125 T11045
2-9
2-10
REMOTE
ENABLING ETHERNET
(Optional)
INTERFACE
USB (Online installations only)
MASTER
I/O BOARD MIO SETTER
SOM
GNUIB (RS485)
SLAVE
I/O BOARD HPU
GNUIB (RS485)
SLAVE
I/O BOARD
(Some models only)
MFU
T31649

2-11
Electronic control
Electronic control
See illustration opposite. The electrical control system consists of:
Master Input/Output Unit (MIO)

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

the processor and platesetter.
High Power Unit (HPU)

The HPU-board holds all the high voltage in- and outputs for the control of heaters,
motors etc.
Motor Filter Unit (MFU)

The MFU board is a slave controlling speed and current flow of one DC motor only.
Often placed very close to the motor itself.
All commands and power supply for the board are received via the GNUIB RS485
cable whereas power supply for motor control is recieved via a separate cable.
Touch Screen Control Panel

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

2-12
Electronic control

Cleaning and Maintenance
3-1
General
Part 3: Cleaning and Maintenance
General
This chapter holds the special service information such as adjusting procedures,
cleaning of pumps etc.
For software related service information please refer to the separate "Software Service
Information" manual.
For user related maintenance and cleaning procedures refer to the Plate Processor User
Manual.
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 is still
active, making the drive system run idle at intervals.
There will be NO advice when the JOG function starts.

3-2
Safety check
Safety check
"
Below described safety check should be performed at least once a year.
Electrical
• Check proper function of:
– Lid switch:
The processor must stop when the switch is deactivated. The "COVER OPEN"
message must appear in the control panel display.
– Main switch:
The processor must turn off when set to "0" (off).
– Emergency stop:
The processor must turn off when activated.
– GFCI (F10):
The processor must turn off when activating the yellow button.
Emergency
stop
Upper
side panel
Control panel
Field
wiring box Lid switch
Electronics
cabinet
Main switch
T2640
GFCI
Lower
side panel
Mechanical
• Check proper function/location of:
– Upper side panels, left/right:
Make sure the fenders are properly secured with 2 screws each.
– Lower side panels, left/right.
– Covers, electronics cabinets:
Make sure covers are secured by screws.

3-3
Safety check
Fuses DIN rail

Fuses F20 for brush motor (M4) is placed
on the motor behind the left fender. Fuse
F19 for drive motor (M1) is placed on the
DIN rail (see fig.) in the electronics cabinet.
Other fuses for the various functions are

located on the fuse PCB in the electronics
cabinet (see fig.) behind the left side panel.
A fuse label on the inside of the lid shows
the position and rate of the fuses.
#
When changing a fuse, first switch
off all power to the machine.
Always ensure that the new fuse is
2
of the correct rating according to
4
the label. Fuses T2622

3-4
Cleaning
Cleaning
Cleaning and maintenance procedures to be carried out on a regular basis are
described in the "User's Manual" for plate processors.
Cleaning accessories
$
Never use any hard tools or abrasive materials when cleaning any part of the
processor.
Apron, rubber gloves and eye goggles.

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

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

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

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

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

3-5
Cleaning
Hand shower
A hand shower is located on the rear left hand side of the base frame.
Use the hand shower for cleaning purposes.
#
Only use the hand shower when all power has been disconnected from the
processor.
Ensure that the hand shower tap is closed when the hand shower is not in use.
T31621
Container contents
"
When one or more containers have been exchanged it is very important that
the correct hoses are connected to them.
• Check that the replenish containers are sufficiently filled. Refill or replace if
necessary.
• Empty/replace waste containers.
• Replace gum if it is dirty, too thin or too thick.
Removing rollers from block bearings
1 2 3
T31626

3-6
Cleaning
Removing rollers from clutch bearings
1 2 3
T31627
Developer section
Major cleaning
Follow the procedure described for cleaning in the User's Manual but use a solution of
tank cleaner if needed.
Wash section
Major cleaning
Follow procedure described for cleaning in the User's Manual, but use a 10% citric acid
solution instead of water.

3-7
Cleaning
Gum section
Daily cleaning
The gum applicator roller ensures a uniform distribution of gum on the gum roller.
The applicator roller needs to be cleaned each time the processor is shut down in order
to ensure proper distribution of gum to the plates. Follow the steps below:
Shut down:
• Press the stand-by key to shut down the processor.
• Lift up the top cover.
• Lift the gum applicator roller (a) out and clean it.
• Clean the upper gum roller (b) with a moist cloth.
• Place the gum applicator roller in upper position ©) ready to next start-up.
• Close the top cover.
Start-up:
• Lower the gum applicator roller (a) to process position (d).
• Close the top cover.
• Press the stand-by key on the control panel to switch the processor to stand-by
mode.
a
c
T31631
d

3-8
Cleaning
Cleaning of valves in the replenish pumps

If a replenishment pump ceases to function
properly, run it with some warm water in VALVE
order to clear the pump of chemicals. VALVE
If this does not help, take the pump apart
and clean both of the small valves in warm
water.
T436
Cleaning of the circulation pumps

If the circulation pump ceases to function
properly clean the pump following this description.
• Cut off the power to the unit by removing the top cover.
• Empty the tank section.
• Dismount the hoses from the pump. Be careful not to spill the chemicals on the floor.
• Note the position of the outlet nozzle (5).
• Dismount the pump.
• Dismount the cover (4) and pull out the impeller (3) and the impeller housing (1).
• Clean the inside of the cover, the impeller and the impeller housing in warm water.
• Reinstall in reverse order, observing that the outlet nozzle (5) of the cover is placed
as it was before dismounting it, and that the O-ring (2) is placed correctly in the
groove of the impeller housing (1).
1
2
3
4
5 T 31064

3-9
Maintenance
Maintenance
Changing developer filter

The developer filter unit is located F ON
OF
underneath the top cover in the right side of
the processor. 1
• Unscrew the filter cover (1)
(counterclockwise) and slowly lift it off.
The filter element (2) will hang on to the 2
cover.
• Mount a new filter element underneath
the cover and lower it slowly into the 3
vessel to avoid splashing.
• Make sure that the O-ring (3) is fitted
properly in the filter vessel groove (4)
then tighten the cover (1) (clockwise). 4
• Reset the filter area:
Enter the " -> Manual task" and select
the "DEV filter replaced" dialog.
$
Pressing "Confirm replace" will
reset filter area counter. T31620
Adjustment of spray tubes

The pressure in the spray tubes can be adjusted to obtain the best possible application
of water to the plate. Pressure is adjusted as shown on the illustration below.
The valve is fully open from the factory. Normally no adjustments are necessary.
t31623

3-10
Maintenance
Adjustment of gum flow

The gum distribution bar is adjusted from the factory. If further adjustment is needed
loosen the nut (a) and then turn the block (b) downward for adding less gum to the
gum roller or upwards for adding more gum.
x.
Ma
a
b
n.
Mi
T31625

3-11
Maintenance
Changing the brush roller cloth

The brush roller cloth can be replaced in case of heavy fouling or wear.
• Take out the brush roller.
• (1) remove the pin and the bearing.
• (2) remove the strip holding the cloth.
• (3) pull off the cloth and apply the new cloth (use talcum).
• (4) wrap it round the roller edge and fasten it with a strip.
• Stretch the cloth to obtain a smooth fit along the roller, wrap it round the other roller
edge and hold it tight while fastening with a strip.
• Mount the pin and bearing (1).
• Reinstall the brush roller.
1
2
T31102...

3-12
Maintenance
Setting rollers and brush rollers
Installation of rollers
$
Make sure to align the gears on the upper and lower rollers.
The gear on the lower rollers has a plate/guide that must fit into the gear of
the upper rollers.
Drive/scrub chain
The drive/scrub chain should be lightly lubricated with SAE 20/50 Oil, and the
tension checked and reset if required every 6-12 months.
All of the bearings are sealed and require no maintenance.
Roller pressure
If the pressure between each pair of rollers is excessive then an undue load is applied
to the drive motor and the rollers will bow. This will result in the middle of the plates
becoming wet, and a possible drive motor failure. If the pressure is too slack, the plates
will slip on their way through the processor, and the plates will be wet all over. Both
situations will allow residues to carry over between tank sections resulting in an
uneven wash.
Adjusting gap between the rollers

• Ensure the machine is switched off.
• Lift the top cover. Pressure 0.5 mm feeler gauge
adjustment (important to check
• Remove the roller and upon screws both ends of rollers)
reassembling as pairs lay it flat on the top
edges of the tank.
• The initial setting of a uniform gap of 0.5
mm. (0.020") between the rollers is
essential to set the correct pressure. This
gap should be checked with a feeler Gears shown are not
gauge, which should touch both rollers used in all applications
T31628
without rotating them.
Drive rollers pressure

To set the pressure for the drive rollers do the following:
85 models: Tighten each adjusting screw 1 turn.
Tighten the drive rollers in the gum section 1¼ turns.
125-165 models: Tighten each adjusting screw 1 ¼ turns.
Tighten the drive rollers in the gum section 1½ turns.

3-13
Maintenance
Scrub roller in wash section Pressure adjustment screw
For adjustment of scrub roller follow the

procedure below:
• Press on the control panel and press "Eject plate".

Then press "Forward".
Define the "touch point" (the point where the scrub
roller is just touching the lower support roller). The
touch point is defined as follows: T31672
a All four adjustment screws (see figure ) need to be loosened anti-clockwise

so that the scrub roller is NOT causing the support roller to rotate.
b Each adjusting screw is then adjusted clockwise until the Support Roller
starts to rotate. Once the support roller has started to rotate the adjusting
screw must be adjusted anti-clockwise until the support roller just stops
rotating. This procedure is repeated for all four adjusting screws.
c Procedure described for "b" is then repeated in order to ensure accurate

"base point".
• Adjust the final scrub roller pressure as follows:

Plush cover Adjust roller down to just before touch point
roller and then turn the screws ¼ turn clockwise.
$
Please do never exceed ½ of a turn clockwise as this may potentially cause
plate jam in the WASH section.
Bristle brush The scrub roller pressure is then finally defined by

roller adjusting each of the four adjusting screws ½ of a
turn clockwise.
$
Please do never exceed 1 of a turn clockwise as this may potentially cause
plate jam in WASH section.
Roller reassembling
Replace the roller assemblies in the tank.
Once the rollers are replaced and no further adjustments are necessary, repeat the
"Preparation for Processing" section of this manual to check the correct transport of the
plate through the processor before use.
The overall height of the drive/gum rollers and scrub roller is determined by the slot
depth in the tank side walls and is therefore not adjustable.

3-14
Maintenance
Chain maintenance
Regular chain maintenance is important if maximum life is to be achieved.
The following maintenance schedule is suggested:
After processing 400 hours/6,500 m2

... whatever comes first:
• Check chain adjustment and rectify if necessary.
After processing 2,500 hours/80,000 m2

... whatever comes first:
• Carry out above check
• Check for wear on side plates of the chain link.
• Check for chain elongation
• Check cleanliness of components.
• Remove any accumulations of dirt or foreign materials.
• Check for shaft and sprockets alignment.
• Check for wear on sprockets.
• Check the conditions of the lubricant.
Lubrication:
Chain drive should be protected against dirt and moisture and be lubricated with
good quality, non-detergent petroleum based oil. A periodic change of oil is desirable.
$
Heavy oils and greases are generally too stiff to enter the chain working
surfaces and should NOT be used.
A multi grade SAE 20/50 oil would be suitable.
Care must be taken to ensure that the lubricant reaches the bearing area of the chain.
This can be done by directing the oil into the clearances between the inner and outer
link plates, preferably at the point where the chain enters the sprocket on the bottom
strand. Please see below:
T31682

3-15
Maintenance
Idler sleeve bearings maintenance

Once a year or for every 1,000 hours the idler sleeve bearings have to be lubricated as
show on the illustation below. Recommeded oil type: Mineral Oil to ISO VG (SAF30).
$
Normally self-lubricating bearings are considered maintenance free, however,
we recommend a drop of mineral oil to be applied to each bearing on an
annual basis.
T31845
The illustation below shows the idler sleeve bearings to be lubricated.
G I H
D D
D D
D G D
A C
B
C F
C C E
T31846
B C H I

3-16
Maintenance
Chain adjustment procedure

Follow the procedure below when chain adjustment is needed.
1. Total view - Processor 85:

Refer to the steps described later and indicated in the drawing below.
Step 3 Step 6 Step 4
T31683-1
Step 5
Total view - Processor 125-150-165:

Refer to the steps described later and indicated in the drawing below.
Step 3 Step 6 Step 4
T31683-1
Step 5

3-17
Maintenance
2. Main motor and chain motor:

• Dismount the cover (a).
Loosen the screws holding the motor (b).
• Adjust motors sideways position on eccentric (c) in order to adjust chain slack.
Slack should be 8 mm.
• Tighten screws (b) and mount the cover (a).
a c c
3 Final chain:
• Loosen the big sprocket (d) from the
back side of the drive plate.
8 mm
• Adjust the sprocket sideways in the
slot in order to adjust the chain slack.
d
Slack should be 8 mm.
• Fasten sprocket. T31683-4
4 Main chain:
• Loosen sprocket (e) on drive plate
backside. Loosen lock nut.
• Adjust chain tension on adjustment
e f
screw (f). Chain tension must be
between 10° and 15° measured on e
tension scale on lower chain tensioner
(g). T31683-5
• Fasten lock nut and fasten sprocket.

g

3-18
Maintenance
5 Scrub chain:
• Adjust the chain tensioner (h) until
the notch is aligned with thread M5
(i). Chain tension must be between
10° and 22.5°.
i
• Mount the lock screw and fasten the
chain tensioner.
Position of scrub chain tensioner may
T31683-6
vary from one processor model to
another but tensioning method is the h
same.
6 Motors and drive plate:

• Motors must be aligned with the
drive plate when the chains have been
tightened. j
• Align the motors with the drive plate
by turning the screws (j) until motors T31683-7
are aligned with drive plate. j

3-19
Maintenance
How to check for potential chain wear

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

3-20
Maintenance
Control the length
• Control the length of the chain to measure the extension of the chain.
2
• This needs to be done each year or after 80,000 m plates.
• Measure the chain extension between the given numbers of pitches.
• See the recommendation under each drawing later in this chapter.
• If the chain is over the given maximum length between the given numbers of
pitches, it is time for chancing.
"
Please be aware that in case either the chain or the gears are worn out, both
chain and gears have to be replaced.

26 pitches
26 pitches New = 248 mm
New = 248 mm Used = > 252 mm
Used = > 252 mm

3-21
Maintenance
Chain Kit Roller drives 85
59 pitches
New = 562 mm
Used = > 570 mm
Chain Kit Roller drives 125
43 pitches
New = 409 mm
Used = > 415 mm

3-22
Maintenance
Chain Kit Roller/Scrub motor 85
22 pitches
New = 210 mm
Used = > 213 mm
26 pitches
New = 248 mm
Used = > 252 mm
Chain Kit Roller/Scrub motor 125
22 pitches
New = 210 mm
Used = > 213 mm
26 pitches
New = 248 mm
Used = > 252 mm
Changing roller bearing

• All the roller bearings need to be changed after 2,500 production hours or 80,000 m2
plate what ever coming first.
• To secure the roller drive stability it is necessary to change the complete bottom part
of the bearing and not just the inner bearing part.

3-23
Maintenance
Roller bearing kit 85 - 125
Item Specification Quantity
1 MILLED, BEARING, ROLLER, D54 2
2 BEARING, TURCITE L=50 MM 10*/12
3 BEARING, TURCITE L=45 MM 2*
4 BEARING, TURCITE “A” D20.15 / D25 12
* models 85 only
Kit picture
1 2
4
3
Roller bearing kit 85 - 125

• 1. Drain the processor from chemistry and water.
• 2. Take all the transport rollers, plush scrub roller

and segment roller out of the processor. See
illustration opposite.

3-24
Maintenance
• 3. Remove the complete roller bearings and

disassemble the bearings, as it is shown in the
illustration opposite. Mount the new bottom part
of the bearing in where the new “Turcite” bearing
is mounted together with the old top part of the
bearing.
• 4. The bottom part of the roller bearing at the roller pair in the gum section is 5 mm
shorter that the rest of the bearings. Be sure that they are mounted in the right
position again. (Valid only for 85 model.)
•
• 5. Remove the tubular pin (item 1 in the
illustration) from the top roller and then remove 1
the “turcite” bearing (item 2). Use a 6 mm

mandrel to drive out the pin. 2
• 6. Mount the new “turcite” bearing (item 2) part number SLOT

1
Press the tubular pin (item 1) back again and be sure
that the pin is centred in shaft, and the slot must be
point opposite the shaft end.
• 7. Mount the complete roller bearings again at each roller

pair. See bullet no 4 regarding the gum rolle\r bearing.
(Valid only for 85 model.)
8. Adjust the transport roller pressure according to

the instruction in the service manual. See page 3.15.
9
• 9. Mount the new milled bearing (item 10) part
number at the segment roller in drier section.
(see bullet no 5 and 6 regarding the tubular pin - 10
item 9).
• 10. Fill up the processor again and start up the processor.
• 11. Adjust the plush scrub roller according to the service manual. See page 3.16.

Trouble shooting
4-1
General
Part 4: Trouble shooting
General
If the processor does not work properly, refer to the following pages to find the
paragraph that comes closest to your problem.
The trouble shooting guide is divided into 2 sections:
a. Problems with the processor
b. Problems with processed material
For information about alarm messages see the "Control Panel" manual.
For cleaning and maintenance subjects see the processor user manual.
Use the "Test functions" parameters on the control panel to test individual
components. See the "Software Service Information" manual.
The electrical diagrams are located in Appendix A.
"
To change a fuse, switch off all power to the machine first.
Always ensure that the new fuse is of the correct rating according to the
diagram.
WARNING!
When performing any service, maintenance, calibration, or trouble shooting
etc. it may be necessary to override the function of the processor’s
interlock switches.
In these cases please be aware, that the processor’s JOG-function is still
active, making the drive system run idle at intervals.
There will be NO advice when the JOG function starts.

Trouble shooting
4-2
Before starting trouble shooting
Before starting trouble shooting
IMPORTANT!
Plates and chemicals are very sensitive materials and correct storage is vital to obtain a
satisfactory production result. Incorrect storage may very well result in unsatisfactory
processing quality etc.
Contact your local supplier for information about storage requirements for plates and
chemicals.
Before making adjustments of the equipment make sure that incorrect storage of
plates and chemicals can be excluded.
Problems with the processor

SYMPTOM PROBABLE CAUSE REMEDY
NO FUNCTION ACTIVE • 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.
• Fuse(s) blown. • Replace fuse.
PROCESSOR CANNOT • Configuration error. • Reload software.
INITIALIZE (If main power has been
cut off temporarily the
processor switches to off
mode - green led flashes).
• Defective PCB. • Replace PCB.
• Cables not properly • Check cables and make
connected. proper connections.
MACHINE WILL NOT • MMU-PCB defective. • Replace defective part.
START UP
MACHINE DOES NOT • Input sensor (s) defective. • Replace defective sensor.
START WHEN A PLATE
IS INSERTED
NO WASH WATER • Water tap closed. • Open water tap.
ALTHOUGH MACHINE • Water solenoid valve
IS IN “PROCESS” MODE. defective. • Replace valve.
• Water solenoid valve filter • Clean filter.
clogged.
• Processor with filter: Filter • Open valve.
valve closed.
• Processor with level • Check sensors and clean/-
sensor: Level sensor in replace whatever is
wash dirty or defective. necessary.
• Electronics defective. Replace defective
electronics.

Trouble shooting
4-3
Problems with the processor
DRYER BLOWER WORK, • Fuse(s) blown. • Replace fuse.

HEATER DOES NOT • Temperature sensor • Replace temperature
defective. sensor.
• Heating element defective. • Replace heating element.
• Electronics defective. • Replace defective
electronics.
DRYER BLOWER DOES • Fuse(s) blown. • Replace fuse.
NOT • Blower defective. • Replace blower.
WORK. • Electronics defective. • Replace defective
electronics.
NO GUM ALTHOUGH • Gum container empty. • Refill container.
MACHINE IS IN • Gum hose blocked. • Clean hose.
“PROCESS” • Pump valves blocked or • Clean or replace valve.
MODE. defective. • Replace pump.
• Pump defective. • Replace fuse.
• Fuse(s) blown. • Replace defective
• Electronics defective. electronics.
GUM PUMP RUNS • Gum hose blocked. • Clean hose.
BUT NO FINISHER. • Pump valves blocked or • Clean or replace valve.
(NO ALARMS) defective.
DEVELOPER • Fuse(s) blown. • Replace fuse.

REPLENISHMENT • Pump defective. • Replace pump.
PUMP DOES NOT • Electronics defective. • Replace defective
WORK. electronics.
DEVELOPER • Replenishment hose • Clean hose.

REPLENISHMENT blocked.
PUMP RUNS BUT NO • Pump valves blocked or • Clean or replace valves.
REPLENISHMENT. defective.
• Replenish container empty. • Refill container.
REPLENISHMENT • Replenishment parameters • Make correct settings.
SYSTEM settings not correct.
DOES NOT WORK • Electronics defective. • Replace defective
ALTHOUGH electronics.
THE MACHINE IS IN
”PROCESS” MODE.
NO DEVELOPER • Replenish container empty. • Fill replenish container.
CIRCULATION • Fuse(s) blown. • Replace fuse.
• Processors with filter: • Replace filter insert.
Filter clogged.
• Processors with filter: • Open valve.
Filter valve closed.
• Developer circulation • Replace pump.
pump defective.

Trouble shooting
4-4
Problems with processed material
NO WATER • Pump defective or clogged. • Clean and/or repair

CIRCULATION. pump.
• Water filter clogged. • Replace filters.
• Water spray bar clogged. • Clean spray bar.
See Part 3.
• Fuse blown. • Replace fuse.
• Level sensor in wash dirty • Check sensor and clean/-
or defective. replace whatever is
necessary.
ROLLER DRIVE MOTOR • Drive gears and/or worms • Check all gears and worms
RUNS, defective. gears on rollers, and make
BUT NO PLATE sure they move freely.
Replace any defective part.
TRANSPORT.
Problems with processed material

SYMPTOM PROBABLE CAUSE REMEDY
PLATE IS NOT • Dryer temperature is set • Set dryer temperature a
COMPLETELY too low. little higher.
DRY • Gum section applying to • Check gum section.
much gum.
• Dryer section is • Check dryer section.
malfunctioning.
PLATE HAS STRIPES • Defective or dirty rollers or • Take rollers and/or guides
LENGTH- guides. out, inspect and wash them.
WISE OR CROSSWISE Rollers with dents or other
marks must be changed.
• Clean the spray tubes.
• Wash spray tubes clogged. See Part 3.
WASHING NOT • Spray tube clogged. • See earlier in this chapter.
SUFFICIENT Clean spray tube.
• Brush not turning. • Check the brush and fix
the problem.
• Brush pressure not • Adjust brush pressure.
sufficient.
• Water circulation pump • See "Cleaning of the
does not run. pumps" in Part 4.
• Rollers dirty in wash • Clean rollers.
section.
PLATE HAS AN UNEVEN • Gum container nearly • Refill container.
GUM empty. • Take rollers out and clean
• Gum rollers dirty. them.
• Gum distributing roller not • Correct the placement of
in place. the roller.
• Gum pump clogged. • Take pump apart and
clean valves.

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
iso-metric drawings, descriptions and part numbers.
Ordering spare parts

When ordering spare parts:
Please state carefully the spare part number, the specification and the number of
items wanted.
Special spare parts

Some of the spare parts (covers, panels etc.) are available in different colors. In these
cases please refer to Appendix A “Additional spare parts” for the correct numbers for
your specific processor.
PCB's and software
IMPORTANT!
All spare part PCB's with software proms will be delivered without software installed.
Contact the processor supplier for information about software.
The Service Technician must download software from a CD.
See "Electrical" in this chapter for Software CD spare part number.
Instructions for downloading and upgrading software are stored on the software CD.

Spare parts
5-2
4
3
2
5
29
9
10
11
6
15
20
27
14
24 26
28 22
16 25 12
17
12
13 12
19
8 23
T8574
PANELS

Spare parts
5-3
Panels
Panels
Pos. 85 125 Specification
1 10026005 10024856 COVER, TOP, COMPLETE W. SPRING
2 35362 35362 HANDLE
3 45764 SPRING,GAS 200N
21108780 SPRING, GAS 500N D8/D19
4 21041091 21041091 ACTUATOR, SWITCH, SAFETY
5 SEE APPENDIX A
6 10031354 10031354 SENSOR, OPTO, 60MM, CABLE, COMPLETE
7 10038499 10038496 PANEL ,SIDE ,FRAME ,RIGHT
8 10038501 10038497 PANEL, SIDE, FRAME, LEFT
9 10030464 10032426 COVER, PLUMB, RH
10 10030238 10032427 COVER, DRIVE, LH,
11 10039870 10039870 DISPLAY, COMPLETE
12 10037729 10037729 BLACK, TAPE, 1.5", VELCRO, LOOP, LONG
13 SEE APPENDIX A
14 21839033 21839033 TUBE, SPACING, LONG
15 10031346 10031346 BRACKET, SENSOR, REAR
16 10040558 10040558 SWITCH, EMERGENCY STOP
17 21080333 21080333 DISC, YELLOW, EMERGENCY STOP, D70
18
19 10040560 10040560 CABLE, EMERGENCY STOP
20 10040092 10039978 PANEL, FRONT
21
22 21113212 21113172 FINGER, GUARD
23 10021826 10021826 COVER, SWITCH, LID, COMPLETE
24 35598 35598 CIRCLIP, D14, A2, DIN 471
25 0180202 0180202 GUIDE, SILICONE D25 INCL.BUSHING
26 10051708 10051708 TUBE, SPACING
27 21113708 21113708 SUPPORT, ROLLER, SHAFT
28 21113165 21113149 ROLLER, ASSY, INFEED, COMPLETE
29 10040089 10040052 PANEL, REAR

Spare parts
5-4
13
8
11 12
3 6
2
14
9 5
1 4
15
10
T8575
STAND

Spare parts
5-5
Stand
Stand
1 21050957 21050957 CASTOR, SWIVEL
2 35933 35933 WASHER D13/24X2, 5 A4
3 35122 35122 NUT M12 HE 4
4 21050996 21050996 FOOT, STANDARD 135 HIGH, 16MM THREAD
5 15078 15078 WASHER D17/30X3 4
6 15435 15435 NUT M16 HE 4
7 21050207 21050207 CLIP, SPRING, POLY, COAT
8 21060339 21060339 BRASS, HOSE, TAIL, 3/4", BSPx1/2"
9 10025109 10022931 PANEL, REAR, BASE
10 10025768 10022927 PANEL, FRONT, BASE
11 21050039 21050039 SPRAY GUN, NOZZLE
12 0011361 0011361 FITTING, VALVE, BALL 1/2" MA/FE
13 10017951 10017951 MANIFOLD, MAINS WATER, COMPLETE
14 15427 15427 NUT M12 HE TH 4
15 21114285 21114285 JACKING BLOCK, 110 MM DIA. X 80 MM HIGH NOT ALL MODELS
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-6
5
4 2
7 1
6
3
T8576
FEED TABLE

Spare parts
5-7
Feed, table
Feed, table
1 21114763 TABLE, INPUT, LARGE, 1000 MM
2 21114758 21113957 TABLE, INPUT, 400 MM
21113399 TABLE, INPUT, 300MM
3 21050972 21050972 CLIP 1/4", RETAINING, GEAR
4 21110018 21110018 BUFFER, SKIFFY 049 0800 11407
5 22934224 22934224 LID, STOP
6 21800144 STAY, TABLE, INPUT
7 21070166 21070166 SCREW, M5X6, HE, SO, CH, DIN912
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

Spare parts
5-8
2
3
1
T8589
DELIVERY TABLE

Spare parts
5-9
Delivery, table
Delivery, table
1 21107631 TABLE, TOP, DELIVERY
2 10021577 FOAM, STRIP, 15x6
3 21107633 TABLE, DELIVERY, STOP
4 21107632 LEG, TABLE, DELIVERY
5 21020129 SILICONE, RED, 1.5MM X 50MM, ROLL
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-10
H C
D G D
D D D
C G D
A B
C C
C F E
C C C
21
21
20 5
1 4
2
3
8
7 8 9 10
A B C
8 18 8 8
11 12 8 13 8
19
16 16
8
D E F
8 18
14 15
19
8
G H
T8577
DRIVE PLATE (CD)

Spare parts
5-11
Drive plate (CD 125)
Drive plate (CD 125)

Pos. 125 Specification
1 21108632 FINAL DRIVE CHAIN, 125/150, 53 PITCHES
2 22602316 LINK, CHAIN, No.26, 3/8"x7/32 SIMPLEX"
3 10022028 CHAIN, MAIN, CD, 369 PITCHES
4 10021666 CHAIN, MOTOR SCRUB, 73 PITCHES
5 10021662 CHAIN, MOTOR, MAIN, 93 PITCHES
6 10032141 CHAIN, SINGLE/TWIN SCRUB, 123 PITCHES
7 10017451 SPROCKET, 11T
8 21050120 BEARING 22 SFT 3/4"
9 21101816 SPROCKET, 21T DUPLEX, CONCENTRIC
10 10021642 IDLER, MAIN, DRIVE, 19Z
11 10016630 DRIVE, SHAFT, ASSY, 19Z
13 21050091 SCRUB, SHAFT, ASSY, 19Z
15 10021661 IDLER, SCRUB, DRIVE, 19Z
16 21050089 SPROCKET, 19Z 06B-1, M8 BORE
17
18 10025418 SHAFT, LOCK, CLUTCH
19 10025802 BRACKET, LOCK, CLUTCH
20 10025415 CHAIN, TENSIONER, SE11, SCRUBCHAIN, COMPLETE
21 10025416 CHAIN, TENSIONER, SE11, DRIVECHAIN, COMPLETE
22
23
24
25
26
27
28
29
30

Spare parts
5-12
2
12
8
11
17
4
3 1
16
13
14 15
9
6 10
7 5
5
T8578
CHAIN DRIVE PLATE (CD)

Spare parts
5-13
Chain drive plate (CD 125)
Chain drive plate (CD 125)

1 35113 SCREW, M8X16 HE SO CP 4
3 21113578 SPROCKET, 23Z 06B-1,15 MM BORE
4 10024646 MOTOR, PARVALUX, PM6D LIS, 9 RPM
5 10021315 SPROCKET, CHAIN, TENSIONER, KS06(1)15-10
6 10025415 TENSIONER, CHAIN, SE11, SCRUB, COMPLETE
7 10025416 TENSIONER, CHAIN, SE11, DRIVE, COMPLETE
8 10022306 SPROCKET, 36TX3/8"P, 15 MM BORE W. KEY
9 10024291 CLUTCH, CASE, SCRUB
10 10026003 SPRING, COMPRESSION, DI23X1.75X40.4
11 10022224 CLUTCH, CASE, DRIVE
12 10024649 MOTOR, SD13 LIS, WIRED
13 10038304 BLOCK, CHAIN, TENSIONER
14 1516 NUT M8 HE THIN 4
15 5111X086000 SET SCREW M8 X 60 DIN 933
16 5234 SCREW M6X20
17 10037749 SPACER, CLUTCH, DRIVE
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-14
D G D H
D D
D G G
A
B C C
C F E 21
C C
21
20
1
4 5
3 2
8
7 8 9 10
A B C
8 18 8 8
11 12 8 13 8
19
17 17
8
D E F
8 18
14 16
19
8
G H
T8577
DRIVE PLATE (DOUBLE SCRUB)

Spare parts
5-15
Drive plate (double scrub 85)
Drive plate (double scrub 85)

1 10032142 CHAIN, FINAL DRIVE, 57 PITCHES
2 22602316 LINK, CHAIN, No.26,3/8"x7/32 SIMPLEX"
3 10023774 CHAIN, MAIN, 275 PITCHES
4 10024015 CHAIN, MAIN SCRUB, 73 PITCHES
5 10024014 CHAIN, MOTOR MAIN, 73 PITCHES
6 10023772 CHAIN, DOUBLE SCRUB, 119 PITCHES
8 21050120 BEARING 22 SFT 3/4"
9 21101816 SPROCKET, 21T DUPLEX, CONCENTRIC
10 10021642 IDLER, MAIN, DRIVE, 19Z
15
16 10021661 IDLER, SCRUB, DRIVE, 19Z
17 21050089 SPROCKET, 19Z 06B-1, M8 BORE
18 10025418 SHAFT, LOCK, CLUTCH
19 10025802 BRACKET, LOCK, CLUTCH
20 10025415 CHAIN, TENSIONER, SE11, SCRUBCHAIN, COMPLETE
21 10025416 CHAIN, TENSIONER, SE11, DRIVECHAIN, COMPLETE
22
23
24
25
26
27
28
29
30

Spare parts
5-16
2
12
3
11 4
17
8 1
9
16
13
10
6 14 15
5 7 5
7
T8578
CHAIN DRIVE PLATE (DOUBLE SCRUB)

Spare parts
5-17
Chain drive plate (double scrub 85)
Chain drive plate (double scrub 85)

3 10022306 SPROCKET, 36TX3/8"P, 15 MM BORE W. KEY
4 10024646 MOTOR, PARVALUX, PM6D LIS, 9 RPM
5 10021315 SPROCKET, CHAIN, TENSIONER, KS06(1)15-10
6 10025415 TENSIONER, CHAIN, SE11, SCRUB, COMPLETE
7 10025416 TENSIONER, CHAIN, SE11, DRIVE, COMPLETE
8 21113578 SPROCKET, 23Z 06B-1,15 MM BORE
9 10024291 CLUTCH, CASE, SCRUB
10 10026003 SPRING, COMPRESSION, DI23X1.75X40.4
11 10022224 CLUTCH, CASE, DRIVE
12 10024649 MOTOR, SD13 LIS, WIRED
13 10038304 BLOCK, CHAIN, TENSIONER
14 1516 NUT M8 HE THIN 4 439
15 5111X086000 SET SCREW M8 X 60 DIN 933
16 5234 SCREW M6X20
17 10037749 SPACER, CLUTCH, DRIVE
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-18
12
13
10
11 24
7
28
15 25
26
only 125
10
14
1 2 3
24
16
6
28
20 18
28
17
5 28 4 22 19
8 24
27 only 85
21
7 23
T8579
GROUP FILTER DEV AC-5P

Spare parts
5-19
Group filter dev ac-5c
Group filter dev ac-5c

1 10031098 21109444 AC-5C, PUMP, WIRED ASSY, ENCAP., IMPELLER
2 10035422 10035423 CONNECTOR, FILTER/PUMP
3 21114286 FITTING, HOSETAIL, 3/4"BSP x 3/4", MODIFIED
21060057 HOSE ADAPTOR 3/4" 90 DEG
4 22080199 FTG ADAPTOR 3/4 X 3/4 M
22086216 FITTING, REDUCER, 1"BSP M X3/4"BSP M
5 22070447 22070447 HOSE CHEM EPDM 3/4 IN
6 10048114 10048114 BALL, VALVE, 3/4"BSP, 3WAY, MODIFIED
7 21060040 21060040 ADAPTOR HOSE, PP 3/4"X3/4"
8 21112093 21112093 FIT, ELBOW, 3/4"BSP M/F, 10MM THREAD
9 57727 57727 FILTER, INSERT, 9 7/8", 150 MIC, REUSE
10 35385 35385 O-RING, D19.3X2.4, FPM
11 21792259 21792259 TUBE, INNER, FILTER, 10"
12 21110139 21110139 LABEL, FILTER, TOP
13 10017804 10017804 LID, FILTER, COMPLETE
14 10035355 10035355 FILTER, HOUSING, 10"
15 21110489 21110489 O-RING, 77MMX3MM, VITON, SHORE 70
16 22085147 22085147 FITTING, ELBOW, 1/2" BSP, 3/4" HOSE
17 15847 15847 CLAMP, HOSE D12.0-13.7
18 21060186 21060186 FITTING, PLUG, 1/4"BSP, PP
19 10031290 10031290 VALVE, 3/4" BSP, FITTING
20 21060422 21060422 FITTING, HOSETAIL, 1/4" BSP x 10MM
21 5313 5313 CLAMP, HOSE D13.7-15.3 PL SNP8
22 10030528 10030528 HOSE, SILICONE, D10/D14
23 21060150 21060150 VALVE, FP 226-8B-8B-F, SPE 5741890
24 21060674 21060674 HOSE, BRAIDED, 3/4", RED
25 - 22086380 VALVE 3/4BSP(FM) - PP
26 - 21114286 FITTING, HOSETAIL, 3/4"BSP x 3/4", MODIFIED
27 21792146 21792146 BRACKET, FILTER DRAIN VALVE, AC3C
28 6323 6323 CLAMP, HOSE D13-27

Spare parts
5-20
48
49
50
42
41
39
46
53
45 47
10
17 39 19
39
11 44
39
25 25
18
51 22 51
31
26 39
12 37
27 30
43
29 2
7 28 23 3
32
35
26 26
26 6
5 52
29 25
36 21
29 8
7 25
26
34
9 32 35
2
13
17
17
14
39 25
20
14 20 34
15
53
14 33
16 53
14
20
53
40
T8580
PUMP / CIRCULATION

Spare parts
5-21
Pump / circulation
Pump / circulation
2 22085504 22085504 FTG, HOSETAIL, 3/4"BSP X 25, PP
3 10046848 10046848 VALVE, BALL, 2 WAY, 3/4" 90'ANGLE
5 10026036 10026036 BRACKET, PUMPS AND TAPS, W/LABEL
6 10031094 10031094 PUMP, OSC, GUM, COMPLETE
7 21060040 21060040 ADAPTOR, HOSE, PP 3/4"X3/4"
8 22085087 22085087 FITTING, ELBOW, 1/2" BSPx1/2" HOSE
9 10022908 10022908 PUMP, AD 550, WITH PLUG,
10 10031426 10031426 CAP, SEAL, MH57, M12
11 10032143 10032418 DRAIN, MANIFOLD
12 21060057 21060057 ADAPTOR, HOSE, 3/4" 90 DEG
13 22085528 22085528 FITTING, ELBOW 90, 3/4"BSPx25 HOSE
14 21060678 21060678 HOSE, BRAIDED, 1", RED
15 21060690 21060690 FITTING, TEE, HOSE, 25MM, BARB
16 21060685 21060685 FITTING, TEE, HOSE, 25MM, BARB
17 6062 6062 CLAMP, HOSE D18-38
18 22085544 22085544 HOSE WIRE REINF PVC 10ID
19 21109550 21109550 VALVE, SOLENOID, TWIN, SDT 180 ,24V,DC
20 21060670 21060670 HOSE, BRAIDED, 1/2", RED
21 10032370 10032370 DRAIN, MANIFOLD, COMPLETE
22 21107092 21107092 PUMP, BELLOWS, DEV, M8, GRI, EPDM, COMPLETE
23 10032366 10032366 VALVE, BALL, 3-WAY, 1-1/2", BSP, COMPLETE
24
25 6332 6332 CLAMP, HOSE D09-16
26 6323 6323 CLAMP, HOSE D13-2790
27 10026012 10026012 BRACKET, VALVE
28 21240223 21154228 PIPE, DRAIN, 355 LG (14")
29 21060674 21060674 HOSE, BRAIDED, 3/4", RED
30 10034866 10034866 HOSE, SILICONE, D10/D17

Spare parts
5-22
48
49
50
42
41
39
46
53
45 47
10
17 39 19
39
11 44
39
25 25
18
51 22 51
31
26 39
12 37
27 30
43
29 2
7 28 23 3
32
35
26 26
26 6
5 52
29 25
36 21
29 8
7 25
26
34
9 32 35
2
13
17
17
14
39 25
20
14 20 34
15
53
14 33
16 53
14
20
53
40
T8580
PUMP / CIRCULATION

Spare parts
5-23
Pump / circulation
Pump / circulation
31 10018312 10018312 FTTTING, WASTE, WASH, COMPLETE
32 5371 5371 CABLE-TIE 150X3.5 T30R
33 10040880 10040880 SINGLE, CHECK, VALVE, 1/2" HOSE
34 10017014 10017014 SUCTION, SENSOR, 2-PIN
35 26138 26138 HOSE, SPIRAL D25/30
36 21060239 21060239 HOSE Y, 3/4"
37
38
39 6019 6019 CLAMP, HOSE, D8-22
40 21060176 21060176 TUBE, REPLENISH, BOTTLE, 1/2" DIA
41 21060128 21060128 HOSE, ADAPTOR, FEMALE, 3/4"BSP, TO, 13
42 45592 45592 O-RING, D15.54x2.62, EPDM
43 15862 15862 CLAMP, HOSE D16.8-18.4 SNP12
44 21060679 21060679 HOSE, BRAIDED, 1", BLUE
45 6080 6080 HOSE 1/2", REINFORCED (PER M)
46 21060671 21060671 HOSE, BRAIDED, 1/2" BLUE
47 21060176 21060176 TUBE, REPLENISH, BOTTLE, 1/2" DIA
48 10041041 10041042 TUBE, SPRAY, NOZZLE, GUM
49 10036016 10036016 FLOWREGULATOR, GUM
50 21059084 21059084 O-RING, D12.29X3.53
51 6341 6341 HOSE, D10/D14, PVC, RED, PER METER
52 6342 6342 HOSE, D10/D14, PVC, BLUE, PER METER
53 15510 15510 CLAMP, HOSE D11-18MM
54
55
56
57
58
59
60

Spare parts
5-24
7
3 4 7
1 2
5
6
8
11
9 13 12
2 23 13
4 22 16
5 33 17 10 12 13
3 19
18
14
20 25
24
23
15 22
21
31
30
20
26
27
32
19 28
29
T8581
TANK BASE

Spare parts
5-25
Tank base
Tank base
1 21116265 PLATE, GUIDE, COMPLETE
2 5124 SCREW M5X6 HE SO CP
3 21050028 FINAL DRIVE COLLAR 1/2"
4 21655209 BLOCK, SPRAYBAR, END
5 21153206 SUPPORT, BLOCK
6 21153150 21154132 TUBE, CHILLER
7 21040073 21040073 CABLE GLANDS, M20, 8-13MM
8 21060178 21060178 BSP HEX PLUG 3/4"
9 21253216 21253216 MANIFOLD, DISTRIBUTION, BLOCK
10 10014671 10014671 FITTING, ELBOW, 3/4"RG(BSP), 1/2" HOSE
11 21112247 21112247 FITTING, HOSETAIL, 1/2"
12 15510 15510 CLAMP, HOSE D11-18 MM
13 6080 6080 HOSE 1/2", REINFORCED, PER METER
14 10025918 10025918 STACKPIPE, DRAIN
15 35355 35355 O-RING D5.0X2.5 EPDM
16 10040806 10040806 SWITCH, FLOAT, 15KOHM, COMPLETE
17 88820 88820 STOPPER, TANK, D12
18 21060191 21060191 PLUG, HEX, 1/2", BSP
19 21106975 21106975 HEATER, TANK, COMPLETE
20 25302 25302 O-RING 19X4 46 6051
21 87520 87520 SENSOR, LEVEL, 90, DEGREE, COMPLETE
22 35386 35386 O-RING D16.3X2.4 FPM
23 10037727 10037727 NUT M12 HE 4
24 44968 44968 FITTING, BUSHING, ½"RG-D6
25 43724 43724 SENSOR, TEMP NTC (90MM CABLE)
26 10023498 10023498 SENSOR, CONDUCTIVITY, DIGITAL
27 10023497 10023497 WASHER, NITRILE, SENSOR
28 10023496 10023496 NUT, 3/4", BSP, PLASTIC
29 21793104 21793104 BRACKET, TANK, BASE
30 10031354 10031354 SENSOR, OPTO, 60MM, CABLE

Spare parts
5-26
7
3 4 7
1 2
5
6
8
11
9 13 12
2 23 13
4 22 16
5 33 17 10 12 13
3 19
18
14
20 25
24
23
15 22
21
31
30
20
26
27
32
19 28
29
T8581
TANK BASE

Spare parts
5-27
Tank base
Tank base
31 10024911 10024911 BRACKET, SENSOR, MOUNTING
32 - 10041028 PLATE, DRIVE, SUPPORT
33 10043228 10043228 PIN, DOWEL, D6h8 X 60
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

Spare parts
5-28
1
1 4 11
2 4 2 7
12 25
3 8
3 15 16
5
22
13
18
17
6
19
16
6 17 16
9
14
10 8 16
25
17
24
14
17
20
22
21 9
14
24
14
23
14
21
T8582
GROUP ROLLER

Spare parts
5-29
Group roller
Group roller
1 35598 35598 CIRCLIP, D14, A2, DIN 471
2 21114912 21114922 SHAFT, IDLER, LONG
3 21839023 21793020 SHAFT, IDLER, SHORT
4 10042645 10042645 ROLLER, GUIDE, NYLON D25
5 21114911 - SHAFT, IDLER, SHORT
6 10037188 10037189 IDLER, DRIVE, BAR, NYLON, COMPLETE
7 10046059 10046059 BEARING ,ROLLER, D54
8 21050125 21050125 FINAL, DRIVE, WHEEL 3/4", RUBBER
9 10017387 10017387 PIN, TUBULAR D6X45, DIN 1481
10 10017500 10019189 FINAL, DRIVE, BAR, COMPLETE
11 10026001 GEAR, 2.5M, 19 TEETH, SS, WITH GRUBSCREW
21050172 GEAR, DRIVE, 78 PCD, M3, 26 TEETH
12 10018253 10019286 ROLLER, GUM, W/PIN, UPPER, COMPLETE
13 10018095 21722302 ROLLER, DRIVE, LOWER
14 10019170 10018180 BLOCK, BEARING, QUICK RELEASE, COMPLETE
15 21103503 21103630 ROLLER, SPREADER, GUM
16 10018251 10019284 ROLLER, DRIVE, W/PIN, UPPER, COMPLETE
17 10018089 21250301 ROLLER, DRIVE, LOWER
18 10018252 10019285 ROLLER, BRISTLE, W/PIN, COMPLETE
19 10035958 10035952 ROLLER, SLICK, LOWER
20 21050783 21050783 SPRING, 1/2"X3/4" 0.064
21 10037392 10037392 BEARING, TURCITE "A" D20.35 / D25.33
22 10019179 10019179 BLOCK, BEARING, BRUSH, QUICK, COMPLETE
23 - 54316 SPRING, D12.6/1.2, L=42
24 10037393 10037393 BEARING, TURCITE "A" D20.15 / D25
25 10044377 10018180 BLOCK, BEARING, QUICK RELEASE, COMPLETE
26
27
28
29

Spare parts
5-30
15
3 5
2 15
8
32 36 16
33
35
34
24
9 25
10 26
3
23
11 8 8
12 27
22
6
21 20
7 16
13 28
4 11
15 18
37 17
14 19
25
29
30
31
T8584
GROUP DEV KIT CD TWIN-SCRUB

Spare parts
5-31
Group dev kit cd twin scrub

1 10025705 LID, DEVELOPER
2 21793302 ROLLER, DEVELOPER, ¥40, TWIN SCRUB
3 21050064 GEAR, 23T, 25 MM BORE, DELRIN
4 10044445 BUSH, LONG, GEARBOX TURCITE
5 10025397 BEARING, BLOCK
6 35434 O-RING 13.3x2.4 EPDM
7 21050123 GEAR, 18T, SS, 45, PCD
8 15074 SCREW M5X10
9 10041446 BUSH, SHORT, GEARBOX TURCITE
10 10022037 SHAFT, LONG, GEARBOX
11 10017387 PIN, TUBULAR D6X45, DIN 1481
12 6191 BUSHING D5/13X6
13 21150403 SHAFT, GEARBOX, SHORT
14 21982594 BUSH, RING, TURCITE
15 21982595 BUSH, FLANGE, TURCITE
16 21450218 GEAR BOX, RETAINER (SHORT)
17 10022045 SHAFT, GEAR, DRIVE
18 10022104 CIRCLIP, D12X1.3, A2, DIN6799
19 21050997 GEAR, 26T, ROLLER
20 21050993 GEAR, 41T
21 21050992 BUSH, FLANGE, 52 LONG
22 21073397 GRUB SCREW, M5x16, HE, SO, CP, DIN916
23 21545304 ROLLER, DRIVE, LOWER
24 21545303 ROLLER, DRIVE, UPPER
25 10041447 TURCITE BUSH-SCRUB & RUBBER ROLLERS
26 10026001 GEAR, 2.5M, 19 TEETH, SS, WITH GRUB SCREW
27 10031301 GUIDE, DEV, REAR
28 21112908 GUIDE, FRONT, DEV
29 21050220 RE-ENTRY CAM

Spare parts
5-32
15
3 5
2 15
8
32 36 16
33
35
34
24
9 25
10 26
3
23
11 8 8
12 27
22
6
21 20
7 16
13 28
4 11
15 18
37 17
14 19
25
29
30
31
T8584
GROUP DEV KIT CD TWIN-SCRUB

Spare parts
5-33

31 21072912 NO 8 X 1 1/2, S/TAP, PAN, HD, SCREW S/S
32 21585301 ROLLER, DEV EXIT, LAY ON, COMPLETE NOT ALL MODELS
33 21982567 BLOCK, WEDGE, ROLLER NOT ALL MODELS
34 21793301 ROLLER, DEVELOPER, D60
35 21112957 SCRUB, COVER
36 10023254 SCRUB, COVER, D60
37 21793220 BLOCK, ARM, ROLLER, SCRUB
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

Spare parts
5-34
22
12
11
3
13 14
2
14
8 15
3 10
6
5
12
7
16 16 4
4
19
9
20 4 10
14 10
21 16
17
18
T8588
GROUP DEV KIT DOUBLE SCRUB

Spare parts
5-35
Group dev kit double scrub
Group dev kit double scrub

1 10025720 LID, DEVELOPER
2 10025998 ROLLER, DEV EXIT, LAY ON
3 21792220 BLOCK, BEARING, ROLLER
4 21113447 GEAR, 15T, 30 PCD, STAINLESS STEEL
5 5124 SCREW M5X6 HE SO CP
6 21792263 SUPPORT, STRIP, DEVELOPER, MESH
7 21153115 PRESSURE, PLATE, SUPPORT (NP)
8 21005120 DEV, ROLLER, ASSY
9 10030126 MESH, DEVELOPER, LONG
11 15038 NUT M5 KN BK PL
12 6191 BUSHING D5/13X6
13 10030974 SLAVE, BEARING, BLOCK, DRILLED
14 10041444 GEARBOX BUSH, LONG 85 TURCITE
15 21109996 BLOCK, SLAVE, SINGLE, ADJUST
16 10041443 GEARBOX BUSH, SHORT 85 TURCITE
17 21850403 SHAFT SHORT, GEARBOX
18 10022104 CIRCLIP, D12X1.3, A2, DIN6799
19 21109258 BLOCK, GEARBOX, ADJUSTMENT
20 10017387 PIN, TUBULAR D6X45, DIN 1481
21 10023915 SHAFT, GEARBOX, (LONG)
22 10024519 SCRUB, COVER, D35
23
24
25
26
27
28
29
30

Spare parts
5-36
1
3
11
12
2
3
2
3
9
7
10
8 5
6 6
7
8
4
7
8
T8583
GROUP TUBE SPRAY WATER GUM

Spare parts
5-37
Group tube spray water gum
Group tube spray water gum

1 10035138 10035280 TUBE, GUM
2 21107930 21107930 VALVE, BALL, 1/2 BSP MALE PLUS ONE NUT
3 21107931 21107931 O-RING 13 I/D X 3 WALL EPDM
4 10024865 TUBE, WATER, SINGLE
5 21050028 FINAL, DRIVE COLLAR 1/2
6 10020204 21107870 TUBE, SPRAY, WATER, DOUBLE, COMPLETE
7 5127 5127 SCREW, GRUB 5 X 16 MM
8 21801115 21801115 BLOCK, SPRAY BAR, END
9 - 21107871 TUBE, SPRAY, WATER, COMPLETE
10 - 5124 SCREW M5X6 HE SO CP
11 10036016 10036016 FLOWREGULATOR,GUM
12 21059084 21059084 O-RING, D12.29X3.53
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

12
7 6 1
2
3
10
4 11
13
5
9
7
10
6
11
T8585
GROUP DRYER

Spare parts
5-39
Dryer
Dryer
1 10025859 10025858 COVER, GUARD, AIRTUBE, COMPLETE
2 21839009 10024952 DRYER, TUBE, TOP, COMPLETE
3 10040234 10025864 DRYER, TUBE, BOTTOM, COMPLETE
4 6295 6295 GROMMET D6/9X1.5
5 26385 26385 SENSOR, TEMP THERMISTOR, PLASTIC
6 21835086 21835086 DUCT, DRYER
7 10017818 10017818 HEATER, ELEMENT, COMPLETTE
8 - 10017894 FAN, RIGHT, DRYER
9 10017895 10017895 FAN, LEFT, DRYER
10 35396 35396 GUARDS, FINGER
11 10023607 10024370 COVER, DUCT, DRYER
12 6293 6293 HANDLE, BLACK
13 10040356 10040357 BLACK, TAPE, 30MM, VELCRO, LOOP
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Spare parts
5-40
11 1
12
30
10 14 11
13
9
32 31
28 10
29 3
16 8
17 4 5
2 6
7
18 33 26
24
27 25
19 22 15
20 21
23
ENCLOSURE ELECTRICS T8586

Spare parts
5-41
Electrical
Electrical
1 16414 16414 SWITCH, 194L-16, 66.5X66.5
2 54563 54563 CAPACITOR, 2MF,CA-250, COMPLETE
3 36501 36501 GLAND,CABLE,ST-M 32x1.5
4 36500 36500 LOCKNUT FOR CABLE GLAND M32x1,5
5 10019245 10019245 GUARD, METAL, FAN, (FG-12), 120X120
6 10015202 10015202 BLOWER, COMPLETE
7 10017988 10017988 SHIELD
8 10030625 10030625 GFCI, RELAY, COMPLETE
9 45926 45926 HINGE, SOUTHCO, 96-50-510-50
10 45865 45865 BUSHING, 258-68, D45/50X1.6
11 10007152 10007152 TERMINAL, LOCK, WAGO249-116
12 10007158 10007158 TERMINAL, BLIND, FUSEHOLDER, WAGO, 281-311
13 70158 70158 FUSE, 4A, 5x20
14 10007154 10007154 TERMINAL, FUSEHOLDER, WAGO, 281-611
15 10033257 10033257 TRANSFORMER, 9.5V/4A+24V/3.5A, 36X108MM
16 10015147 10015147 TRANSFORMER
17 10035096 10035096 PCB, HPU-V, SPAREPART
18 10039871 10039871 PCB, SYSTEM-ON-MODULE, SOM
19 6716 6716 FUSE 2A, 6.3X32 MM S/B
20 6896 6896 FUSE 4A, 6.3X32 MM
21 26508 26508 FUSE 15A SC15
22 53794 53794 COVER, PANEL, FUSE
23 36563 36563 PCB, FUSE, F. SINGLE HPU, W. VARISTOR
24 10019350 10019350 PCB, GNUC-II, MIO
25 10030889 10030889 PCB, FILTER, 2xTRANSFORMER, 4A-PTC-RESISTOR
26 10011111 10011111 FUSE, 5X20MM, 3.15AT
27 10040265 10040265 FUSE, 5X20MM, 0.63AT
28 10040488 10040488 RELAY, MOTOR, OVERLOAD, 0.63-1A
29 10017780 10017780 CAPACITOR, 5uF440V AC
30 10021365 10021365 LOCKING, PIN

Spare parts
5-42
11 1
12
30
10 14 11
13
9
32 31
28 10
29 3
16 8
17 4 5
2 6
7
18 33 26
24
27 25
19 22 15
20 21
23
ENCLOSURE ELECTRICS T8586

Spare parts
5-43
Electrical
Electrical
31 26364 26364 PLUG, FEMALE, 4-POL.
32 74048 74048 GROMMET, 5/4"
33 10011284 10011284 FUSE, 1AT, 5.08 MM, VDE
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

Spare parts
5-44

Spare parts
5-45
Cables (not illustrated)
Cables (not illustrated)

10025190 10025085 WIRING HARNESS, Q-SUPREME, GNUC II
10025281 10023964 CABLE, EMERGENCY STOP/COVER SW
10025721 10025721 CABLE, MOTOR
10021834 10016678 WIRING HARNESS, HIGH VOLTAGE
10014821 10014821 CABLE, SHORT. CUT, EMERGENCY STOP
10014793 10014793 CABLE, MAIN SWITCH->FUSE PANEL, HFI
88377 88377 CABLE, HPU-TRAFO
10017196 10017196 CABLE, FUSE PANEL TO HPU
10009030 10009030 CABLE, FUSEPANEL, FILTER, PCB
10015166 10015166 CABLE, BLOWER
10015205 10015205 CABLE, GROUND
10011057 10011057 CABLE, MAINS, IEC 60320, RECEPTACLE
98515 10012827 CABLE, GNUIB, MMU-HCU

Spare parts
5-46

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 5/3 (Panels):
5 10033731 10033744 COVER, SIDE, RIGHT, UPPER, W. LOGO
13 10033730 10033745 COVER, SIDE, LEFT, UPPER, W. LOGO

Appendix A:
A-2
Additional spareparts

Appendix B:
B-1
Electrical diagrams
Appendix B: Electrical diagrams
This chapter includes all electrical diagrams for the processor.
The diagrams cover:
• Main Power Distribution, Fuse panel and Interlocks
• High Voltage Wiring , 230V AC Control Devices, HPU
• Low Voltage Wiring, Sensors and Control Devices
• Motors and Internal Bus Wiring, 8, 24 and 35 VAC Distribution

Appendix B:
B-2
Electrical diagrams
Main Power Distribution
Fuse panel and Interlocks

1 2 3 4 5 6 7 8 9 10
Three Phases Without Neutral, 230V, 3 W + PE C1 C8 C9 X4 X5 X6

4n7 Y2 4n7 Y2 4n7 Y2 X 11
F1 15 AT Phase 3
PE X3 1
S21
12 11 6 F3 15 AT
Ground Fault Interruptor Black Black Return 1
1
Return 3 1
F10
4 Blue N Orange 10 9 Orange 5 Return 2 2
F5 15 AT
I
3 Brown 6 5 Blue 8 7 Blue 4 Return3 Phase 2
L3 . . R5 R6 R7
470K
470K
470K
3
2 Yellow 4 3 Brown 6 5 Brown 3 Phase1 C5 C6 C7
L2 . .
100n X1
1 2 1 4 3 2 Return 2
L1 Red . .
Yellow Yellow Phase2 Match Line To J2 on
4
100n X1
100n X1
F2 High Voltage Wiring
X7 Red 2 1 Red 1 Phase3 15 AT Diagram, page 2
Phase 1
5
Field Wiring Box Main switch F4 15 AT
RV1 Return 1
6
F6 15 AT
Single Phase, 230V, 2 W + PE or 1 W + N + PE
2 2
S21 F7 2AT
Black 12 11 Black
C2 C3 C4 F8
PE 4AT
9 Organge 4n7 Y2 4n7 Y2 4n7 Y2
Orange
Ground Fault Interruptor Fuse Panel X1 X2
X1 short circuit X10
F10 Blue 8 7 Blue
on PCB 1 2 1 2 3 4
4 Blue N Appliance coupler
Yellow/green
For Stacker
I Brown 6 5 Brown
3 Brown 6 5
Blue
L2 (N) . . Blue
Brown
L IN
RTN IN
Yellow 4 3 Yellow
2 Yellow 4 3 Yellow/green
L1 . .
Red 2 1 Red Brown

1 Red 2 1 X57 X1
. . PCB Transformer Filter X41
240 OR1 Orange: 240V T1
Green 1
X7 Field Wiring Box Main switch 230 RD1 Red: 230V To HPU, J1,1
9.5V Green 2
200 BN1 Brown: 200V To HPU, J1,5
Blue 3
240 BK1 110 °C To HPU, J1,2
3 24V Blue 4 3
230 OR2 Black: 0V To HPU, J1,6

200 RD2 Built-In thermoswith with
Three Phases With Neutral, 400V, 3 W + N + PE RTN OUT BN2 Transformer secondary
automatic reset
X2, 2 connections
S21 RTN IN BK2
C1 are shown on page 4
L OUT 100nF L1
Black 12 11 Black X40
PE X2, 1 L IN Orange: 240V T2
R2 Grey 1
Red: 230V To HPU, J1,3
Orange 10 9 Organge 35V Grey 2
Ground Fault Interruptor R1 Brown: 200V To HPU, J1,7
White 3
F10 110 °C To HPU, J1,4
4 Blue N N Blue 8 7 Blue F17 F18 35V White 4
N Black: 0V To HPU, J1,8
1 0.63AT 3.15AT
I
3 Brown 6 5 Brown 6 5 Brown S12,2 2 Built-In thermoswith with
L3 . .
S7,3 3 automatic reset
2 Yellow 4 3 Yellow 4 3 Yellow S12,5 4
L2 . .
S7,6
X52 X51 X50 X43 X42
1 Red 2 1 Red 2 1 Red
L1 . .
1 2 1 2 1 2 1 2
4
Option 4
X7
Field Wiring Box Main switch
X42,1
X42,2
IMPORTANT
S7,2
S7,5
S8,3
S8,6
S8,2
S8,5
X52,2
X52,4
X52,1
X52,3
S12,3
S12,6
Check wiring at Main Terminal X7, Ground Fault Interruptor F10 and Main
Switch S21 before the power supply is switched on. Rewire if necessary
accordingly to attached column on schematics. Also set jumpers as 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4
shown in table below.
Jumper Settings : S8 S7 S12 S9

Line Voltage: Terminal Strip, X7 Fuse PCB Emergency Stop Emergency Stop Emergency Stop
5 Cover Switch Lid 5
Switch Switch Switch (ONLY ON 165)
Three Phases Without Neutral, No jumpers ! X4, X5 and X6 open
230V, L1, L2, L3 + PE Title: Number: Rev.:
Date: Thursday, July 05, 2007
Single Phase, Jumpers between 1 and 2 X4, X5 and X6 open Main Power Distribution
230V, L1, L2 + PE or L1, N + PE Jumpers between 3 and 4 Constructor: KEL 10025469 D
Function: ELECTRONIC AND MECHANICAL ENGINEERING
Doc. No.:
Three Phases With Neutral, No jumpers ! X4, X5 and X6 closed Approval: This drawing belongs to Glunz & Jens en A/S
Fuse Panel And Interlocks and m us t not be us ed or handed over to any
400V, L1, L2, L3, N + PE
unauthorized pers on without our s pecific perm is s ion.
Page: 1 Of: 5 OrCAD
1 2 3 4 5 6 7 8 9 10
Appendix B:
B-4
Electrical diagrams
High Voltage Wiring
230V AC, Control Devices, HPU

High Power Unit, HPU
J2
1
hot, X11,1
2
return, X11,2
3
hot, X11,3
4
return, X11,4
5
hot, X11,5
6
return, X11,6
RV408 RV406 RV407 RV409 RV412 RV410 RV411 RV413 RV416 RV415 RV414 RV405
From X11,
BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16
Fusepanel
Q415 Q413 Q414 Q416 Q419 Q417 Q418 Q420 Q423 Q422 Q421 Q412
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
F10 F11 F13 F12 F14
1AT 1AT 1AT 1AT 1AT
K2 K1 K4 K3 K5 K6
6 5 4 3 2 1 4 3 2 1 6 5 4 3 2 1 4 3 2 1 6 5 4 3 2 1 4 3 2 1
Ground bar
X25
E6,1
E6,2
M6,3
M6,1
M8,3
M8,2
M4,2
M4,1
Chiller,2
Chiller,3
E2,2
E1,2
E1,1
E2,1
E5,1
E5,2
C3,1
C2,1
M2,2
Q2,1
M13,3
M13,2
M19,3
M19,2
M53,3
M51,3
M53,2
M51,2
M18,2
M12,2
M12,1
M18,1
Chiller,1
K5,5
M51,1
Q2,2
K1,4
K1,3
K1,4
K1,3
K4,4
K3,2
K3,1
K5,3
K5,2
K5,3
K5,1
K5,5
X25
K2,5
K2,2
K1,2
K4,2
K6,2
K6,1
M2,3
K2,6
K2,3
K1,1
K4,6
K4,3
C1,2
Q2,2
C1,1 - M2,1
K5,6
K5,5
K5,6
K5,5
C3,2
C2,2
M53,1
K3,3
K3,4
K6,3
K6,4
Chiller
M13 M19 E1 E2 M6 M8 E6 M53 C3 M4 M12 M18 E5 M51 C2 M2 C1
4 3 2 1 4 3 2 1 3 2 1 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 3 2 1 4 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 3 2 1 4 3 2 1 3 2 1 4 3 2 1 3 2 1
M M M M M M M M
Blue
Black
Brown
Blue
Black
Brown
M13 M19 M6 M8 C3 M4 M12 M18 C2 M2 C1
84°C
84°C
3 2 1
Yellow/green
Yellow/green
63 °C 63 °C
Water Repl. Dev. Autofill Plug For Gum. Circ. Dev. Repl. 65 °C Capacitor Dev. Circ. Wash Circ. Electronic 65 °C Capacitor Scrub Motor Capacitor
Pump Pump Chiller Pump Pump M Dryer Blower Pump Pump Fan M Dryer Blower Scrub Motor
E3 E4 1500W Right 1500W Left
E6 M53 E5 M51
Dev. Heater
1000W Dev. Heater Dryer Heater Dryer Blower Dryer Heater Dryer Blower 1 3 5
1000W Right Right Left Left
Q2
Only on 125,
Only on 125, Only on 125, 2 4 6
150 & 165
150 & 165 150 & 165
Variants
Variants Variants
Motor Overload
Relay
Title: Number: Rev.:

High Voltage Wiring
Constructor: KEL 10025469 D
Function: ELECTRONIC AND M ECHANICAL ENGINEERING
Doc. No.:
Approval: This drawing belongs to Glunz & Jensen A/S
230 VAC Control Devices, HPU and must not be used or handed over to any
unauthorized person without our specific permission.
Page: 2 Of: 5 OrCAD
Appendix B:
B-6
Electrical diagrams
Low Voltage Wiring
Sensors and Control Devices

Main Processor Unit, MIO
J10 J11 J17 J12 P3 P2

8 20 2 3 4 5
1 2 5 6 13 14 3 4 14 1 2 3 4 11 12
S2,2 S2,3
1
2
S3,2 S3,3
Red
S2,4
S2,1
S4,4
S4,1
S3,1
S5,4
S5,1
S6,4
S6,1
S4,2 S4,3
R1,1
R1,2
R2,1
R2,2
Blue
Green
(Shield)
Yellow
S5,2 S5,3
S6,2 S6,3
S5 S6 S2 S4
Optional
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
J10,1
J10,2
J10,5
J10,6
J11,4
J11,3
J12,4
J12,3
J12,2
J12,1
J12,11
J12,12
J12,11
J12,12
J10,14
J12,11
J12,12
J10,13
J12,11
J12,12
J11,14
J12,11
J12,12
2
R1 R2 S4 S6 S2 S5 S3 1
1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Conductivity Sensor
Optional
5
3
1 1 1 1 1 1
Plate Setter
S5 S6 S2 S4
Q
Q
Q
Q
L/D
L/D
L/D
L/D
R1 R2 S4 S6 S2 S5
Vcc
Vcc
Vcc
Vcc
See Setter manual for actual
Rntc Rntc S3 GND GND GND GND pin connections, or contact
10K 10K
your Service Suplier.
NC NC NC NC
Q
Output sensor Output sensor Input sensor Input sensor
L/D
Vcc
(Where optical sensors are fitted) (Where optical sensors are fitted)
GND
2 2 4 3 4 3
DEV. temp. Dryer. temp. Input Output Input Output Rewash

sensor sensor Sensor Sensor Sensor Sensor Sensor
High Power Unit, HPU

+24VDC +12VDC
+24VDC +12VDC +15VDC +12VDC 0VDC
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
+
-
J9 J10 J11
1 2 7 8 5 6 3 4 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
Y1,2
Y1,1
Y2,2
Y2,1
Y3,2
Y3,1
B3,2
B3,3
S1,1
S1,2
B2,1
B2,3
B5,1
B5,2
B9,2
B9,3
B4,1
B4,2
B7,2
B7,3
B1,2
B1,3
X21,2
X21,1
J11,15
J11,16
J10,9
J10,5
J10,6
J10,1
J10,2
J10,3
J10,4
J10,7
J10,8
J10,10
J10,13
J10,14
J10,11
J10,12
B9 B2 B3 B7 S1 B4 B5 B1
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 1 2 3 4
J11,4
J11,3
J11,6
J11,5
J11,8
J11,7
J11,9
J11,10
X21
1 1 1
1 2
2 1 2 2 1 1 1 2
24V 24V 24V
15k
15k
15k
15k
15k
15k
15k
15k
Y1 Y2 Y3 1
2 2 2
H1
3 3 3 3 2 2 2 3
2
WASH water GUM drain GUM water Alarm Indicator
DEV. Water DEV. Waste GUM DEV. FILL DEV. Sect. DEV. Sect. Wash sect. Valve Valve Valve DEV. Repl.
Cont. Min. Cont. Max. Cont. Min. Cont. Min. Safety Level Level Level (Optional)
Cont. Min.
Low Voltage Wiring
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
Page: 3 Of: 5 OrCAD
Appendix B:
B-8
Electrical diagrams
Motors and Internal Bus Wiring
8, 24 and 35 VAC Distribution

1 2 3 4 5 6 7 8 9 10
J1 at HPU :
Part of High Power Unit, HPU P1
pin 1 & 5 : 8,5 VAC
pin 2 & 6 : 24 VAC 4 #4
pin 3 & 7 : 35 VAC TX
1 8 #8 1
pin 4 & 8 : 35 VAC TX
J1
2 #2
F2 D45 RX
5
X41,2 - + 7 #7
RX
DC supply to
1 1 AT + C113 3 #3
X41,1 4700uF/25V mikroprocessor GND
1 #1
6
X41,4 6 #6
#1
#2
#3
#4
#5
#6
#7
#8
#9
2 5 #5
X41,3
From X40 & X41
9 #9
on page 1 7
X40,2 P3
1
2
3
4
5
6
7
8
9
F405
3 4AT
X40,1 P1 Parts of MIO
8 F403 F401 1
X40,4 D420 D421 D416 D417 See page 3 for connection to input
TX
4
3
1
2 2
10AF 10AF D425 D426 2 and temperature sensors.
C456 C454 . . TX
50 P CKT
+
+
3
1
3
4
3
Q4112 RX
3
1
4
.
4
+
+
RX
. .
5
4 C457 C455 D427 D428 GND
4
1
3
X40,3 6
D422 D423 D418 D419
2 X 10uF/100V
2 X 10uF/100V
7
DC supply to valves
and solenoids 8
Dual Motor Controller 0V See page 5 of 5 +24V
9
J5 J4
1 4 2 6 3 5 1 4 2 6 3 5
3 3
2 x 25 pair, 1:1
M1,1
F19,1
X11,4
X11,3
X11,2
X11,1
J4,1
J4,5
J4,3
J4,6
J4,2
1
X11
50 P
F19, 4AT 1 2 3 4
2
Man Machine Interface, MMI
4
S11 4
M1,4
1 2 3 4
J4,4
F19,2
M1
1 2 3 4 5 6 Encoder
S11
+5V
GND
Signal
M1
M
Transport Motor
2 X T filter1
5 5

Motors And Internal Bus Wiring
Doc. No.:
Approval: This drawing belongs to Glunz & Jens en A/S
8, 24 and 35 VAC Distribution and m us t not be us ed or handed over to any
Page: 4 Of: 5 OrCAD
1 2 3 4 5 6 7 8 9 10
Appendix B:
B-10
Electrical diagrams

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Service Manual

Edition CA, February 2009

Part 0: General information

The directions given must not be followed by unauthorized personnel.

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

Copyright © 2009 by GLUNZ & JENSEN A/S.

Service Manual - Plate Processors 85-125 0906

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 personnel injury.

Intended use of the equipment

0906 Service Manual, Plate Processors 85-125

"End of lifetime" disposal

Service Manual - Plate Processors 85-125 0906

Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2

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

0748 Service Manual, Plate Processors 85-125

Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Part 2: Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Part 3: Cleaning and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Service Manual - Plate Processors 85-125 0748

Changing developer filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Part 4: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Part 5: Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

0748 Service Manual, Plate Processors 85-125

Drive plate (double scrub 85). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Appendix A: Additional spareparts . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Service Manual - Plate Processors 85-125 0906

0906 Service Manual, Plate Processors 85-125

Processor Installation Manual (1)

Processor Service Manual (2)

Software Service Information (3)

Service Manual - Plate Processors 85-125 0906

CE Declaration Of Conformity (4)

Safety Instruction Manual (5)

User's Manual, Processor (6)

User's Guide, Control Panel (7)

Quick Intro (8)

0906 Service Manual, Plate Processors 85-125

Service Manual - Plate Processors 85-125 0906

Part 1: Technical specifications

The processor does not contain

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

Sound pressure level

0906 Service Manual, Plate Processors 85-125

Plate types Single sided

Plate width 200-850 mm 200-1250 mm

Plate length 285-1100 mm 350-1500 mm

Plate thickness 0.15-0.50 mm

Plate speed 40-150 cm/min 70-230 cm/min

Gum 3.5 l 6.0 l

Service Manual - Plate Processors 85-125 0906

Dryer, process Fixed

Operation 8 l/min 12 l/min

Stand-by 0.0 l/min

0906 Service Manual, Plate Processors 85-125

Processor type 85 125

Processor type 85 125

Service Manual - Plate Processors 85-125 0906