PLATE PROCESSOR

LASER CTP

VERSION _________________ MODEL _____________

SERIAL NO. _______________ YEAR _______________ SOFTWARE VERSION _____________________________

NW.3

V2. 091106

INSTRUCTION, USE AND

MAINTENANCE MANUAL Revision 0 dated 22/01/2007

EGRAF LineaDue - Ph.+39-055.870.83.66- Fax +39-055.870.83.76 Via Torricelli 48/50 Seano (Prato) – ITALY

Homepage: www.egraf.net

The Company reserves the right to make changes and improvements on the machine at any time and without advance notice.

ATTENTION ! This manual is subject to international copyright laws.

Unauthorized publication of the same, whether partial or complete, will be persecuted according to the law !

INDEX

Pagina 2

INDEX

Page

0. PREMISES.............................................................................................................................4 0.1. HOW TO READ AND USE THIS MANUAL ...............................................................4

0.1.1. IMPORTANCE OF THE MANUAL ..................................................................4 0.1.2. SAVING THE MANUAL.....................................................................................4 0.1.3. CONSULTING THE MANUAL .........................................................................5

1. GENERAL INFORMATION ...............................................................................................7 1.1. MACHINE IDENTIFICATION DATA.........................................................................7 1.2. TECHNICAL ASSISTANCE ........................................................................................9 1.3. GENERAL SAFETY WARNINGS ...............................................................................9 1.4. GLOSSARY.................................................................................................................11

2. MACHINE FEATURES .....................................................................................................12 2.1. PRESENTATION ........................................................................................................12 2.2. MACHINE SPECIFICATIONS...................................................................................12 2.3. OPTIONS.....................................................................................................................13 2.4. TECHNICAL SPECIFICATIONS...............................................................................14 2.5. DIMENSIONS .............................................................................................................14 2.6. NOISE LEVEL.............................................................................................................15

3. INSTALLATION.................................................................................................................16 3.1. PRELIMINARY PROCEDURES................................................................................16 3.2. LIFTING, UNLOADING AND TRANSPORT ...........................................................18 3.3. CHECKING OF PARTS SHIPPED .............................................................................21 3.4. INCLUDED ACCESSORIES ......................................................................................22 3.5. MACHINE ASSEMBLY .............................................................................................22 3.6. ELECTRIC POWER CONNECTIONS .......................................................................24 3.7. WATER CONNECTION (DIRECT DRAINAGE SYSTEM)...............................................24 3.8. WATER CONNECTION (WITH WATER RECIRCULATING UNIT) ..................................24

4. PROCESSOR WORK FLOW............................................................................................25

5. CONTROL PANEL.............................................................................................................26 5.1. INTRODUCTION........................................................................................................26 5.2. SAVE THE NEW VALUES.........................................................................................27 5.3. RESUME PAGE ..........................................................................................................28 5.4. HOME PAGE...............................................................................................................29 5.5. DEVELOPER TEMPERATURE.................................................................................30 5.6. DEVELOPING TIME & DEVELOPER BRUSHES SPEED.......................................31 5.7. DRYER POWER..........................................................................................................32 5.8. DEVELOPER REPLENISHMENT (OPERATE CONDITIONS)...............................33 5.9. DEVELOPER REPLENISHMENT (ANTIOXID) ......................................................34 5.10. DEVELOPER REPLENISHMENT (WEEK-END).....................................................35 5.11. SETTING OF THE PLATE SIZES (REPLENISHMENT OPERATE CONDITION) ...............36 5.12. CONDUCTIVITY METER (OPTION) ..........................................................................37 5.13. GUMMING..................................................................................................................38 5.14. COUNTERS.................................................................................................................39 5.15. ALARMS PAGE..........................................................................................................40 5.16. ALARM SIZE (WRONG SETTING IN THE PLATE SIZES FOR OPERATE REPLENISHMENT) 41 5.17. ALARM LID................................................................................................................42 5.18. ALARM TNK 1 (EMPTY DEVELOPER REPLENISHER CAN - OPTION)..............................43

INDEX

Pagina 3

5.19. ALARM TNK 2 (EMPTY GUM CAN - OPTION)...............................................................44 5.20. ALARM LEV (LOW LEVEL IN THE DEVELOPER TANK).................................................45 5.21. ALARM OVER (MOTOR BLOCK/OVERLOAD) ..............................................................46 5.22. ALARM JAM...............................................................................................................47 5.23. ALARM COND (LOW DEVELOPER CONDUCTIVITY - OPTION)......................................48 5.24. ALARM +T°C (DEVELOPER TEMPERATURE OUT OF RANGE) .......................................49 5.25. ALARM TEMP (DEVELOPER TEMPERATURE OVER 40°C) ...........................................50 5.26. ALARM PROB (DEVELOPER TEMPERATURE PROBE MALFUNCTIONING) .....................51

6. SAFETY................................................................................................................................52 6.1. PRECAUTIONS ..........................................................................................................52 6.2. OPERATOR’S SAFETY .............................................................................................53

7. PROCESSOR START-UP ..................................................................................................54

8. MAINTENANCE.................................................................................................................61 8.1. PRIMARY RULE ........................................................................................................61 8.2. CLEANING METHOD................................................................................................62 8.3. CLEANING AND OVERHAULING ..........................................................................63

8.3.1. DEVELOPING SECTION................................................................................63 8.3.2. ROLLERS..........................................................................................................63 8.3.3. SPRAY BARS ......................................................................................................64

8.4. PROGRAMMED PERIODIC OPERATIONS.............................................................64 9. EXPLODED PICTURES ....................................................................................................65

9.1. RIGHT SIDE COMPONENTS ....................................................................................66 9.2. LEFT SIDE COMPONENTS.......................................................................................67 9.3. COMPONENTS UNDER THE TANK ........................................................................68 9.4. COMPONENTS INSIDE THE TANK (LEFT SIDE) ..................................................69 9.5. COMPONENTS INSIDE THE TANK (RIGHT SIDE)................................................71 9.6. OUTSIDE.....................................................................................................................72 9.7. OUTSIDE (REAR SIDE) .............................................................................................73 9.8. ELECTRIC PANEL COMPONENTS .........................................................................74

10. HYDRAULIC AND ELECTRIC DIAGRAMS............................................................75

11. SPARE PARTS TABLES...............................................................................................80

PREMISES

Pagina 4

0. PREMISES

0.1. HOW TO READ AND USE THIS MANUAL

0.1.1. IMPORTANCE OF THE MANUAL

This manual must be considered as an integral part of the machine.

This manual must be saved for the entire life span of the machine.

This manual must accompany the machine whenever the same is assigned to

others.

This manual also includes the electrical and hydraulic schematics, to be used as a reference during all the maintenance and reparing interventions made by qualified personnel only.

0.1.2. SAVING THE MANUAL

Save the manual in a place free of humidity and excessive heat.

Consult the manual without damaging its contents either in part or totally.

Do not remove pages from the manual.

Do not write on the manual's pages. Special forms have been provided for

comments and/or notes.

PREMISES

Pagina 5

0.1.3. CONSULTING THE MANUAL

The manual has been written according to the Machinery Regulations issued by the E.E.C with Law 89/392 and subsequent modifications. The manual is essentially made up of: A. Identification Cover B. Index of Chapters C. Machine Instructions D. Schematics E. Machine's drawing F. Spare parts tables

A - Identification Cover The cover identifies the machine described within the manual. The cover indicates: • Manufacturer's Logo • Type of Machine • Serial number • Date of Compilation • Version

B - Index of Chapters The Index of Chapters lists the subjects covered by the manual.

PREMISES

Pagina 6

C - Machine Instructions This part of the manual provides a detailed description of how the machine operates, the steps required for correct machine operation, instructions for its installation, a description of the safety features, of the machine cycle and of the operator's operating procedures. D - Schematics This part of the manual provides all the electrical and hydraulic schematics required for all the interventions made by qualified personnel. E - Machine's drawings This part of the manual provides the drawings showing different details of the machine. F - Spare parts tables These tables, which make reference to the previous drawings, allow to identify the different details of the machine and supply the related code number.

GENERAL INFORMATION

Pagina 7

1. GENERAL INFORMATION

1.1. MACHINE IDENTIFICATION DATA

The machine's identification data are indicated on one aluminum plate fixed to the body of the machine. The following figure shows how the plate is composed.

GENERAL INFORMATION

Pagina 8

The figure below indicates the location of the plates on the rear part of the machine.

GENERAL INFORMATION

Pagina 9

1.2. TECHNICAL ASSISTANCE

The machine to which this manual refers to is guaranteed by the manufacturer for a period of 12 MONTHS from the date of the invoice (spare parts only). The guarantee will cease if the preventive maintenance terms indicated in the manual are not observed and/or in case of breakdowns due to improper use of the machine. All routine maintenance operations can be carried out by the user's service personnel, while if there are changes in the machine's operating mechanisms, or for extremely difficult operations, or for whatever else is not specifically provided for in the manual, the client must ask the manufacturer's assistance. The manufacturer must receive the request for assistance in writing and the request must contain the machine's identification data, the nature of the defect or of the change to be made.

1.3. GENERAL SAFETY WARNINGS

In accordance with general safety regulations, machine operations must be entrusted to personnel who are qualified to handle the job in accordance with the particular machine and the operations to be carried out. The manufacturer is not responsible for damages to things or persons caused by the negligence of personnel who does not follow the indications contained in this manual. In this regard, the manufacturer has prepared a table which outlines a number of technical qualification levels that are required to the people operating the machine. This table is illustrated below and the machine user's compliance with the technical qualifications outlined must be considered fundamental for the safety of the machine and of the people who operate it.

GENERAL INFORMATION

Pagina 10

Operator

level NOTES QUALIFICATION

01 Non-qualified personnel Running of the machine through control panel controls, material loading and unloading operations

02 Qualified personnel Performs the tasks of level 01 operators, and in addition is able to open the unit's cover to remove the rollers and replace the liquid.

03 Mechanical Service Man Qualified Technician

Performs the tasks of level 1and 2 operators and is able to work on the electrical parts for maintenance, adjustments and repair purposes.

04 Machine Operator Qualified Technician

Performs the tasks of level 1 and 2 operators and, in addition, is able to make changes and set the machine's working functions and processing parameters through the keyboard. Can operate in the presence of live electric voltage in the main control box.

05 Electrical Service Man Qualified Technician

This is highly specialized personnel who is able to perform all the previously listed functions and who, in addition, is able to work on highly complex problems.

In addition, safety regulations call for the following fundamental points: • It is absolutely forbidden to run the machine in an automatic cycle with the

protection panels open. • It is absolutely forbidden to disable the safety mechanisms installed by the

manufacturer in the machine. • The adjustments made while the safety mechanisms are reduced must be

carried out by one single person, and access to the machine area by unauthorized people during these operations must be prohibited.

• The safety mechanisms must be restored immediately upon completion of

the above operations. • All the machine's electric power lines must be turned off while the machine

is cleaned.

GENERAL INFORMATION

Pagina 11

1.4. GLOSSARY

This paragraph covers a list of commonly used terms, abbreviations and acronyms contained in the manual. EEC European Economic Community Kw Electric power measurement unit ON Machine on OFF Machine off dB Sound level measuring unit CYCLE Entire processing phase

MACHINE FEATURES

Pagina 12

2. MACHINE FEATURES

2.1. PRESENTATION The LASER CTP Plate Processor has been manufactured in compliance with the following directives: • Regulation CEI EN 60204-1 “Security of machinery”. Machines’ electric

equipment – part 1: “General rules” (CEI 44-5 classification), III edition file 4455 (April 1998).

• Regulation CEI EN 60950 “Machineries for information’s technology – Safety“ (CEI 74-2 classification ), IV edition file 5927 (February 2001).

The use is mainly addressed to graphic arts industries.

2.2. MACHINE SPECIFICATIONS

• 4 sections: developing, washing, gumming and drying

• Microprocessor PLC (Programmable Logical Controller)

• Touch-screen display, showing processor’s functions and status

• Processing by immersion

• Automatic and adjustable dev. replenishment (in cc/m²) according to the actual

plate size

• Anti-ox replenishment in stand-by conditions (in cc/m²) to maintain consistent

developer activity

• “WEEK-END” replenishment

• Adjustable developing time displaying seconds in the developer

• 1 molleton brush in the developing section (with adjustable independent speed

and pressure calibration)

• 1 molleton brush in the washing section

• Developer tank low level control

• Adjustable gumming time

• Developer filter

MACHINE FEATURES

Pagina 13

• 2nd entry slot for re-washing and re-gumming, with automatic start

• Plate counter (partial and total)

• Two settings for the dryer temperature

2.3. OPTIONS

On customer's request, the machine can be equipped with the following options: • 2nd brush in the developing section

• Chiller unit

• High speed developer tank auto-fill

• Empty replenisher cans alarm (developer and gum)

• Conductivity meter with inductive probe, with values (in mS) displayed on the

main screen

• Bristle brush D50 in alternative to the moleton in the washing section

• Input table

• Output table

• Interface board with the CtP

• Jam detect device (output sensor)

• Automatic gum section cleaning device

• Dev. replenisher bellows pump (single bellow)

• Connection via MODEM for remote diagnostic

• Water recirculating unit

• Drip tray

MACHINE FEATURES

Pagina 14

2.4. TECHNICAL SPECIFICATIONS

Mod. 700 Mod. 900 Max. plate width (mm.) 660 mm 860

Min. plate length (mm.) 370 mm 370

Plate thickness (mm.) 0,12/ 0,30 mm. 0.12/ 0.30

Developing time (seconds) 15 / 90 Sec. 15 / 90

Dev. tank capacity (lt.) 26 LT 33

Water connection 3/4” 3/4”

Drain tube 1” 1/4 1” 1/4

Approx. net weight (Kg.) 270 * Kg.310 *

Electrical supply 208--240 V + T

absorp.: 15 Amp

208--240 V + T

absorp.: 15 Amp.

Cycle 50/60 Hz. 50/60 Hz.

Input line fuses 20 Amp. type 10.3x38 20 Amp. type 10.3x38

Required ambient temperature 15 / 30 °C 15 / 30 °C

* Options not included

2.5. DIMENSIONS

Mod. 700 Mod. 900 a (mm) 350 350 b (mm) 920 920 c (mm) 700 900 d (mm) 1210 1410 e (mm) 970* 970*

H1 (mm) 840 / 990 840 / 990

*Machine height without the adjustable support feet.

a b c d

e

H1H1

MACHINE FEATURES

Pagina 15

2.6. NOISE LEVEL

As do all mechanical parts in movement, the LASER CTP machine produces noise pollution. The manufacturing system and the special measures adopted by the manufacturer assure that the machine's noise level does not exceed acceptable warning values. The machine's approximate noise level value is lower than:

60 dB

INSTALLATION

Pagina 16

3. INSTALLATION

3.1. PRELIMINARY PROCEDURES

In order to install the machine properly and to avoid risks to third parties as well as to the machine assembly personnel, we recommend that the following simple instructions be observed carefully: • The room where the machine will be installed must be absolutely cleared of any

temporary and/or foreign materials before the arrival of the cases containing the

machine or the machine parts to be assembled.

• All necessary masonry and finishing operations (basements, dividers, walls,

columns, etc.) are to be absolutely completed before the arrival and assembly of

the machine parts.

• The area destined for the machine must be properly cleaned, clear of debris and

of any sort of discarded materials. In particular, the floor must be treated with

anti-slipping products for the safety of operating personnel and for the stability of

the structures' supporting legs.

• The above area, cleaned and in order, must be adequately fenced off with red

and white colored bands, with special signs bearing the safety regulations

required by the local authorities (see the sign examples on the following page).

INSTALLATION

Pagina 17

• The following signals (in the local language) must be displayed at the points of

access to the machine assembly area:

ATTENTION MACHINE BEING ASSEMBLED

ENTRANCE AND PRESENCE OF UNAUTHORIZED PERSONNEL

IS STRICTLY PROHIBITED

The minimum signal dimensions are 850 mm base x 450 mm height. The color of the signal must be yellow with black/red printed text.

INSTALLATION

Pagina 18

• The supply of temporary electrical connections needed for the machine's

assembly must comply with the safety regulations issued by the competent local

authorities where the machine will be installed.

3.2. LIFTING, UNLOADING AND TRANSPORT

All lifting and unloading operations must be carried out in compliance with existing safety regulations and especially with due posting of the following warning signs "Notice of Loads in Movement", and "Air Suspended Loads".

Packed materials in wooden cases as well as in cartons must be transported and moved with appropriate transport and/or lifting means (cranes, hoists, transpallets, fork lifts, etc.), utilizing appropriate systems and methods, as indicated in some of the more common, but not necessarily binding, examples shown in figures 03.00 to 03.04 on the following page. If the above lifting means are not available, the packing cases must be handled with extreme caution. The manufacturer will not be responsible for any possible damages due to the lack of appropriate transport and/or lifting means.

INSTALLATION

Pagina 19

YES

YES

YES

INSTALLATION

Pagina 20

Assigned employees must be appropriately protected with gloves against direct injuries when engaged in material handling operations, and protected with a helmet against indirect injuries to the head. The mandatory use of protective eyeglasses is also required when removing nails with the aid of manual or automatic extractor devices. The same attention must be applied during cutting operations, both with mechanic as well as electrical tools, stretched bands and ropes, straps, and metallic fastening parts in general.

Important - Remember that employees are not allowed to pause or walk under air suspended materials, nor go near these materials when they are in motion. Non compliance, as well as non observance of all the special precautionary measures in carrying out the listed operations does not involve the manufacturer in possible injuries to things and/or people.

INSTALLATION

Pagina 21

3.3. CHECKING OF PARTS SHIPPED

It is extremely important that the packed materials be checked immediately upon their arrival. In order to avoid any possible delivery error by the shipping company, a two-step check is carried out for each package received. A) Administrative Check: - number of crates - weights and dimensions B) Technical Check: - Condition of the packing - Soundness of packing These inspections must be carried out visually, in the presence of the shipper's delivery personnel, see figures 03.05 and 03.06.

A maximum degree of resoluteness is recommended in carrying out the above inspection because, at times, possible damages to the packing due to blows or falls are not immediately visible, thanks to the high absorption capacity of today's packing materials.

Fig. 03.05

Fig. 03.06

INSTALLATION

Pagina 22

This does not rule out that the merchandise may have been damaged, in spite of the manufacturer's best attention and care in packing the merchandise. The manufacturer guarantees the perfect suitability of its packing materials both in terms of their composition as well as their mechanical resistance. Note: In regard to the above points, the manufacturer reminds the buyer that according to recurrent national and international regulations, the merchandise always travels at buyer's risk and peril, and unless otherwise specified when the order is confirmed, the merchandise travels uninsured. Therefore, any claim for damages due to shipping, loading, unloading and unpacking cannot be attributed to the manufacturer.

3.4. INCLUDED ACCESSORIES • Instruction, use and maintenance manual

• N°1 hexagonal spanner 2.5 mm

• N°1 hexagonal spanner 5 mm

• N°4 articulated support feet M16

• N°1 First intervention kit

3.5. MACHINE ASSEMBLY

The machine described in this manual is totally assembled by the manufacturer. No particular installation norms are required in order to use the machine because it is packed already assembled. In case the installation is to be carried out by the user, proceed as follows: • Remove all packing material.

• Carefully level the processor with a water level.

• Insert input and output tables (if present).

• If the option "Drip Tray" is present, follow the instructions below.

INSTALLATION

Pagina 23

INSTALLATION

Pagina 24

3.6. ELECTRIC POWER CONNECTIONS

• Arrange the equipments and the electric connecting positions following the

current rules and the equipments’ regulations of the nation.

3.7. WATER CONNECTION (Direct drainage system) • Water inlet

The main water duct must be connected to the socket located underneath the left

side of the processor, interposing a filter, a regulating tap and a closure lock.

In case of very hard (calcareous) water, insert also ian anti-calcareous filter.

In case the water pressure is not sufficient, the processor should be modified to

function correctly (ask the manufacturer).

• Water drain The draining tube (1"¼) must be as short as possible and for no reason the water

drain point must be higher than the draining outlet located underneath the

processor.

3.8. WATER CONNECTION (with water recirculating unit)

The water recirculator has to be connected carefully following the instructions

described in the manual of the water recirculator.

IMPORTANT: if the processor is equipped with the gum section cleaning device, it is not possible to connect the machine with a water recirculator. In case the operator wants to use a water recirculator anyway, it is required to electrically disconnect the solenoid valves of the gum section cleaning device (water inlet and drain switch).

PROCESSOR WORK FLOW

Pagina 25

4. PROCESSOR WORK FLOW

Dev. section brush Washing

section brush

Developer tank

Rinsing spray bars

Gumming section

Drying section

2nd brush in the dev. section

(option)

CONTROL PANEL

Pagina 26

5. CONTROL PANEL The setting of the different parameters for the proper working of the machine can be

made through the main display, located on the side panel of the processor.

5.1. INTRODUCTION The machine control panel is touch screen LCD, on which the different parameters

and information about the machine status are shown.

The parameters which can be set by the operator are outlined with a rectangle, thus simulating a real push-button.

For all the keys with active values (that is to say that can be set and changed by the operator):Example: Developer temperatureWhen touching the related key (in the example the key indicated with “Developer temp. Set”), the display shows a keyboard to be used to set the new value; in the example, digit 23.5 to set a temperature of 23.5°C), then press ENTER. The keyboard disappears and a new page appears, in which the operator is asked if he wants to update the used program with this new value (see next page).

ENTER keyBS key to cancel the last digit

CLR key to cancel all the digits

ESC key to leave the keyboard and confirm

the “old” value

CONTROL PANEL

Pagina 27

5.2. SAVE THE NEW VALUES

After having set a new value for any parameter and pressed the ENTER key, the

keyboard disappears and a new page appears, in which the operator is given two

options:

1. Press the “YES” key, thus saving the new value of the parameter and updating

the used program. The “old” value will be definitively replaced by the new value.

2. Press the “EXIT” key. In this case, the new value of the parameter is anyway

valid and effective, but it will be lost when the machine is switched off or if

another program is activated. The “old” value is stored in the PLC memory and

will be restored if the machine is switched off.

CONTROL PANEL

Pagina 28

5.3. RESUME PAGE

.

DEVELOPER TEMPERATURE It shows the current temperature in the developer

DEVELOPING TIME, expressed in seconds during which the plate is immersed in the developer

ROTATION SPEED of the developing section expressed as % of the max speed

DEVELOPER REPLENISHMENT shows the amount of replenisher (cc/m2) introduced in the tank any time a plate is processed

HOME PAGE Press this key to go to the Home Page (Menù and Channel, see next page)

DRYER POWER It shows the blower power which has been set: L-Low H-High

SERVICE

SERVICE usually not visibile; contact the technical service when flashing

It shows the processor status RUN or SLEEP mode

The machine control panel is a touch screen LCD The parameters which can be set by the operator are outlined with a rectangle, thus simulating a real push button. At the switch on of the machine (POWER ON), the following page appears on the LCD

ATTENTION: This page simply shows the main parameters of the working channel which has been selected. To go to specific page in which all the parameters can be adjusted press the HOME PAGE key to see the shortcuts to all the single pages

CONTROL PANEL

Pagina 29

5.4. HOME PAGE

The operator can open this page in any moment when pressing the “HOME” key which can be found in any page..

Shortcut to DEVELOPING TIME and DEVELOPER BRUSHES SPEED page

Shortcut to DEVELOPER REPLENISHMENT page

Shortcut to PLATE SIZES page

Shortcut to PLATE COUNTER

Shortcut to CONDUCTIVITY METER page

Shortcut to DRYER POWER page

Shortcut to GUMMING MODE page

Shortcut to DEVELOPER TEMPERATURE page Shortcut to ALARM

PAGE. It flashes when an alarm is activated

It starts a rinsing and gumming cycle . Press before feeding a plate through the second entry slot (over the main lid )

It changes the processor status. The internal word shows the current status

CONTROL PANEL

Pagina 30

5.5. DEVELOPER TEMPERATURE

Current temperatureof the developer in the tank

TEMPERATURE BAR : it shows the difference between the programmed developer temperature and the current developer temperature (with changes of + 0.5°C)

TEMPERATURE key : it shows the programmed value of the developer temperature – Press this key to set a new value. Back to HOME PAGE

CONTROL PANEL

Pagina 31

5.6. DEVELOPING TIME & DEVELOPER BRUSHES SPEED

Back to HOME PAGE

DEVELOPING TIME, expressed in terms of seconds during which the plate is immersed in the developer

Rotation speed of brushes in the developing section, expressed as a % of the max speed

CONTROL PANEL

Pagina 32

5.7. DRYER POWER Back to HOME PAGE

Press to change the blower power from LOW POWER to HIGH POWER and viceversa

INVISIBLE KEY: touch this key to enter the “Engineer Menu”, where it is possible to set some technical parameters (see later) and to see the software version.To be used by skilled engineers only.

CONTROL PANEL

Pagina 33

5.8. DEVELOPER REPLENISHMENT (OPERATE CONDITIONS)

The operating replenishment is the amount of developer replenisher introduced into the developer tank any time a plate is processed.This amount is expressed in cc/m2 and it is usually recommended by the plates manufacturer.The software will automatically replenish according to the real plate size (see PLATE SIZES page).

NOTE: The accuracy of the amount of the developer replenisher introduced into the developer tank is guaranteed by the calibration made by the factory

Back to HOME PAGE To ANTIOXID REPLENISHMENT page

Press to set the replenishment quantity (cc/m2) (min.: 0 –max.: 999)

MANUAL REPLENISHMENT key: touch (and keep pressed) this key to activate the replenishment pump, which will work as long as the key is pressed. The value shows the quantity (in cc) introduced.

CONTROL PANEL

Pagina 34

5.9. DEVELOPER REPLENISHMENT (ANTIOXID)

The antioxid replenishment is the amount of developer replenisher introduced into the developer tank when the machine is in stand-by conditions, to keep the developer in optimal conditions.To reach this aim, the replenisher pump is activated at regular intervals, independently from the OPERATE replenishment. The amount is expressed in cc.NOTE: the antioxid replenishment works only if the machine is in RUN conditions.

Back to HOME PAGE To START-UP REPLENISHMENT page

Amount of replenisher introduced into the developer tank.Set to 0 (zero) to disable it.

Time interval between every antioxid stroke, with machine in stand-by conditions.Value expressed in minutes.

CONTROL PANEL

Pagina 35

5.10. DEVELOPER REPLENISHMENT (WEEK-END)

The START-UP REPLENISHMENT happens any time the machine is switched on: in this moment, the software causes the automatic replenishment of the developer, introducing a certain amount of replenisher, equal to the amount set in this page. Set to 0 to deactivate it.

Back to HOME PAGE

To OPERATE REPLENISHMENT page

Amount (in. Cc) of developer replenishment to be introduced in the developing tank when the machine swithes from SLEEP to RUN mode. The software introduce the set quantity, multiplied by the hours, during which the processor remain in the sleep mode. Set “0” to desactivate it

CONTROL PANEL

Pagina 36

5.11. SETTING OF THE PLATE SIZES (replenishment operate condition)

This page allows the operators to enter up to 10 different plate sizes, according to which the operating replenishment will happen.

IN ORDER TO ALLOW THE SYSTEM TO WORK PROPERLY, PLEASE KEEP INTO CONSIDERATION THAT THE PLATE SIDE INDICATED WITH “Y” IS ALWAYS THE ONE PERPENDICULAR TO THE PROCESSOR INPUT ROLLERS, INDIPENDENTLY FROM THE FACT THAT IT IS THE LONG OR THE SHORT SIDE OF THE PLATE.

Press the keys to change/enter the plate sizes values (in mm., min.: 200 – max.: 2040). NOTE: IN ORDER TO ALWAYS HAVE AN ACCURATE REPLENISHMENT ACCORDING TO THE PLATE SIZE, ALL THE DIFFERENT "Y" VALUES MUST BE ENTERED PROGRESSIVELY, FROM THE LOWEST TO THE HIGHEST.

EXAMPLE: imagine to enter a plate size of: Y=1000 X=700.When the plate is processed, the software measures exactly the length (Y) of the plate (mm. 1000) and automatically combines it with the related width (X) value (mm. 700).Automatically, the software calculates that the plate area is of m2 0.7 (m. 1.00 by m. 0.70).Supposing to set a replenishment value of 200 cc/ m2, the machine will introduce 140 cc (200x0.7) of replenisher into the tank.As it is possible to set up to 10 plate sizes, every time a plate is processed the machine measures the length of the plate (Y) to which automatically combines the related width (X), and then calculates the amount of replenishment to be introduced.

Back to HOME PAGE

SCROLL keys: to move within the 10 available plate sizes.

CONTROL PANEL

Pagina 37

5.12. CONDUCTIVITY METER (option)

This page is active only if a conductivity meter (optional) is installed.

The conductivity meter shows the conductivity of the developer, expressed in Milli-Siemens.Please note that this value is correct only if the developer temperature is equal to the programmed one.

Back to HOME PAGE

ALARM AT key: touch to set a conductivity value under which an alarm indicates that it is advisable to change the developer in the processor (min.: 0 –max.: 200). Set to 0 to deactivate it.This alarm is not active if the current temperature differs from the programmed temperature of more than +0.5°C.We suggest to set the alarm value only after the end of the first cycle of the developer, that is to say after that the operator has had the possibility to see the conductivity value at which the replacement of the developer is needed. Use the conductivity value displayed just before the replacement as alarm for the next replacement.

Conductivity CURRENT VALUE

Touch to set a conductivity value over which an alarm will be activated

CONTROL PANEL

Pagina 38

5.13. GUMMING

Press to enter the GUMMING TIME. Set to 0 (zero) in case the gumming is not needed.

Back to HOME PAGE

Press to activate the washing of the gumming section (option, to be installed during the machine manufacturing). The washing cycle lasts about 3 minutes (as shown by the bar).The washing of the gumming section is advised any time the machine is switched off.

CONTROL PANEL

Pagina 39

5.14. COUNTERS

Press to RESET the partial counter

Number of plate processed since last reset

Back to HOME PAGETotal number of plate processed

CONTROL PANEL

Pagina 40

5.15. ALARMS PAGE The machine gives the operator a few alarms in case the software detects any malfunctioning.

In these cases, the word “Alarm” appears on the page the operator is currently looking at.To check which alarm has been activated , go to the Home Page and press the ALL button to show a page in which all the alarms are displayed. The activated alarm is indicated through a black background. Press the button of the activated alarm to have the description of the problem; after some seconds, the display will automatically switches back to the general “Alarms page” indicated here below.The alarm ends only when the cause is eliminated.

CONTROL PANEL

Pagina 41

5.16. ALARM SIZE (Wrong setting in the plate sizes for operate replenishment)

WHAT HAPPENED?

The system has detected that the operator, when enteringthe 10 different plate sizes (according to which the operating replenishment will happen) did not entered the different “Y" values progressively, from the lowest to the highest.The processor returns to normal operating condition when all the “Y" values are entered progressively, from the lowest to the highest.

Press the “Please check” key to go to the “Plate Sizes” page and correct the error

CONTROL PANEL

Pagina 42

5.17. ALARM LID

WHAT HAPPENED?1. The top cover of the processor is not properly closed.2. The safety key (to move the transport rollers manually) has been inserted and activated.

Due to safety reasons, any function of the machine is not allowed.

Back to previous page (ALARMS page)

!! ATTENTION SEE Chapter SAFETY !!Only the person in charge of the machine security can activate the “FW / RV” keys for the manual movement of the transport rollers (FW=forward; RV=reverse). These keys are deactivated with the machine in normal operate conditions; to activate them, insert the By-Pass Key into the lock under the plate feed in table. The key status is indicated in the lower part of the display.the output

CONTROL PANEL

Pagina 43

5.18. ALARM TNK 1 (Empty developer replenisher can - option)

WHAT HAPPENED?The developer replenisher can is empty.Fill the can with the replenisher or change the can, then touch the ON key to make the pump fill the pipe and to stop the alarm.

ON key: touch it after the re-fill or change of the can to make the pump fill the pipe and stop the alarm. Each touch activates the pump for a few seconds.

Back to previous page (ALARMS page)

CONTROL PANEL

Pagina 44

5.19. ALARM TNK 2 (Empty gum can - option)

WHAT HAPPENED?The gum can is empty.Fill the can with gum or change the can, then touch the ON key to make the pump fill the pipe and to stop the alarm.

ON key: touch it after the re-fill of the can to make the pump fill the pipe and to stop the alarm. Each touch activates the pump for a few seconds

Back to previous page (ALARMS page)

CONTROL PANEL

Pagina 45

5.20. ALARM LEV (Low level in the developer tank)

WHAT HAPPENED?The level of the developer in the main tank is low.Fill the tank with developer until the correct level is reached (overflow level).

Back to previous (ALARMS page)

AUTO key: it activates the dev. tank auto-fill pump, which will work for 3 minutes (allowing to pump into the tank a quantity of approx. 20 liters of developer, corresponding to the standard capacity of dev. cans). After the pump stops, the alarm will be activated again if the dev. level in the tank is not correct yet; in this case, the Alarm LEV 1 page will be displayed again: press the AUTO key again. Repeat the procedure if needed. The pump will stop automatically when the correct level in the dev. tank is reached. STOP key: press it to stop the pump. The developer inlet pipe is located on the rear left side of the machine and it is indicated with the label “DEV.CHARGE”.

CONTROL PANEL

Pagina 46

5.21. ALARM OVER (Motor block/overload)

WHAT HAPPENED?An overload or a block of the transport motor has been detected. The machine stops.To re-start the machine, find out and remove the cause (transport chain blocked, transport motor fuse blown, etc.), then switch off and switch on the machine through the main switch

Back to previous page (ALARMS page)

CONTROL PANEL

Pagina 47

5.22. ALARM JAM

WHAT HAPPENED?1. The input sensor is always busy (i.e. the plate is not pulled by the input rollers) 2. A plate (detected by the input sensor) has not been detected by the output sensor (option) within the time after which it should reach it (i.e. plate jam)

Back to previous page (ALARMS page)

CONTROL PANEL

Pagina 48

5.23. ALARM COND (Low developer conductivity - option)

SETUP key: conductivity value at which the developer has to be replaced (set by the operator). In case the operator wants to set a new alarm level, press this key (min.: 0 max.: 200). Set to 0 (zero) to deactivate the alarm.

CURRENT CONDUCTIVITY VALUE of the developer

WHAT HAPPENED?The current conductivity of the developer reached the alarm level (set by theoperator). The developer in the processor tank should be replaced.

SETUP key: conductivity value al which an alarm will be activated (set by the operator). In case the operator wants to set a new alarm level, press this key (min.: 0 max.: 200). Set 200 to deactivate the alarm

CONTROL PANEL

Pagina 49

5.24. ALARM +T°C (Developer temperature out of range)

WHAT HAPPENED?The system has detected that the difference between the current and the set developer temperature is over 1.5°C.The machine stops, not allowing to feed any additional plate into it. The processor returns to normal operating condition when this difference will be lower than 1.5°C.The alarm can be disabled (allowing the operator to use the machine even in case of a temp. difference higher than 1.5°C) by pressing the DISABLED button.

Back to previous page (ALARMS page)

CONTROL PANEL

Pagina 50

5.25. ALARM TEMP (Developer temperature over 40°C)

WHAT HAPPENED?The temperature of the developer in the main tank is higher than 40°C. All the machine functions stop and the alarm cannot be reset through the control panel.Switch off the machine through the main switch and contact the after-sales assistance service.

Back to previous page (ALARMS page)

CONTROL PANEL

Pagina 51

5.26. ALARM PROB (Developer temperature probe malfunctioning)

WHAT HAPPENED?The system has detected a malfunctioning of the developer temperature probe.All the machine functions stop and the the alarm cannot be reset through the control panel.Switch off the machine through the main switch and contact the after-sales assistance service.

Back to previous page (ALARMS page)

SAFETY

Pagina 52

6. SAFETY The model LASER CTP plate processor has been manufactured in compliance with CE safety rules as stated in the “Machine Regulations”.

6.1. PRECAUTIONS

For the safety of the machine and of the operators in charge of running it, the following rules should be observed and, in addition, the warnings listed in chapter 1.3 should be consulted as well: • The machine must be attended to only by authorized personnel (see par. 1.3).

• The machine must never be overloaded beyond its planned limits.

• Never start the machine without controlling, visually, its "All Clear" status.

• The machine's operators must never wear excessively ample clothes to avoid the

risk of getting entangled.

• The machine's external area must remain clear from unauthorized people.

• The operators must immediately report any defect noted during machine

operation to the person in charge of the department as these defects may cause

damages in the ensuing operational processes.

The manufacturer and its technical staff are available for solving any problem for the purpose of improving, where necessary, the safety conditions.

SAFETY

Pagina 53

6.2. OPERATOR’S SAFETY

The machine's areas at risk are provided with "Fixed Protections" which cannot be removed without the aid of specific tools. The only panel which can be opened without using any tool is the machine’s main transparent lid. In case this lid is opened, a safety sensor will not allow the machine to work. At the same time, a visual and acoustic alarm (“LID” alarm) will be activated (see also chapter “ALARMS”). When this lid is open, in case of need it is possible to manually activate the movement of the transport rollers (forward-reverse), inserting and rotating the key switch in the rear of the processor. Important note! 1. THE SAFETY KEY SWITCH TO MANUALLY ACTIVATE THE TRANSPORT

ROLLERS HAS TO BE KEPT BY THE PERSON IN CHARGE OF THE SAFETY OF THE DEPARTMENT.

2. THIS PERSON CAN ACTIVATE THE KEY ONLY IF PERSONALLY PRESENT AT THIS OPERATION.

Please make reference to the “LID” alarm page to see the two buttons for the manual movement of the rollers (forward-reverse): these buttons are deactivated during the normal operating cycle and become active only with the key inserted and activated. The red emergency stop pushbuttons are located in a visible area, are easy to turn on and are provided with a self-retaining device that locks their position. The risk areas have been identified by the manufacturer with colored adhesive labels that illustrate the danger point and its cause.

PROCESSOR START-UP

Pagina 54

7. PROCESSOR START-UP Please follow these instructions to start-up the machine:

1. Carefully level the processor with a water level, according to the following

instructions: a. place the water level over the first couple of rollers (input side), in the middle,

then adjust the machine’s feet until the machine is perfectly leveled. b. place the water level on the right side of the PVC tank and adjust the the 2

feet (front and rear) to level the machine. c. same as above for the left side. d. Repeat the above described operations until all the sides of the processor are

perfectly leveled.

2. Check that all the rollers are in

their proper position and well

fixed with the tool provided (see

picture 1).

Please note that in case of use

of a tool different from that

provided by the manufacturer

may cause to the roller to be not

perfectly fixed. In case this

should happen, be aware that

when rotating the roller may cause serious damages to the plates and to the

processor’s mechanic.

3. Check that the roller pressing devices are located in their correct position.

4. Check that the roller pressing device through screw of the rollers couple #5 (from

the processor input) are located in their correct position (see pictures 2 and 3)

and adjusted as described below:

a. loosen completely the screws of the roller pressing device (both right and left)

Pict. 1

PROCESSOR START-UP

Pagina 55

b. adjust both screws until they just touch the contact point below (zero

pressure)

c. now screw them in using the “L” spanner making a 180° (half turn) turn

clockwise (the right screw first, then the left one)

d. only following this procedure the adjustment is correct.

A higher pressure will not result in any additional advantage; on the contrary, an

increase of the pressure obtained through an additional turn of the spanner does

not give any advantage, and could damage the rubber of the rollers and in

general the mechanic of the processor due to the increased friction.

5. Check that the plate conveyor/guide (immersed in the developer) is located

correctly (see picture 4) and fixed with its screws (see picture 5).

Pict. 4 Pict. 5

Pict. 2 Pict. 3

PROCESSOR START-UP

Pagina 56

6. Check that the brush (or brushes) in the developing section and that its/their

pressing devices through spring are positioned correctly (see pictures 6 and 7).

ATTENTION! The adjustments of the brush pressure and of the guides (see picture 7) are

made by the manufacturer. In case of need, these adjustments can be made

again only by an engineer authorized by the manufacturer. In any case, the

pressure in respect to the guide cannot be higher than 1 mm approximately, as

otherwise the brushes and the machine itself could be seriously damaged.

7. Check that the developer anti-ox cover is in its correct position (see picture 8).

Pict. 6 Pict. 7

Pict. 8

PROCESSOR START-UP

Pagina 57

8. Check that all the spray bars are located and fixed properly (see pictures 9, 10,

11 and 12).

9. Check that the gum distributing roller covered with molleton is in its correct

position (it has to evenly rest on the corresponding gum squeegee roller) (see

picture 13).

Pict. 9 Pict. 10

Pict. 12

Pict. 11

Pict. 13

PROCESSOR START-UP

Pagina 58

Pic 21

1

2

Liquid level

I4197

10. If the chiller has to be used with water heat exchange, that can be recognised by

the small pump (Pic 21-[I4197]), the internal tank must be filled checking the liquid

level with the transparent hose. Place such hose, in the position that can be seen

in the picture, and open the valve present at the end of this hose. Fill the chiller

tank with anti-freeze fluid (90% water + 10%

glycol) through the top opening (pict. [2]) till

the fluid level inside the transparent hose

reaches the level indicated in the picture.

Note that the chiller unit must be switched

on (with the chiller fan on) and working since

at least 2 minutes before checking the fluid

level and also to make the top-off. In case a

top-off is made, be sure that the top tap

(pict. [2]) and the valve is properly closed. It

is recommended to make the check on a

regular basis.

11. If the processor has to work offline, an input table has to be mounted (see

pictures 14 and 15).

Pict. 14

Pict. 15

PROCESSOR START-UP

Pagina 59

12. Check that all the draining taps (accessible from the left side window of the

processor) are closed (developer tank drain, filter holder drain and chiller drain, if

present).

13. Prepare a can with synthetic gum for processors diluted as follows:

• 50-70% water

• 30-50% gum

Insert into the can the 2 pipes indicated with GUM. ATTENTION, the pipe with

the bigger diameter (gum drain) has to be inserted for 10 cm. as a maximum. Cut

the part of this pipe in excess.

ATTENTION

The gum has to be replaced with a certain periodicity. In particular, we recommend

to replace the gum every time the developer is replaced, due to high stickiness

caused by the evaporation of the water contained and for the unavoidable pollution

due to the carry over of small quantities of developer.

14. Prepare a can with the chemical to be used to replenish the developer in the

main tank, then insert the pipe indicated with DEV.

PROCESSOR START-UP

Pagina 60

15. IMPORTANT: prepare an empty can (with a capacity of at least 20 lt.) and insert

the pipe indicated with OVERFLOW. The pipe has to be inserted for 10 cm. as a

maximum. Cut the part of this pipe in excess.

16. Put the main yellow-red switch on the position ON.

17. Unlock the emergency pushbuttons (slightly rotate them clockwise).

18. Switch on the processor by pushing the green button close to the display.

19. After a few seconds, the alarm “LEV” and, if present, the alarms “TNK1” and

“TNK2” will be activated on the display. If the machine is equipped with automatic

dev. tank filling device, please see paragraph “Low level in the developer tank” to

see how to proceed to fill the tank. In case the machine is not equipped with the

auto-fill pump, the operator needs to fill the dev. tank manually until the level of

the drain plug is reached. Concerning the alarms “TNK1” and “TNK2”, please

make reference to the paragraphs “Empty developer replenisher can” and “Empty

gum tank” to see how to proceed.

Note: As far as the possible dilution of the developer in the main tank and in the

replenisher can is concerned, please make reference to what recommended by

the manufacturer of the chemicals and of the plates.

20. Before starting to work, set on the display all the working parameters (such as,

for example: developing time, brush speed, replenishment, drying power, etc.).

21. Wait for the developer temperature to reach the set value.

22. Feed 3-4 test plates to check the correct working of the processor and to run in

the brushes and the rollers.

23. Fine adjust the gum tap, so that the gum flow is not excessive.

24. Check the quality of the photographic result of the plate (this control has to be

made together with an engineer of the plates and chemicals used and an

engineer of the CtP) in order to properly adjust the values of the parameters set.

MAINTENANCE

Pagina 61

8. MAINTENANCE As the manufacturer has selected the LASER CTP construction materials with particular care and has dedicated scrupulous attention to the machine's design and development, the unit does not require special maintenance for its continuous and safe operation. By following the few, simple instructions summarized below, the LASER CTP machine will provide constant and absolutely reliable long-range service.

8.1. PRIMARY RULE

The main rule that the user's service department must observe is to keep the machine absolutely clean and clutter-free. Careful cleaning must be carried out, even partially, whenever the line stops. Cleaning operations must follow precise rules depending on the structures to be cleaned and the cleaning products to be used. The use of products that may damage the machine's components should be avoided. If movement has been halted for long periods of time, pour a small quantity of lukewarm water along the rubber rollers. If the machine must remain inactive for a long period of time, the main developer, replenishment and gumming solutions must be removed. Carefully clean the machine, the rollers, each single tank, each spray bar, etc.. Fill the main tank, the gum and the replenishment cans with water. After that, run a cycle, take away the upper rollers and leave the machine inactive for the necessary period of time.

MAINTENANCE

Pagina 62

8.2. CLEANING METHOD

A distinction must be made on whether the machine components and parts to be cleaned are made of metal or non-metal materials. The most important rule is not to use metal containing instruments, such as brushes with metal threads, steel wool scraping pads, metal spatulas and scrapers. In sum, best care and results can be obtained by observing the following guidelines:

1. ALWAYS USE industrial vacuum cleaners to suck away every trace of possible

foreign matter from the room as well as from the machine before a more detailed cleaning of the machine itself.

2. ALWAYS USE clean rags or paper for cleaning the machine. 3. USE synthetic leather for drying the parts cleaned. 4. USE, when necessary, appropriate brushes to clean the more hidden and difficult

to reach areas. The basic recommended cleaning scheme is described in the following page and helps to avoid the improper use of unsuitable cleaning detergents and utensils.

METAL

NON-FERR0US

Since the materials are always light, anodized alloys, choose liquid detergents, free of low density sodium chloride and sodium, that contain petrol or ethyl alcohol.

CLEANING

PARTS

FERROUS

Because these are stainless steel parts, use creamy detergents that in addition to cleaning also polish. Do not use powder compounds nor compounds made of phosphoric derivatives.

MATERIALS

NON-METAL

NYLON - PVC POLIZENE

These parts are scattered throughout the line.. Clean by using only water and liquid low concentrate neutral soaps. Rinse only with water and dry accurately.

PARTS ABS, PLEXIGLASS,

METHACRYLATEand PLASTIC W/ FIBERGLASS

COVERS

Concerns the machine covering. Clean as outlined above,while absolutely a voidingche micalsolvents, alcohol, and petrol.

MAINTENANCE

Pagina 63

Remember that the machine will remain clean longer if the rooms in which it is located are kept clean and in order. The cleaning of the room must always precede the cleaning of the machine. A clean machine and a properly cleaned room are the best guarantees for the machine's proper operation.

8.3. CLEANING AND OVERHAULING

8.3.1. DEVELOPING SECTION Follow the instructions below to properly clean the developer tank:

• Switch off the machine.

• Drain the tanks.

• Check for any deposit on the heating element.

• Fill the main tank with water.

• Change the gum can with a tank containing water.

• Change the replenisher can with a tank containing water.

• Run the machine for 10 minutes.

• Wash the rollers with water or specific cleaners. Never use brushes or other abrasive elements, solvents, acids or generic alkali.

• Drain the main tank and rinse it with lukewarm water.

• Be sure that any part is perfectly dry.

• Replace the filter.

• Fill the main tank with new developer.

8.3.2. ROLLERS

• Remove the roller holders.

• Extract the upper rollers.

• Take out the the lower rollers after unscrewing them with the spanner provided.

• Wash the rollers with water or specific cleaners. Never use brushes or other abrasive elements, solvents, acids or generic alkali.

MAINTENANCE

Pagina 64

Filter

ATTENTION! In case of use of specific cleaners for the cleaning of rollers, tanks and brushes, please remember to carefully clean any part with abundant water, in order to eliminate any cleaner residual, that, being acid, would make the developer precipitate.

8.3.3. SPRAY BARS Clean the spray bar holes with a pin. If this operation is not sufficient, the spray bars must be extracted and washed

accurately.

8.4. PROGRAMMED PERIODIC OPERATIONS • Weekly:

Check that all the spray bars holes are unobstructed; otherwise clean them.

Remove the dust from the filter of the chiller unit using a suitable vacuum cleaner.

• At every developer change: General cleaning of the machine as described above (main developer tank, gum section, upper/lower rollers and spray-bars).

Replace (and not simply wash) the developer filter (the replacement of the filter is mandatory, as the filtering activity cannot be restored simply washing it).

• Every 6 months: Grease the transport chain and check it is tight; Grease the metal gears; Apply a small quantity of silicone on the roller terminals. Remove the dust gathered at the entry of the chiller unit with a vacuum.

THE ABOVE OPERATIONS ARE ABSOLUTELY NECESSARY FOR THE PROCESSOR'S PROPER OPERATION. THE MANUFACTURER IS NOT RESPONSIBLE FOR DAMAGES DUE TO NON-COMPLIANCE WITH THESE RULES.

EXPLODED PICTURES

Pagina 65

9. EXPLODED PICTURES This chapter includes pictures of some details of the machine.

EXPLODED PICTURES

Pagina 66

9.1. RIGHT SIDE COMPONENTS

F3089

F3531

E2105

F3557

E2162

M1035

M1041 F3073 + F3093

E2187

F3530

E2191 E2202

F3556

EXPLODED PICTURES

Pagina 67

9.2. LEFT SIDE COMPONENTS

E2191

I4220

I4205 I4199

E2034 F3017 F3022

I4199 OR I4216

E2176

E2262

E2187

I4008

EXPLODED PICTURES

Pagina 68

9.3. COMPONENTS UNDER THE TANK

PIC. 1

PIC. 2

I4167

I4206

I4105

PIC. 3

I4197

I4090

I4132

I4131

I4180

F3403

I4200

I4218

I4220

I4219

I4008

I4008

EXPLODED PICTURES

Pagina 69

9.4. COMPONENTS INSIDE THE TANK (LEFT SIDE)

Pic 1

F3023 +

E2013

F3550

F3462

F3460

E2014

M1017

F3522 M1568 M1008

F3275

F3275

F3479 F3399

F3540

M1568 M1565 or M1552

M1564 Or M1551

M1565 Or M1552

M1564 Or M1551

F3476

M1615 M1614

EXPLODED PICTURES

Pagina 70

PIC. 2

F3462

F3523

M1564 Or M1551

I4191

F3571 Or F3469

F3476

F3477

M1017

F3462

F3522

M1564 Or M1551

M1417

F3166

F3527

F3078

M1564 Or M1551

F3563 Or F3562

F3565 Or F3468

M1417

F3523 F3565 Or F3468

F3166

M1417

EXPLODED PICTURES

Pagina 71

9.5. COMPONENTS INSIDE THE TANK (RIGHT SIDE)

PIC. 1 PIC. 2

F3476

M1017

F3477

F3570

T5028 Or T5015

F3535

F3560

F3041

F3275

F3560

F3555 Or F3481

M1567

M1615 M1614

EXPLODED PICTURES

Pagina 72

9.6. OUTSIDE

I4212

I4217

I4214

M1373

F3549 + E2013

T5025 Or T5012

T5021 Or T5008 E2218

E2198 +

M1540

E2107 E2108 E2109

E2203 +

E2204

E2194

I4270

M1562

M1561

EXPLODED PICTURES

Pagina 73

9.7. OUTSIDE (REAR SIDE)

F3335

M1646

F3749 F3750

F3545 F3519

M1024

M1646

EXPLODED PICTURES

Pagina 74

9.8. ELECTRIC PANEL COMPONENTS

E2209 E2199

E2195

E2203

E2044

E2042

E2190

E2196

E2149

E2041

HYDRAULIC AND ELECTRIC DIAGRAMS

Pagina 75

10. HYDRAULIC AND ELECTRIC DIAGRAMS This chapter includes the hydraulic and electric diagrams of the processor.

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

91

95

90

M1A M1

Right

Left

CONTROL PANEL (display GT01)

L1

L2/N

SWITCH ON board

Conductivity Meter Sensor

F6T3.15A

F1F20A

F3F20A

F11T63mA

F13F6,3A

F15F2,5A

F17F6,3A

F4F1A

F16F1A

F18F6,3A

F7F6,3A

F14F1A

F12F1A

F10F6,3A

F9F1A

F8F1A

F5F1A

WHITE BLACK

Right - Emergency - Left

IG L1

L2/N

CM

Fuse 10.3x38 - Fast KLK Type

Fuse 10.3x38 - Fast KLK Type

Fuses F4 to F18 and F20 to F22: 5x20 - Glass Type

TO PLC

GreenBluBrown

0

+ - PEPE+ -

J12 J13

J14 J15

PE PE

7

TO PLC

0

0

7

UP

UP

DOWN

DOWN

CABLAGGIO LASER NW.1-2 OPEN NW.2-3

A3 SEZIONE POTENZA 1.0

27-03-2006

Title

Size Document Number Rev

Date: Sheet 1 of 3

Brown

Brown

BluBluBlack

WhiteBrown

Blu

Brown

Brown

BluBluBlack

White

105

106

106

105

107

107

108

108

12

12

13

13

14

14

18

16

5 520

20

20

21

21

21

646431

31

32

32

112

7267

22

Black

Black

Black

18

39

46

4646

114114

48

48

48

48

113

113

111 111

111

48

48

57

5759

6

59

55

55

65

65 80 63

GR

EE

N

WH

ITE

6

7374

74

8181

81

87

70 77

241

242

242 242

241241

242 242

241 241

242242

241 241

2

1

53

52

93

97

22

22 24

24

24

99

99 78

78

789998

98

98 58

58

58

1

2

18

16

36

27 25828384

23

66 17

72

39

96

35

BR

OW

N

29

29

30

30

34

34

BROWN

BLACK

G/Y

BROWN

GREEN

WHITE

BROWN

BLACK

111

M2

F21

F6,

3A

S4

+VOut

-V

J11

_1 *

2 *

3 *

4 *

5 *

6 *

7 *

8 *

9 *

10 *

11 *

12 *

J3

1 *

2 *

3 *

4 *

5 *

6 *

7 *

8 *

9 *

10 *

11 *

12 *

13 *

14 *

P4c

SW1

R1

J16

1 *

2 *

3 *

4 *

P3

J2

1 *

2 *

3 *

4 *

R5

J11

_ 1 *

2 *

3 *

4 *

5 *

6 *

7 *

8 *

9 *

10 *

11 *

12 *

J10

1 *

2 *

3 *

4 *

5 *

6 *

7 *

8 *

9 *

10 *

11 *

12 *

R2

RT1°t

SL4

F20

F2,

5A

SL3

P4b

SST

J17

1 *

2 *

3 *

4 *

5 *

6 *

P2

J7

1 *

2 *

3 *

4 *

SL1

M4A

M5

R4

M3

MTB56 EGRAF

MTB56

EN

AB

LE

CLO

CK

SD

AT

A

CO

M-

0V+24

V

1

+20

mA

CO

M

Pt1

00_B

Pt1

00_A

Pt1

00_A

J4

1 *

2 *

3 *

F22

F6,

3A

P6

P4a

J5

1 *

2 *

3 *

4 *

5 *

P1

J9

1 *

2 *

3 *

4 *

5 *

6 *

J2

P5

S2

+V

OutCom

-V

R3

J6

1 *

2 *

3 *

4 *

5 *

6 *

7 *

8 *

9 *

10 *

M4

Aux

J1

1 *

2 *

3 *

4 *

5 *

J10

_1 *

2 *

3 *

4 *

5 *

6 *

7 *

8 *

9 *

10 *

11 *

12 *

SW2

S1*

+V

OutCom

-V230V 24V

0V0V

TR1230/24 - 260VA

*

*

*

*

7761

19

7087

19

67 7772

66

P7

8988

898888

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

FP0 C32P

TO J17 - 24VCC

Brown

Blu

Green

Main BoardMain Board

RS232c PORT

7

To SWITCH ONBoard

To SWITCH ON board

X

TO J17 - 24VCC

LASER NW.1-2 OPEN NW.2-3

A3 PLC unit and CONTROL PANEL connections 1.0

27-03-2006

Title

Size Document Number Rev

Date: Sheet 2 of 3

BR

OW

NB

LU

GR

EE

N

WH

ITE

WHITE

BR

OW

N

BROWN

GREENWHITE

GREEN

GR

EE

N

BROWN

POWER

1 2 3

Y0-Y7

123456789

10

POWER

1 2 3

X0-X7

123456789

10

DB 9 - MALE

1

Y8-YF

12345678910

X8-XF

12345678910To J15 of main board

To J12 of main board

To J13 of main board

To J14 of main board

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

Developer recirculation pump

IG

S4

Lid-open sensor

Sensor to start cycle

Developer heating element

Empty developer replenisher sensor

S1

Developer replenishment pump

Developer temperature safety sensor

Emergency STOP push button Left or Right

Chiller unit (compressor)

FP0E16RS

Transport rollers motor encoder

Right Dryer fan element

PLC moduleDeveloper low level sensor

2nd Developer replenishmentSINGLE BELLOW pump (OPTION)

Left dryer heating element

Diverter valve for gum drain

Main switch

Right dryer heating element

P4A: Solenoid valve for gumming wash

FP0C32P

TR1

S2

Gumming pump

Transport rollers motor

Output sensor for jam detect device (optional)

Empty gum sensor

Interface board with the CTP(Optional)

Developer tank auto-fill pump

Left Dryer fan element

Washing brush motor

First Developer brush motor

P4B: Water inlet solenoid valve

P4C: Water inlet solenoid valve

MTB56Dual A/D Converter

Conductivity Meter SensorCM

Developer temperature sensor

1.0

LASER NW.1-2 OPEN NW.2-3 table of contents

A3 table of contents

27-03-2006

Title

Size Document Number Rev

Date: Sheet 3 of 3

M1A

P6

M3

SST

P2

PR10

SW1

SW2

R1

SL3

R2/R3

M5

P3

M4A

SL1

M1

SL4

R4/R5

P4

M4

P7

P1

M2

P5

t

RT1

AUX

HYDRAULIC AND ELECTRIC DIAGRAMS

Pagina 79

HYDRAULIC DIAGRAM

SPARE PARTS TABLES

Pagina 80

11. SPARE PARTS TABLES

RIF. 9.1 RIGHT EXTERNAL SIDE COMPONENTS

Part s/n Description

F3089 Pinion Z20 3/8” hole d.14 E2162 Rollers motor E2105 Encoder sensor F3557 Revolution counter M1041 Reduction gear 1/80 F3073

+ F3093

Transport motor shaft Iron pinion Z9 3/8”

M1035 Chain 3/8” E2187 Motor 70 revolutions E2191 Centrifugal fan 80 x 42 E2202

F3556 Iron pinion Z14 3/8” hole d.14 F3530 Nylon guide chain d.40 F3531 Nylon guide chain d.40 (eccentric hole)

RIF. 9.2 LEFT EXTERNAL SIDE COMPONENTS

Part s/n Description

E2191 Centrifugal fan 80 x 42 E2202 Fan heating element I4199 Oscillating pump with spring I4216 Bellows pump (single bellows) E2176 Developer heating element E2187 Motor 70 revolutions E2262 Temperature probe PT100 Stainless steel E2034

+ F3017

+ F3022

Developer temperature safety sensor Adaptor for developer temperature safety sensor Developer temperature safety sensor rest

I4205 Water inlet 3 ways solenoid valve 24V I4008 Valve 1/8” M/F I4220 Foot valve

SPARE PARTS TABLES

Pagina 81

RIF. 9.3 COMPONENTS UNDER THE TANK

Part s/n Description

I4197 Pump MD10 I4090 PVC valve 3/4" F/F I4131 90° Fitting ¾” I4132 Fitting ¾” I4180 Filter holder I4219 Valve PP black 3/4" M/F F3403 Empty can sensor I4008 Valve M/F 1/4” I4200 Dav. tank auto-fill pump I4218 90° Fitting for pump I4200 I4220 Foot valve I4167 “T” female fitting 1”1/4 in black polypropylene I4206 Zone valve 24 V I4105 Mechanic filter 100my

RIF. 9.4

COMPONENTS INSIDE THE TANK – LEFT (FIG. 1)

Part s/n Description

F3550 Ultraflex roller D25 x 16 h.5 F3462 “T” Spring pressing device M1017 Spring diam. mm. 10 F3522 Roller pressing device through spring (Laser) M1564 M1551

Rubber roller 50,3 x 700 Rubber roller 50,3 x 900

M1565 M1552

Rubber roller 50,3 x 700 with hole Rubber roller 50,3 x 900 with hole

M1568 Roller rest shank diam. 14 M1008 Roller bush D20 D14 F3023

+ E2013

Lid-open switch holder Lid open magnetic switch

F3460 Level sensor rest E2014 Developer level sensor F3275 Nylon gear Z25 hole 14 F3479 Nylon gear Z25 crown hole 14 F3399 Stainless steel shaft for idle nylon gear F3540 Roller pressing device through spring dev. squeezing (Laser) F3476 Spring pressing device for brush M1615 M1614

Bristle brush D38 mod.70 Bristle brush D38 mod.90

SPARE PARTS TABLES

Pagina 82

RIF. 9.4 COMPONENTS INSIDE THE TANK – LEFT (FIG. 2)

Part s/n Description

F3477 Brush bush M1017 Spring (diam. 10 mm) F3476 Spring pressing device for brush I4191 Spray bar coupling F3565

Or F3468

Stainless steel roller d.30 for gumming mod. 700 Stainless steel roller d.30 for gumming mod. 900

M1417 Molleton sleeves for stainless steel roller F3462 “T” Spring pressing device F3522 Roller pressing device through spring (Laser) F3166 Polythene roller d.15 h.10 F3571 F3468

Water spray bar mod 700 Water spray bar mod 900

F3527 Screw pressing unit (Laser) F3523 Screw pressing unit (with adj.) M1564

Or M1551

Rubber roller 50,3 x 700 Rubber roller 50,3 x 900

F3565 Or

F3562

Stainless steel roller d.30 for molleton mod. 700 Stainless steel roller d.30 for molleton mod. 900

F3078 Roller shank center square F19

SPARE PARTS TABLES

Pagina 83

RIF. 9.5 COMPONENTS INSIDE THE TANK - RIGHT (FIG. 1)

Part s/n Description

F3560 Nylon gear Z25 crown h.19 F3570 Overflow F3476 Brush spring pressing device M1017 Spring diam. 10 mm F3477 Brush bush nw F3535 Polythene roller 38 x 20 h.10.5 F3563

+ F3562

Stainless steel roller D30 for molleton mod. 700 Stainless steel roller D30 for molleton mod. 900

M1417 Molleton sleeves for stainless steel roller T5028

Or T5015

Polythene guide mod. 700 with support Polythene guide mod. 900 with support

M1615 M1614

Bristle brush D38 mod.70 Bristle brush D38 mod.90

RIF. 9.5 COMPONENTS INSIDE THE TANK - RIGHT (FIG. 2)

Part s/n Description

F3560 Nylon gear Z25 crown h.19 F3275 Nylon gear Z25 h.14 F3041 Nylon gear Z20 h.14 M1567 Bush d.18 h.12 F3555

Or F3481

Wash brush back-up roller (nylon) D40 mod. 700 Wash brush back-up roller (nylon) D40 mod. 900

SPARE PARTS TABLES

Pagina 84

RIF. 9.6 OUTSIDE

Part s/n Description

F3549 +

E2013

Lid-open magnet holder (Laser) Lid open magnetic switch

M1373 Lid piston T5025

Or T5012

Metal lid Laser mod. 700 Metal lid Laser mod. 900

E2107 +

E2108 +

E2109

Red emergency pushbutton Base for contact Element of normally closed contact

E2198 +

M1540

“ON-OFF” board Ctpnw

Panel for “ON-OFF” board Ctpnw E2218 Display panel GT 01 E2203

+ E2204

Main switch Main switch extension

M1561 Left side cover M1562 Right side cover E2194 Key switch I4075 Cooling unit CE/UL 50/60 Hz for Europe T5021

Or T5008

Input table mod. 700 Input table mod. 900

I4217 Fitting ¼ npt I4214 Gum dispenser 1/4 int.6 I4212 Gum dispenser terminal 1/4 24x0,8

SPARE PARTS TABLES

Pagina 85

RIF. 9.7

OUTSIDE (REAR SIDE)

Part s/n Description

F3545 Or

F3519

Upper output rod d.15 mod. 700 Upper output rod d.15 mod. 900

F3749 Or

F3750

Lower output rod mod. 700 Lower output rod mod. 900

M1024 Viton o-ring diam. 13,11/2,62 F3335 White polythene roller diam. 25 hole 15 M1646 Rubber roller D35 Th15

REF. 9.8 ELECTRIC PANEL COMPONENTS

Part s/n Description

E2196 Socket 9 pins rs232 E2209 A/D converter for temperature probe and conductivity

meter E2149 PLC module E2195 Electronic board Ctpnw E2203 Main switch Ctpnw E2044 Grey fuseholder 5 x 20 E2042 Grey terminal board E2041 Blue terminal board E2190 Panel socket 230V - UL E2199 Transformer 220/24v 260va “UL”