Service Manual

Raptor Thermal 68/85

Service manual
Raptor Thermal 68/85

T1965

Edition ED, October 2011

This book has part No. 51265
 General information
0-2
This manual

Part 0: General information

This manual

Products covered
This manual is valid for: Raptor Thermal 68 from serial no 92261-0115.
Raptor Thermal 85 from serial no 91801-0450.

The serial number is specified on the processor name plate located on the rear end of
the tank on the left side (when standing behind the processor).

#
This manual is for Service Technicians only.

The directions given must not be followed by unauthorized personnel.

Always read the Safety Instruction Manual part No 21741 before installing or
operating the equipment.

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

Haslevvej 13
DK-4100 Ringsted
Denmark
Phone:+45 57 68 81 81
E-mail: gjhq@glunz-jensen.com
Internet: www.glunz-jensen.com

Copyright © 2005 by GLUNZ & JENSEN A/S.

Service Manual - Plate Processors 68-85 1119

 General information
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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.

Other manuals
A description of manuals available for this machine is made later in this chapter.

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.

Problems
If help is needed to correct any problem with the equipment, please contact your
supplier.

"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 all polymeric components with a minimum weight of 20 g
(0.7 oz), are marked with material specification according to the ISO 11469 standard.
• Polyurethane, tank etc., must be incinerated at a suitable incinerating plant with a
temperature of combustion of min. 900° C (1652° F).
• 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.

0945 Service Manual - Plate Processors 68-85

 General information
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Important!
• Approvals:
– Approvals will appear from the labels attached to the processor name plate or
the frame part of the processor.
• Unintended use of the equipment:
Glunz & Jensen A/S do not take any responsibility for any damage or accidents
caused by unintended use of the equipment:
– As the equipment is certified by accredited test laboratory (UL International
Demko A/S) it is absolutely prohibited to make any modifications, electrical nor
mechanical, of the equipment. If however this prohibition is disregarded, Glunz
& Jensen's warranty will no longer apply and the certification labels for UL,
C-UL, and CE certification of the equipment shall be removed as the certification
will no longer apply to the equipment.
• Intended use of the equipment:
– Development of photographic materials as specified in “TECHNICAL
SPECIFICATIONS” in Section 1 of this manual.
• Installation:
– Never install the processor in explosive environments.
– It is the responsibility of the owner and operator/s of this processor, that the
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 located on the rear panel
of the processor

Service Manual - Plate Processors 68-85 0945

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Warnings, cautions and notes !

Throughout the manual warnings, cautions, and notes are written in bold on a grey
background like the example below:

$
Always replace a fuse with one of the same size and rating as the old one.

Explanation:

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.

0945 Service Manual - Plate Processors 68-85

 Table of contents
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Table of contents
Part 0: General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
This manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Products covered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2
Reservations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
"End of lifetime" disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3
Important! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-4
Warnings, cautions and notes ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-5
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 emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Mechanical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tank capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Water requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Water consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Exit table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Voltage tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Power consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Service Manual - Plate Processors 68-85 0945

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Developer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Replenishment/anti-oxidation system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Wash section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Gum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Circulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Gum-clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
By start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
By shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Dryer section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Transport system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Electronic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Master processor unit (MPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
High power unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Man machine interface unit (MMU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Part 3: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Safety check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning of valves in the replenish pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Dismounting small circulation pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Cleaning of the circulation pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Adjustment of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Cleaning of spray tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Rollers and brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Removing brush rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installing brush rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Adjusting the brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Adjustment of gears for wash brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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

0945 Service Manual - Plate Processors 68-85

 Table of contents
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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
Stand, closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Exit, table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Feed table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Handshower and level sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Pump / circulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Developer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Wash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Gum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Cables (not illustrated) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Appendix A: Additional spare parts . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B: Electrical diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Main power distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Fuse panel and interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
High voltage wiring I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
230V AC, control devices, HPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
High voltage wiring II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
230V AC components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
High voltage wiring III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
230V AC, control devices, LPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-8
Low voltage wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Sensors and control devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-10
Motors and internal bus wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12
8, 24 and 35V AC distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-12

Service Manual - Plate Processors 68-85 0945

 Table of contents
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0945 Service Manual - Plate Processors 68-85

 General information
0-10
Manuals

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1.
Service manuals
The manuals listed below are for service technicians only. In addition the service
technicians will need the manuals listed opposite as "User Manuals".

Processor Installation Manual (1)

Language: English
Contents: Installation of the processor

Processor Service Manual (2)

Language: English
Contents: Technical specifications
Functional description
Maintenance
Trouble shooting
Spare parts
Electrical diagrams

MPT Service Information (3)

Language: English
Contents: Menu structure (service menus)
Control panel, Service information
Calibration procedures

Service Manual - Plate Processors 68-85 0945

 General information
0-11
Manuals

User manuals
User manuals available for the equipment:

CE Declaration Of Conformity (4)

Languages: Various
Contents: Survey of the directives to which the equipment conform

Safety Instruction Manual (5)

Languages: 28
Contents: General Safety Information

User's Manual, Plate Processor (6)

Languages: 14
Contents: Operating and cleaning procedures

User's Manual, MPT Control Panel (7)

Languages: 4
Contents: Functional description
Menu structure (user available)
Operation and programming
Alarm list

MPT Quick Guide (8)

Languages: 4
Contents: Quick guide to Control Panel user functions

Keep the manuals with the machine for reference at all times.

0945 Service Manual - Plate Processors 68-85

 General information
0-12
Manuals

Service Manual - Plate Processors 68-85 0945

 Technical specifications
1-1
General environmental information

Part 1: Technical specifications

General environmental information

The processor does not contain

• Ozone depleting substances according to Montreal protocol
• Asbestos
• Polychlorinated biphenyl or Poly- Cyclohexylenedimethylene Terephthalate
• Mercury
• Cadmium
• Lead as additive to plastic parts

Plastic parts
Plastic parts >50g are marked according to ISO 11469.

Batteries
No batteries in this equipment.

End of life
Estimated product life: 10 years
Spare parts and service period: 7 years after last sales.

Recycling
The processor should be disposed at a certified appliance recycling centre or
processing centre.
Recycling Passport with specifications of components and materials used in this
processor is available on www.glunz-jensen.com/support.

Packaging
Plastic packaging materials are marked according to ISO 11469.

Noise emission
Acoustical noise according to ISO 11201:1996
Sound pressure level
Operational mode: 61 dB
Stand-by mode: 41 dB

0945 Service Manual - Plate Processors 68-85

 Technical specifications
1-2
Mechanical specifications

Chemical emissions
3
Ozone: 0 mg/m
3
Dust: 0 mg/m
3
Styrene: 0 mg/m

Heat emissions
Process: 3100 W (approx. 10600 BTU/hour)

Stand-by: 750 W (approx. 2560 BTU/hour)

Mechanical specifications

Performance

68 85
Plate types Single sided
thermal offset plates

Plate width 200 - 675 mm 200 - 850 mm

min.- max. (7.9 - 26.6") (7.9 - 33.5")

Plate length 290 - 1100 mm 290 - 1100 mm

min.- max. (11.4 - 43.3") (11.4 - 43.3")

Plate thickness 0.15 - 0.30 mm 0.15 - 0.30 mm

min.- max. (0.006 - 0.012") (0.006 - 0.012")

Plate speed 40 - 120 cm/min 40 - 120 cm/min

(15.7 - 47.2"/min) (15.7 - 47.2"/min)

Brush speed
at 50 Hz 60 - 150 rpm
at 60 Hz

Tank capacities

68 85
Developer, total 17.0 l 22.0 l
ex. filter, pumps etc. (4.5 US gal.) (5.8 US gal.)

Wash 11.0 l 13.5 l

ex. filter, pumps etc. (2.9 US gal.) (3.6 US gal.)

Service Manual - Plate Processors 68-85 1140

 Technical specifications
1-3
Mechanical specifications

Temperatures

68 85
Developer 20 - 40 °C
min. - max. (68 - 104 °F)

Dryer, process 35 - 55 °C
min. - max. (95 - 131 °F)

Water requirements

68 85
Pressure 1 - 6 bar
min. - max. (29 - 87 psi)

Water consumption

68 85
Operation 14 l/min 16 l/min
(if no wash recirculation) (3.7 US gal/min) (4.2 US gal/min)

Stand-by 0.0 l/min 0.0 l/min

(if no wash recirculation) (0.0 US gal/min) (0.0 US gal/min)

Weights

68 85
Weight, empty 190 kg 235 kg
(418 lb) (518 lb)

Weight, shipping 255 kg 305 kg

(562 lb) ( 672 lb)

Weight, with liquids approx. 220 kg approx. 272 kg

(485 lb) (600 lb)

Exit table

68 85
Capacity Max. 30 plates.
NOTE! Consider risk of scratches

0945 Service Manual - Plate Processors 68-85

 Technical specifications
1-4
Mechanical specifications

Dimensions

Side view
265 cm (104.3")

101.0 - 110.0 cm
82.8 - 91.8 cm (39.8 - 43.3")
(32.6 - 36.1") 76.3 - 85.3 cm
(30.0 - 33.6")
75.3 cm (29.6")

87.2 cm (34.3")

Top view
115.8 cm (45.6") 30.3 cm (11.9")

68: 108.0 cm (42.5")

85: 125.5 cm (49.4")
68: 79.9 cm (31.5")
85: 97.4 cm (38.3")

93.2 cm (36.7")
75.7 cm (29.8")

40.1 cm (15.8") 78.8 cm (31.0")

T31510

Service Manual - Plate Processors 68-85 0945

 Technical specifications
1-5
Electrical specifications

Electrical specifications

Power supply

$
The requirements below are specifications for preparing the installation
protection. It is important to prepare the fuses/circuit breakers with adequate
capacity as specified here.

"
Specifications on the processor's name plate is the actual input current and
will thus not be identical to below mentioned.

68 85
EUR-models 3W + N + PE, 3W + N + PE,
~400V / 3x7 Amps, 50-60 Hz ~400V / 3x7 Amps, 50-60 Hz

US-models Single phase, 2W + PE, Single phase, 2W + PE,

230V / 2x11 Amps, 50-60 Hz 230V / 2x11 Amps, 50-60 Hz
3 phases, 3W + PE, 3 phases, 3W + PE,
230V / 3x10 Amps, 50-60 Hz 230V / 3x10 Amps, 50-60 Hz

JAP-models Single phase, 2W + PE, Single phase, 2W + PE,

200V / 2x11 Amps, 50-60 Hz 200V / 2x11 Amps, 50-60 Hz
3 phases, 3W + PE, 3 phases, 3W + PE,
200V / 3x10 Amps, 50-60 Hz 200V / 3x10 Amps, 50-60 Hz

Voltage tolerances

68 85

Voltage tolerances ± 10 % ± 10 %

Power consumption

68 85

EUR-models Max. 3100 Watts 3100 Watts

US-models Max. 3100 Watts 3100 Watts

1140 Service Manual - Plate Processors 68-85

 Technical specifications
1-6
Electrical specifications

Service Manual - Plate Processors 68-85 0945

 Functional description
2-1
General

Part 2: Functional description

General
(See illustration below)
The basis processor contains four major sections:

4 3 2 1

some models some models

only only

T1988

Developing of the plate and removing of the remaining unexposed

1 Developer
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 placed
on the right side of the processor.
The control panel functions are described in the MPT Control Panel manual.

0945 Service Manual - Plate Processors 68-85

 Functional description
2-2
General

DEVELOPER
S1
INPUT SENSOR

OVERFLOW
SPRAY-TUBE

M1 TRANSPORT B1 DEV. TANK OPTIONAL

ROLLER M MIN. SENSOR
MOTOR
CHILLER TUBE
M2 DEV.
M
BRUSH R1 E1 DEV. HEATING
MOTOR TEMP. SENSOR

FILTER
1 x 10"
20-150 my

M3
DEV. CIRC.
PUMP
(IWAKI) CHILLER

K1
FILL-UP DEV

DEVELOPER

MIN. B11
SENSOR OPTIONAL

OPTIONAL DEV. WASTE CONT.

MAX. SENSOR

B15
M4
DEV REPLENISH WASTE

REPLENISH

DEV REPL. B10

CONT. MIN.
SENSOR
T1989 ...
OPTIONAL

Service Manual - Plate Processors 68-85 0945

 Functional description
2-3
Developer section

Developer section
(See illustration opposite).

In the developer section the plate is developed.

Circulation
A circulation pump recirculates the developer in the section.

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 optain
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 has been turned off
for a long period.

The replenishment/anti-oxidation developer is added to the section by means of a

pump.

0945 Service Manual - Plate Processors 68-85

 Functional description
2-4
Developer section

TAP WATER
WASH
TAP WATER

K8
VALVE

FLOW LIMITERS

SPRAY TUBE

DRAIN

CIRCULATION WATER
WASH

TAP WATER
REPLENISH

K8
VALVE

FLOW LIMITERS
OVERFLOW

OPTIONAL
SPRAY TUBE
WASH TANK B2
FILTER MIN. SENSOR
1 x 10"
20 - 150 my

DRAIN
VALVE

CIRC. PUMP
M10

DRAIN
T1990

Service Manual - Plate Processors 68-85 0945

 Functional description
2-5
Wash section

Wash section
In the wash section the developer solution is washed off the developed plate.

The water is applied to the plate through a spray-tube above the plate.

0945 Service Manual - Plate Processors 68-85

 Functional description
2-6
Wash section

GUM

APPLICATION TUBE

M23
GUM CIRC. PUMP
DRAIN
OPTIONAL:
K1
GUM CIRC. PUMP

T1991
OPTIONAL
B9
GUM CONT.
MIN. SENSOR

GUM/FINISHER

Service Manual - Plate Processors 68-85 0945

 Functional description
2-7
Gum

Gum
(See illustration opposite).

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 you
should rewash and regum the plate (optional feature).
(See how in the Processor User Manual).

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, so
the gum runs back from the section into the container and keeps recycling.

Gum-clean
The processor features an automatic gum-clean program which automatically cleans
the gum section rollers at start-up and shut-down.
(when parameter "GUM CLEAN" in the configuration menu is set to "ON").
It is possible to select processing program and change program settings during the
cleaning process.

By start-up
The gum clean cyclus starts when the stand-by key is pressed (display shows
"STARTING GUM").
The gum pump will apply gum for a specified period without the rollers turning. After
this period the rollers turn shortly backwards followed by a period turning forwards.
The procedure takes approx. 20 min. and ensures a uniform gum layer on the first
plate to be processed.

"
The gum-clean process does not apply any water to the gum solution. When
needed add extra water to the gum manually according to the gum
manufacturers recommendations.

By shut-down
The gum clean cyclus starts when the stand-by key is pressed (display shows
"STOPPING GUM"). The rollers will turn for a specified period without any gum
applied (approx. 10 min.). The gum cyclus however can be stopped any time by
pressing "STOP".
The processor automatically switch into off-mode after finishing the cyclus.

"
The gum cleaning cyclus can be stopped any time by pressing "STOP".

0945 Service Manual - Plate Processors 68-85

 Functional description
2-8
Gum

DRYER
S2
OUTPUT SENSOR

R2
DRYER TEMP.
SENSOR

M M9
FAN
HEATING
ELEMENT
E2+E3 T1979

4 3 2 1

some models some models

only only

T1988

Service Manual - Plate Processors 68-85 0945

 Functional description
2-9
Dryer section

Dryer section
(See illustration opposite).

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
(See illustration opposite).

The plate is transported through the processor by a series of rollers and roller guides.
The rollers are driven by a drive motor and a worm gear drive system.

The rollers (1) at the developer section entrance always run dry to ensure a
homogeneous development. The guide (2) and rollers (3) ensure that the plate is
transported correctly through the developer solution and the guide (4) 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 the spray
bar (5). The wash section entrance rollers (6) prevents that the wash water runs back
into the developer section. Water is squeezed off the plate by the wash section exit
rollers (7).

The sections each contains a spray tube (8) and a pair of rollers (9).
The exit roller pair (10) takes the plate when dry and leads it out of the processor.

0945 Service Manual - Plate Processors 68-85

 Functional description
2-10
Transport system

Remote surveillance

or

PC PC with Modem

GNUXB (optional)

MPU PIM

GNUIB Plate
Setter

HPU

MMU
T 2583

Service Manual - Plate Processors 68-85 0945

 Functional description
2-11
Electronic control

Electronic control
(See illustration opposite).

The electronics consists of:

Master processor unit (MPU)

The whole electronic system is controlled by the MPU-board.
It has two separate communication lines (buses): GNUIB for all internal
communication in the processor.
GNUXB for external communication between the processor and a PC or modem.

Option: The MPU-board can be equipped with a PIM (Plate setter Interface Module)
for the communication between the processor and a plate setter in case of an online
installation.

High power unit (HPU)

The HPU-board holds all the high voltage in- and outputs for the control of heaters,
motors etc.

On the HPU-board is a switch S1 for HPU settings. The setting should be as illustrated
below.

S1
B A

T2600

Switch S1 A : Not used

Switch S1 B : OFF = HPU
ON = Not used
Man machine interface unit (MMU)
The MMU-board is the Control Panel board from which the user operates the
processor.
If necessary it is possible to add extra MMU-modules.

0945 Service Manual - Plate Processors 68-85

 Functional description
2-12
Electronic control

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-1
General

Part 3: 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 "MPT Service
Information" manual.
For user related maintenance and cleaning procedures refer to the Plate Processor User
Manual.

WARNING!
Please note that where this label DANGER
appears on the processor, electrical ELECTRICAL SHOCK HAZARD
shock hazard still exists when the DISCONNECT ALL EXTERNAL POWER
SUPPLY BEFORE SERVICING
main switch is turned off.
TO BE SERVICED BY AUTHORIZED PERSONNEL ONLY

RISQUE DE CHOC ÉLECTRIQUE

AVANT TOUTE INTERVENTION,

DÉBRANCHER TOUTES LES SOURCES DE COURANT

MAINTENANCE PAR PERSONNEL

AUTORISÉ SEULEMENT

WARNING!
When performing any service, maintenance, calibration, or trouble
shooting etc. it may be necessary to override the function of the
processor’s interlock switches.
In these cases please be aware, that the processor’s JOG-function is still
active, making the drive system run idle at intervals.
There will be NO advice when the JOG function starts

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-2
Safety check

Safety check

"
Below described safety check should be performed at least once a year.

Electrical
(Refer to the electrical diagrams in the back of this manual).
• Check proper function of:
– Lid switch. Processor must stop when the switch is deactivated. The "COVER
OPEN" message must appear in the control panel display.
– Main switch. Processor must turn off when set to "0".
– Emergency stop. The processor must turn off when activated.

Mechanical
• Check proper function/location of:
– Side fenders, left/right. Make sure the fenders are properly secured with 2
screws each.
– Lower side panels, left/right.
– Top covers, front/rear.
– Inner covers.
– Covers, electronics boxes. Make sure covers are secured by screws.

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-3
Fuses

Fuses
Fuses for motors are placed on the motors behind the left fender.

Other fuses for the various functions are located in the electronics cabinet behind the
upper right fender. The fuses are placed on the fuse PCB behind the cover.
A fuse label on the inside of the cover for the wiring box 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 of the correct rating according to the label.

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-4
Cleaning

Cleaning

Cleaning of valves in the replenish pumps

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

VALVE
VALVE

T436

Dismounting small circulation pumps

Dismounting of the rinse (1) and finisher (2) circulation pumps from the pump bracket
(3) is made without use of tools. Simply press the snap locks and release the pumps.

Cleaning of the circulation pumps is described on the next page.

1
2

T31526

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-5
Cleaning

Cleaning of the circulation pumps

(See illustrations below)

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

1
2
3
4

T31064

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-6
Cleaning

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.

Cleaning of spray tubes

Developer section
Clean the spray tubes in the developer section with hot water to remove potential
blocking of the holes.

Wash section
Clean the spray tubes in the wash section with hot water to remove potential blocking
of the holes. Occasionally, depending on the local water quality, it may be necessary to
use a drill bit to clean the holes and remove sediments mechanically.

t31558

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-7
Rollers and brush rollers

Rollers and brush rollers

General
Inside the top cover is mounted a label showing the roller configuration. Each
brush/roller is marked with a small number (see instruction on the label). Install the
rollers by referring to the roller numbers on the label.

Label with
roller configuration
10

1 3 5 7 9 11 13 15

2 Steel 8 10 12 14 16

T31545

Installation of rollers
See illustration below.

$
Make sure to align the gears on the upper and lower rollers.
The gear on the lower rollers has a plate/guide that must fit into the gear of
the upper rollers.

T31590

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-8
Rollers and brush rollers

Removing brush rollers

Use the special tool (1) when removing brush rollers. Follow the instruction below:
• Stand to the right of the processor.
• Remove the spray tubes (2).
• Insert the roller key between the upper brush roller and the lower support roller as
shown (3).
• Lift up the roller key (4) and force the upper brush roller out of the bearing.
• Repeat (3) and (4) for the gear end of the brush roller.
• Use the roller key to hold the brush roller (5) and lift the brush roller out of the
bath/tank (6).

1 2

3 4

T31578

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-9
Rollers and brush rollers

Installing brush rollers

• Inside the top cover is mounted a label showing the rollers.
• Stand on the right side of the processor and hold the brush roller with both hands.
• Place the gear end of the brush roller on the gear of the support roller in the left side
of the tank wall.
• Use the roller key to lower the right end of the roller into the bath/tank (2).
• Insert the roller key between the upper roller and the lower roller as shown (3).
• Press the roller into the bearing by pressing the roller key upwards (4).
• Repeat (3) and (4) for the gear end of the brush roller.
• Mount the spraytubes (5).

1 2 3 4

T31579

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-10
Rollers and brush rollers

+
6

2
6
4
5

1
T31559

5a 90°

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-11
Rollers and brush rollers

Adjusting the brushes

General
The following describes a standard adjustment for the brushes.
The brush adjustment can vary from one processor to another as it must apply to the
specific plate and chemistry type etc.

(See illustration opposite).

Tools:
- 5 mm allen key with ball end, and
- Test plate 100x200x0.3 mm (developed).

Processor conditions
The processor must be started up and ready to process.
Set developer brush speed according to recommendations from the plate
manufacturer.

Preparations
• Open the processor top cover.
• Remove the upper roller (1) in the developer section before adjusting.
• Activate the interlock switch (2).
• Press the manual start key (3).

Adjusting
• While the brush (4) runs use the test plate (5) to test the brush pressure in both sides
and in the middle. Make sure that the test plate (5) is entered at right angles (5a) to
the rollers.
• Adjust the brush pressure on the screws (6) (clockwise = tighten) until you feel a
slight grip ("kiss'n touch").
Make sure that you obtain a uniform grip in both sides and in the middle.
• From this point turn the screws (6) 1/4 turn clockwise in each side. 1/4 turn is a
common pressure which will work in most occasions. Please refer to plate
manufacturers specifications.

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-12
Rollers and brush rollers

3
1
3

2
5
6

4
7

T31584 6

Service Manual - Plate Processors 68-85 0945

 Maintenance
3-13
Rollers and brush rollers

Adjustment of gears for wash brush

IMPORTANT!

$
When the main drive shaft has been dismounted/remounted due to change of
parts, service checks, etc. it is very important to make a final adjustment
according to the description below.

Procedure of adjustment
See illustration opposite.
• Mount the main drive shaft (1) on the tank wall and tighten the 2 screws (2) on each
of the 4 brackets (3) holding the shaft.
• Loosen the screws (2) on each bracket (3) 1/4 turn.
• Place a 0.5 mm feeler gauge (4) between the gear (5) and the bearing (6).
Alternatively use pieces of offset plate equal to 0.4 mm - 0.6 mm (e.g. 2 x 0.3 mm
offset plate).
• Turn the gear (7) manually to adjust the space gap between the gear (5) and the
bearing (6) to fit the feeler gauge (4).
• Tighten the screws (2) on the brackets (3) for the main drive shaft.
• Remove the feeler gauge (4).
• Finally make sure that the adjustment has left a small gap between the gears (5) and
(7).

0945 Service Manual - Plate Processors 68-85

 Maintenance
3-14
Rollers and brush rollers

Service Manual - Plate Processors 68-85 0945

 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 "MPT Control Panel" manual.

For cleaning and maintenance subjects see the processor user manual and chapter 3 in
this manual.

Use the "TEST FUNCTIONS" parameters on the control panel to test individual
components. See the "MPT 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 may still be
active, making the drive system run idle at intervals. There will be no "bip
advise" or display message when the processor is in stand-by mode or process
mode!

0945 Service Manual - Plate Processors 68-85

 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

Service Manual - Plate Processors 68-85 0945

 Trouble shooting
4-3
Problems with the processor

SYMPTOM PROBABLE CAUSE REMEDY

NO WASH WATER • Water tap closed. • Open water tap.
ALTHOUGH MACHINE IS • Water solenoid valve • Clean filter.
IN “PROCESS” MODE defective.
• Water solenoid valve filter • Open valve.
clogged.
• Processor with filter: Filter • Check sensors and clean/-
valve closed. replace whatever is
necessary.
• Processor with level sensor: • Replace valve.
Level sensor in wash dirty
or defective.
• Electronics defective. • Replace defective
electronics.
DRYER BLOWER WORK, • Fuse(s) blown. • Replace fuse.
HEATER DOES NOT • Temperature sensor • Replace temperature sensor.
defective.
• Heating element defective. • Replace heating element.
• Electronics defective. • Replace defective
electronics.
DRYER BLOWER DOES • Fuse(s) blown. • Replace fuse.
NOT WORK • Blower defective. • Replace blower.
• 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.
• Pump defective. • Replace pump.
• Fuse(s) blown. • Replace fuse.
• Electronics defective. • Replace 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 WORK • Electronics defective. • Replace defective
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 SYSTEM • Replenishment parameters • Make correct settings.
DOES NOT WORK settings not correct.
ALTHOUGH • Electronics defective. • Replace defective
THE MACHINE IS IN electronics.
”PROCESS” MODE

0945 Service Manual - Plate Processors 68-85

 Trouble shooting
4-4
Problems with processed material

SYMPTOM PROBABLE CAUSE REMEDY

NO DEVELOPER • Replenish container empty. • Fill replenish container.
CIRCULATION • Fuse(s) blown. • Replace fuse.
• Processors with filter: Filter • Replace filter insert.
clogged.
• Processors with filter: Filter • Open valve.
valve closed.
• Developer circulation pump • Replace pump.
defective.
NO WATER CIRCULATION • Pump defective or clogged. • Clean and/or repair 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,BUT NO PLATE defective. gears on rollers, and make
TRANSPORT sure they move freely.
Replace any defective part.

Problems with processed material

SYMPTOM PROBABLE CAUSE REMEDY
PLATE IS NOT • Dryer temperature is set too • Set dryer temperature a
COMPLETELY DRY low. little higher.
• 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-WISE OR guides. out, inspect and wash them.
CROSSWISE Rollers with dents or other
marks must be changed.
• Wash spray tubes clogged. • Clean the spray tubes.
See Part 3.

Service Manual - Plate Processors 68-85 0945

 Trouble shooting
4-5
Problems with processed material

SYMPTOM PROBABLE CAUSE REMEDY

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 pumps"
does not run. in Part 4.
• Rollers dirty in wash • Clean rollers.
section.
PLATE HAS AN UNEVEN • Gum container nearly • Refill container.
GUM empty.
• Gum rollers dirty. • Take rollers out and clean
them.
• Gum distributing roller not • Correct the placement of
in place. the roller.
• Gum pump clogged. • Take pump apart and clean
valves.

0945 Service Manual - Plate Processors 68-85

 Trouble shooting
4-6
Problems with processed material

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-1

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.
The Service Technician must download software and instructions from:
www.glunz-jensen.com.

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-2

10

9 11

7 8

12
13
6

15
5
1 2

16
3

14

T8475
PANELS

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-3
Panels

Panels
Pos. No 68 85 Specification

1 SEE APPENDIX A
2 22859 22859 PANEL, SHADOW
3 35369 35369 CLIPS, PANEL, Z3239.5010
4 SEE APPENDIX A
5 SEE APPENDIX A
6 35362 35362 HANDLE, SOUTHCO TP. P2-44
7 10008119 SPRING, GAS, 200N, 265,5/100, 7321PI,DAMPED
10008120 SPRING, GAS, 250N, 265.5/100, 2698TP,DAMPED
8 25823 25823 CIRCLIP D4X0.7 RA-4-411-ME DIN 6799
9 45927 45927 HINGE, SOUTHCO, 96-50-520-50
10 45926 45926 HINGE, SOUTHCO, 96-50-510-50
11 SEE APPENDIX A
12 45891 45891 ACTUATOR, SAFETY, SWITCH, AZ17/170-B5
13 45865 45865 BUSHING, 258-68, D45/50X1.6
14 15262 15262 NUT M6/D10X18
15 87571 87571 ROLLER, W/HOLDER
16 10012806 10011480 GUIDE, EXIT, ROLLER
17
18
19
20
21
22
23
24
25
26
27
28
29

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-4

4
8

10

1 9
5

11

13

12

3
14

2
T8518

STAND

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-5
Stand

Stand
Pos. No 68 85 Specification

1 1388 1388 STOPPER D120X10

2 35359 35359 LEG, TRAPEZOID, D40, METAL
3 35360 35360 NUT, LEG, ADJ.TRAPEZOID 36-KM 1
4 45865 45865 BUSHING, 258-68, D45/50X1.6
5 0063966 0063966 BUSHING 258-66
6 SEE APPENDIX A
7 SEE APPENDIX A
8 SEE APPENDIX A
9 10001618 10001618 BRACKET, ATTACHMENT, STAND
10 10001424 10001424 SCREW, M6X16, HE, HFC8007
11 10007033 10007033 STOPPER, DOMED, BLANKING, D38
12 35358 35358 BUSHING, TRAPEZOID, D40X2
13 10009615 10009615 GASKET, D41/33/2
14 57173 57173 LEG, TRAPEZOID
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-6

T8477
2

STAND CLOSED

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-7
Stand, closed

Stand, closed
Pos. No 68 85 Specification

1 SEE APPENDIX A
2 SEE APPENDIX A
3 50946 50946 BRACKET, LATCH
4 35279 35279 LATCH, SWELL FOR PANEL, SIDE, STAND
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-8

EXIT TABLE

T8478

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-9
Exit, table

Exit, table
Pos. No 68 85 Specification

1 SEE APPENDIX A
2 SEE APPENDIX A
3 SEE APPENDIX A
4 SEE APPENDIX A
5 45804 45804 LINCH PIN D41X4.5, PLATED YELLOW
6 74616 74616 EDGE, PROFILE, TABLE, EXIT
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-10

10

6
8

11
7
3 1

11

T8479
FEED TABLE

Service Manual - Plate Processors 68-85 1135

 Spare parts
5-11
General

Feed table
Pos. No 68 85 Specification

1 SEE APPENDIX A
2 SEE APPENDIX A
3 54381 54381 PIN, GUIDE, TABLE, FEED
4 15262 15262 NUT M6/D10X18
5 SEE APPENDIX A
6 85271 98116 GUIDE, ENT, UP
7 87571 87571 ROLLER, W/HOLDER
8 98026 98026 STOP, EMERGENCY
9 85242 98048 BRACKET, SENSOR, INPUT
10 16787 16787 SWITCH, ASSY 10-59220-010
11 15263 15263 SCR M6X30 HE ELZ
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-12
General

9
1

See "Pump/-
4 Circulation"

5
12

13
6 10

11

T8487

HANDSHOWER AND CONTAINER LEVEL SENSORS

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-13
General

Handshower and level sensors

Pos. No 68 85 Specification

1 35315 35315 HOLDER, PIPE D20

2 74388 74388 GASKET, EPDM, SHORE70, 24X17X2
3 10002936 10002936 FITTING, HANDSHOWER
4 10003060 10003060 HOSE, 1/2"X3/4"RGX2.5M
5 45911 45911 GASKET, FIBER, ½", D18X12.5X2
6 0011361 0011361 FIT. VALVE, BALL ½" MA/FE
7 10003029 10003029 CHECKVALVE, DW14/DN10GF
8 73901 73901 JET, SHOWER, RAPTOR
9 45932 45932 HOLDER, PIPE, D16, W.LOCK
10 10002724 10002724 SENSOR, LEVEL, 2-PIN, REPLENISH/WASTE
11 10003282 10003282 TUBE, SUCTION, REPLENISH
12 6323 6323 CLAMP, HOSE D13-27
13 54208 54208 BRACKET, SENSOR, LEVEL, REPLENISH
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-14
General

4
6
7
3 4

8 3
1

14
21 41 5
21 2
39
22
15
2
38
15 10

22 11
9 12 13

11

12
40 16 11
14
12
17 6
7
16 16
18 23
18 55
19 8
19 23 55
20 20 16 56
23 25
18 23 55 55
23 57
19
20 28
24 56
23 30 31
42
27 29
32 26 55
45 16
18 16
33
20 19 18
33 19
33 20 52
43 34 35 51
33
34
53
46 53
54 52
36 46
37 50
33
60
59
33 33 49 Dev

58 46
52 53 53
43 47 52
51
54 44
46 33 48
46 33
Wash
33
46
61
59 33
58 T8481
48
62
PUMP/CIRCULATION

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-15
Pump / circulation

Pump / circulation
Pos. No 68 85 Specification

1 98274 98274 STANDPIPE

2 6169 6169 O-RING D20X2
3 14458 14458 SPRING, STANDPIPE D30X25
4 73016 73016 BRACKET, DRAIN, OVERFLOW
5 88500 88500 STANDPIPE, DEV
6 10009485 10009485 BUSHING, SPRING
7 74226 74226 SPRING, D12.5, T1.6, L19, K12.3
8 10003357 10003357 SPRING, SILICONE, SPRAY
9 10011348 10011348 PUMP, BELLOW, KBR-2XAUM, W.PLUG
10 10003120 10003120 PUMP, OSC., TP.17000-157
11 15510 15510 CLAMP, HOSE D10-16
12 10001635 10001635 HOSE, PVC, 9X13, RED (PER M)
13 25852 25852 FIT. TEE, HOSE D10X90’ TS10
14 36342 36342 FITTING, OUTLET, PUMP, KBR
15 36343 36343 FITTING, NUT, PUMP, KBR
16 73195 73195 BUSHING, TUBE
17 32796 32796 TUBE, CIRCULATION
18 73193 73193 BUSHING, SUPPORT, TUBE
19 25344 25344 O-RING D22.1X1.6
20 32796 32796 TUBE,CIRCULATION (PER M)
21 10003917 10003917 VALVE, POPPET, ASSY., PUMP, BELLOW, IWAKI
22 36341 36341 FITTING, INLET, PUMP, KBR
23 6019 6019 CLAMP, HOSE D8-22
24 10003130 10003130 FITTING, MANIFOLD, SPRAY, WASH
25 10003168 10003168 FITTING, MANIFOLD, SPRAYBAR, DEV
26 10037727 10037727 NUT M12 HE 4 934
27 35386 35386 O-RING D16.3X2.4 FPM
28 87520 87520 SENSOR, LEVEL, 2-PIN, 90 DEGREE
29 43724 43724 SENSOR, TEMP NTC (90mm CABLE)
30 74070 74070 FITTING, BUSHING, 3/8"RGXD6

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-16

4
6
7
3 4

8 3
1

14
21 41 5
21 2
39
22
15
2
38
15 10

22 11
9 12 13

11

12
40 16 11
14
12
17 6
7
16 16
18 23
18 55
19 8
19 23 55
20 20 16 56
23 25
18 23 55 55
23 57
19
20 28
24 56
23 30 31
42
27 29
32 26 55
45 16
18 16
33
20 19 18
33 19
33 20 52
43 34 35 51
33
34
53
46 53
54 52
36 46
37 50
33
60
59
33 33 49 Dev

58 46
52 53 53
43 47 52
51
54 44
46 33 48
46 33
Wash
33
46
61
59 33
58 T8481
48
62
PUMP/CIRCULATION

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-17
Pump / circulation

Pump / circulation
Pos. No 68 85 Specification

31 35355 35355 O-RING D5.0X2.5 EPDM

32 10060371 10060371 PUMP, CIRCULATION, MEDIUM
33 6323 6323 CLAMP, HOSE D13-27
34 10004622 10004622 HOSE, ELBOW 90, MODIFIED
35 45789 45789 CARTRIDGE, HEATER, 1000W, W CABLE
36 8181X000700 8181X000700 O-RING, 15.88 X 2.62
37 74492 74492 NUT, UNION, MALE, 3/4"RG X 16.3
38 10004402 10004402 O-RING, ASSEMBLY, PUMP, BELLOW, IWAKI
39 74399 74399 PIN, CYLINDRE, D8/D6 FOR SPRING
40 73305 73305 PUMP, BELLOW, KBR-3X, W.PLUG
41 8372 8372 SPRING, CONICAL
42 10060371 10060371 PUMP, CIRCULATION, MEDIUM, or W. WASH FILTER
10003389 10003389 PUMP, MD-15 W.O. WASH FILTER
43 6019 6019 CLAMP, HOSE D8-22
44 15770 15770 INSERT, FILTER, 50MY
45 85706 85706 FITTING, HOSE, 1/2"-D20, MODIFIED
46 10003177 10003177 HOSE, D16 MM, REINF. (PER M)
47 10003403 10003403 VALVE, SOLENOID FOR TAPWATER
48 7077 7077 DRAIN VALVE ½"
49 35879 35879 FILTER, BOTTOM.
50 SEE APPENDIX A
51 35878 35878 FILTER, TOP
52 10004710 10004710 FITTING, ELBOW, SWIVEL, ¾"
53 25380 25380 O-RING D24.99X3.53
54 0012153 0012153 O-RING FOR FILTER CARTRIDGE
55 10008509 10008509 HOSE, RUBBER, 19X27, 1MM, EPDM, BLACK
56 6042 6042 CLAMP, HOSE D20-32
57 10008698 10008698 FITTING, WASTE
58 10002474 10002474 BRACKET, WATER VALVE
59 10003506 10003506 HOSE, PUMP, MD-15, CIRC.WASH

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-18

4
6
7
3 4

8 3
1

14
21 41 5
21 2
39
22
15
2
38
15 10

22 11
9 12 13

11

12
40 16 11
14
12
17 6
7
16 16
18 23
18 55
19 8
19 23 55
20 20 16 56
23 25
18 23 55 55
23 57
19
20 28
24 56
23 30 31
42
27 29
32 26 55
45 16
18 16
33
20 19 18
33 19
33 20 52
43 34 35 51
33
34
53
46 53
54 52
36 46
37 50
33
60
59
33 33 49 Dev

58 46
52 53 53
43 47 52
51
54 44
46 33 48
46 33
Wash
33
46
61
59 33
58 T8481
48
62
PUMP/CIRCULATION

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-19
Pump / circulation

Pump / circulation
Pos. No 68 85 Specification

60 10002949 10002949 VALVE, SOLENOID, COMPLETE TAPWATER

61 10003068 10003068 VALVE, SOLENOID,COMPLETE RECIRCULATION
62 25700 25700 VALVE, SOLENOID ES 90/88 3.3L/MIN
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-20

7
6
5
4

3
2 7
1 28 27
4 3226
37 35 4 27
25 4 28
24 26 33
4 34 18
18 26 28
21 27 36 26
4
32
20
19 23
23
13
30 33
4
4
29 9
8
16

31 11 10
12
22 11
15
14

13

12

17

T8482
DRIVE

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-21
Drive

Drive
Pos. No 68 85 Specification

1 73209 73209 GEAR, Z22, M2, LEFT

2 10002910 10002910 BEARING, DRIVE
3 10002994 10002994 O-RING D21X1.5 EPDM
4 73241 73241 CLIPS, R-SHAPE, D2.5X20
5 73242 73242 SHAFT, GEAR
6 6520 6520 GROMMET, V-SEAL
7 73240 73240 GEAR, Z16, M2
8 73246 73246 GEAR, Z18, M2
9 98170 98170 FILTER, MOTOR
10 5659 5659 FUSE 5.0A, 6.3X32, S/B
11 10020012 10020012 MOTOR, AF 103.606 24V W. SENSOR
12 88102 88102 BEARING, BRACKET (See instruction in chapter 3)
13 10016983 10016983 GEAR, Z26, M2, D12 (See instruction in chapter 3)
14 85569 85569 BRACKET, BEARING (See instruction in chapter 3)
15 73250 73250 WORM, LEFT, Z2, M2, D12 (See instruc. in ch. 3)
16 98936 98936 BRACKET, BEARING (See instruction in chapter 3)
17 85886 85886 DRIVE, MAIN (See instruction in chapter 3)
18 10022265 10022265 BEARING, DRIVE, BRUSH, COMPLETE
19 10002653 10002653 GEAR, CONICAL, Z20,M1.5,D12
20 10002651 10002651 SHAFT, DRIVE, BRUSH,WASH
21 6169 6169 O-RING D20.24X2.62 EPDM
22 63991 63991 GEAR, CONICAL, Z30(20), M1.5
23 10002034 10002034 SHAFT, DRIVE, BRUSH, DEV (See instruc. in ch. 3)
24 6302 6302 O-RING, D17.1x1.6
25 10016917 10016917 GROMMET, V-SEAL VA-0012RUB
26 73262 73262 GEAR, Z19, M2, D12
27 1860 1860 O-RING D12.1X1.6 NOT ALL MODELS
28 10052597 10052597 STOPPER, D15/M8 NOT ALL MODELS
29 10003438 10003438 FILTER, MOTOR
30 10002642 10002642 GEAR, Z16, M2, D12

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-22

7
6
5
4

3
2 7
1 28 27
4 3226
37 35 4 27
25 4 28
24 26 33
4 34 18
18 26 28
21 27 36 26
4
32
20
19 23
23
13
30 33
4
4
29 9
8
16

31 11 10
12
22 11
15
14

13

12

17

T8482
DRIVE

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-23
Drive

Drive
Pos. No 68 85 Specification

31 6896 6896 FUSE 4A, 6.3X32 MM

32 10052400 10052400 GEAR Z13 D10/28X6 M=2 NOT ALL MODELS
33 22905418 22905418 END, STOP, O16 NOT ALL MODELS
34 10021870 10021870 BEARING, DRIVE, BRUSH
35 10052622 10052622 SHAFT, GEAR, W. O-RING NOT ALL MODELS
36 10052623 10052623 SHAFT, GEAR, BRUSH, W. O-RING NOT ALL MODELS
37 10015930 10015930 SUPPORT, SEAL, BEARING, BRUSH
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-24

37
34
33 34

35
33 3 16 14 14 3 17 45
1
2
37 36

34 34
3

4 16
2 5
14
13
4 15 15 4 8 46

6 13
5 7
6
11 9
10
12
3
4
5 8
5
13
15

5
13
10 2
5 11
13
12

17
28
45
18
29
48
19 46
2 28
13
30
5 6
5
6 21
20 22
31

27
25
24
23
32 26

43 40
47 44 39
38
47 41
43 42
T8483
DEVELOPER

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-25
Developer

Developer
Pos. No 68 85 Specification

1 10004081 10002207 LID, CONDENSATION, DEV

2 43600 43600 BEARING, ROLLER, SNAP, BLACK
3 88958 98233 ROLLER, SH30, STRAIGHT, WITH GEAR
4 88960 88959 ROLLER, SH40, WITH GEAR
5 73262 73262 GEAR, Z19, M2, D12, B15
6 74038 74038 GUIDE, PLATE, GEAR
7 315FJ0055 315FJ0055 CIRCLIP, STAINLESS
8 SEE APPENDIX A
9 10004646 10004646 GUIDE, SILICONE, D25
10 10006668 10006668 NUT, M22
11 35434 35434 O-RING 13.3x2.4 EPDM
12 10006670 10006670 VALVE, TUBE, SPRAY
13 73241 73241 CLIPS, R-SHAPE, D2.5X20
14 85745 85296 BRUSH, D40, W. GEAR, PP 0.10 WHITE RUSH
10001483 10001482 BRUSH, D40,W. GEAR,PP 0.075 LAC RUSH
15 73921 63751 ROLLER, PUR, D40
16 SEE APPENDIX A
17 10002485 10002482 ROLLER, RUBBER, D25
18 10009794 10009779 GUIDE, DEV, REAR, COMPLETE
19 10009793 10009763 GUIDE, DEV, FRONT, COMPLETE
20 10002764 10002764 TUBE, COOLING
21 32383 32383 SENSOR, LEVEL, 2-PIN, 90 DEGREE
22 35386 35386 O-RING D16.3X2.4 FPM
23 10003357 10003357 SPRING, SILICONE, SPRAY
24 74226 74226 SPRING, D12.5, T1.6, L19, K12.3
25 10009485 10009485 BUSHING, SPRING
26 73822 73822 DRIVE, FREE WHEEL
27 10009459 10009459 BEARING, ROLLER, GUIDE
28 10008713 10008713 BEARING, BRUSH, RIGHT, COMPLETE
29 10011407 10011407 BEARING, ROLLER, RIGHT, COMPLETE

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-26

37
34
33 34

35
33 3 16 14 14 3 17 45
1
2
37 36

34 34
3

4 16
2 5
14
13
4 15 15 4 8 46

6 13
5 7
6
11 9
10
12
3
4
5 8
5
13
15

5
13
10 2
5 11
13
12

17
28
45
18
29
48
19 46
2 28
13
30
5 6
5
6 21
20 22
31

27
25
24
23
32 26

43 40
47 44 39
38
47 41
43 42
T8483
DEVELOPER

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-27
Developer

Developer
Pos. No 68 85 Specification

30 10011020 10011020 BEARING, ROLLER, BLACK, 20 KG, COMPLETE

31 10011006 10011006 BEARING, ROLLER, DARK GREY, 6 KG, COMPLETE
32 10009459 10009459 BEARING, ROLLER, GUIDE
33 10002348 10002328 ROLLER, PUR, D30, HEAVY, ST
34 0061432 0061432 CIRCLIP, A12-411, DIN471 A2
35 10002598 10002585 SHAFT, ROLLER, D12
36 6293 6293 HANDLE, BLACK
37 10015420 10015420 BRACKET, ROLLER, PUR
38 10005522 10005522 SHAFT, INTERMEDIATE WHEEL
39 73240 73240 GEAR, Z16, M2
40 15420 15420 SCR M6X12 CR P 4
41 5109 5109 WASHER 6 MM
42 5072 5072 NUT, M8 HE 4
43 10011406 10011406 BEARING, BRUSH, LEFT, COMPLETE
44 10011414 10011414 BEARING, ROLLER, LEFT, COMPLETE
45 SEE APPENDIX A
46 SEE APPENDIX A
47 10008621 10008621 SHELL, BEARING
48 54430 54430 BEARING, ROLLER, LOWER, SPRINGLOAD
49
50
51
52
53
54
55
56
57
58
59

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-28

2 6 11 13 2
2

5
6
1 3
4
10

4
15 11
3 9
15 5 10 12 5
8
7 12
9
8
7 13

4
1
3
8 2
9

7
20
19
18
1 3 20 16
4 5

23
15 21
3
15

22

14
17

17

T8484

WASH

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-29
Wash

Wash
Pos. No 68 85 Specification

1 43600 43600 BEARING, ROLLER, SNAP, BLACK

2 88958 98233 ROLLER, SH30, STRAIGHT, WITH GEAR
3 73262 73262 GEAR, Z19, M2, D12, B15
4 73241 73241 CLIPS, R-SHAPE, D2.5X20
5 88960 88959 ROLLER, SH40, WITH GEAR
6 10004406 10004336 TUBE, SPRAY, WASH COMPLETE
7 10006670 10006670 VALVE, TUBE, SPRAY
8 35434 35434 O-RING 13.3x2.4 EPDM
9 10006668 10006668 NUT, M22
10 10004634 10004626 TUBE, SPRAY, WASH, REAR, COMPLETE
11 10001483 10001482 BRUSH, D40, WITH GEAR (BLACK BRUSH)
12 73921 63751 ROLLER, PUR, TUBE, D40
13 10004422 10004367 TUBE, SPRAY, WASH, FRONT, COMPLETE
14 10011406 10011406 BEARING, BRUSH, LEFT, COMPLETE
15 74038 74038 GUIDE, PLATE, GEAR
16 54430 54430 BEARING, ROLLER, LOWER, SPRINGLOAD
17 10008621 10008621 SHELL, BEARING
18 10003357 10003357 SPRING, SILICONE, SPRAY
19 74226 74226 SPRING, D12.5, T1.6, L19, K12.3
20 10009485 10009485 BUSHING, SPRING
21 10011020 10011020 BEARING, ROLLER, BLACK, 20 KG, COMPLETE
22 10008713 10008713 BEARING, BRUSH, RIGHT, COMPLETE
23 10011013 10011013 BEARING, ROLLER, WHITE, 13 KG, COMPLETE
24
25
26
27
28
29
30

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-30

6 1 34

2
7
6
9

9
8
7
8
3

12

10
5

11

T8485

GUM

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-31
Gum

Gum
Pos. No 68 85 Specification

1 88958 98233 ROLLER, SH30, STRAIGHT, WITH GEAR

2 88960 10045639 ROLLER, SH40, WITH GEAR
3 10014796 10014797 TUBE, GUM
4 10002348 10002328 ROLLER, PUR, D30
5 10002374 10002373 GUIDE, GUM
6 43600 43600 BEARING, ROLLER, SNAP, BLACK
7 73262 73262 GEAR, Z19, M2, D12,B15
8 74038 74038 GUIDE, PLATE, GEAR
9 73241 73241 CLIPS, R-SHAPE, D2.5X20
10 10011020 - BEARING, ROLLER, BLACK, 20 KG, COMPLETE
- 10011013 BEARING, ROLLER, WHITE, 13 KG, COMPLETE
11 10007515 10007515 BEARING, ROLLER, DISTR., GUM
12 54430 54430 BEARING, ROLLER, LOWER, SPRINGLOAD
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-32

12
5
8

2
10 4
6
9 11
3

13

8
10 1
6

22
17
20
21
16 19

18 14

15

T8486
DRYER

Service Manual - Plate Processors 68-85 1119

 Spare parts
5-33
Dryer

Dryer
Pos. No 68 85 Specification

1 10002845 10002845 HOUSING, FAN/HEATER

2 54563 54563 CAPACITOR, 2uF
3 73982 73982 FAN, 2TRE15 W PLUG
4 63043 63043 HEATER 2x750W W.PLUG
5 10003381 10003381 COVER, FAN, HEATER
6 73262 73262 GEAR, Z19, M2, D12, B15
7 86083 86082 COVER, DRYER, COMPLETE
8 73241 73241 CLIPS, R-SHAPE, D2.5X20
9 10013520 10013520 BEARING, ROLLER, SNAP
10 10002826 10002826 WHEEL, RUBBER, D40
11 10003013 10003010 GUIDE, ROLLER, D40
12 10003014 10003011 GUIDE, ROLLER, D40
13 10008065 10006012 AIRDUCT, UPPER
14 10008070 10006023 AIRDUCT, LOWER
15 0151083 0151083 GRID, FAN INCL.TAP
16 41554 41258 BRACKET, GUIDE, HEATER
17 32332 32332 GUIDE, DRYER
18 26385 26385 SENSOR, TEMP THERMISTOR,PLASTIC
19 16787 16787 SWITCH, ASSY
20 74500 74500 BRUSH, ANTISTATIC
21 10011006 10011006 BEARING, ROLLER, DARK GREY, 6 KG, COMPLETE
22 54430 54430 BEARING, ROLLER, LOWER, SPRINGLOAD
23
24
25
26
27
28
29
30

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-34

23

22

19
18
17 11
16
21
20
15

14
10

26
12 27
9 25

6
8
12 13 7
3
4

24
2

T8480
ELETRICAL

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-35
Electrical

Electrical
Pos. No 68 85 Specification

(Not ill.) 10017976 10017976 CD W.SOFTWARE (Please also see page 5.1)
1 10035096 10035096 PCB, HPU-V (NOTE: Without software - see page 5.1)
2 10031624 10031624 PCB, MPU (NOTE: Without software - see page 5.1)
3 6716 6716 FUSE 2A, 6.3X32 MM, S/B
4 6896 6896 FUSE 4A, 6.3X32 MM
5 26508 26508 FUSE 15A SC15
6 35016 35016 SPACER M4X8+25 TP.DI654
7 36563 36563 PCB, FUSE, F. SINGLE HPU, W. VARISTOR
8 36311 36311 TRAFO, RTD300-230
9 36312 36312 TRAFO, RTD060-224
10 10030889 10030889 PCB, FILTER, 2xTRANSFORMER, 4A-PTC-RESISTOR
11 16414 16414 SWITCH, L2-16, 66.5X66.5
12 0151083 0151083 GRID, FAN INCL.TAP
13 26054 26054 FAN, SUNON DP200A 2123XBT
14 10025327 10025327 PCB, MMU (NOTE: Without software - see page 5.1)
15 88129 88129 MMI, CONTROLBOX
16 10030625 10030625 GFCI, 40A/30mA 400V 4-POL
17 45512 45512 SPACER, M6X35+10, TP.DI659
18 3111X000800 3111X000800 STRIP, TERMINAL
19 36501 36501 LOCKNUT FOR CABLE GLAND M32x1,5
20 36500 36500 GLAND,CABLE,ST-M 32x1.5
21 0180216 0180216 NIPPEL, RUBBER RM 10419
22 10061083 10061083 INTERLOCK, SWITCH, S8
23 57971 57971 CONNECTOR,CHILLER
24 10001713 10001713 PIM, MK2 NOT ALL MODELS
25 53794 53794 COVER, PANEL, FUSE
26 10040265 10040265 FUSE, 5x20 mm, 0.63 AT (F17)
27 10011111 10011111 FUSE, 5x20 mm, 3.15 AT (F18)
28
29
30

1119 Service Manual - Plate Processors 68-85

 Spare parts
5-36

Service Manual - Plate Processors 68-85 0945

 Spare parts
5-37
Cables (not illustrated)

Cables (not illustrated)

Pos. No 68 85 Specification

98286 98286 CABLE, HIGH VOLTAGE, WIRINGII

97976 97976 CABLE, TEMP./INPUT SENSORS

10003044 10003044 CABLE, CONTAINER SENSORS
97980 97980 CABLE, VALVES, WATER
97982 97982 CABLE, TRANSPORT MOTOR
98517 98517 CABLE, GNUIB, MPU-HPU/MMU, 0.6M
85696 85696 CABLE, EMERGENCY SWITCH, S8
85630 85630 CABLE, EMERGENCY-STOP

98285 98285 CABLE, VOLTAGE, STANDARD

10020142 10020142 CABLE, BRUSH MOTOR
88377 88377 CABLE, HPU-TRAFO
10024712 10024712 CABLE, SENSORS, LEVEL, HPUV
10013508 10013508 CABLE, TRANSPORT MOTOR, CONVERTER

0945 Service Manual - Plate Processors 68-85

 Spare parts
5-38

Service Manual - Plate Processors 68-85 0945

 Appendix A:
A-1
Additional spare parts

Appendix A: Additional spare parts

Some of the spareparts shown on the ISO-metric drawings in chapter 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 chapter 5.
Please also refer to the ISO-metric drawings in chapter 5.
When ordering spareparts please state carefully the sparepart number, the
specification and the number of items wanted before you send your order.

Pos.No 68 85 Specification

Page 5/3 (PANELS):

1 86059 86059 FENDER, PANEL, RIGHT
4 70297 70297 FENDER, LEFT
5 10012803 10011567 COVER, DRYER
11 70302 70295 PANEL, TOP, HINGED

Page 5/5 (STAND):

6 70327 70327 RAIL, STAND
7 10001308 86136 PANEL, FRONT, STAND
8 10001311 86140 PANEL, REAR, STAND

Page 5/7 (STAND, CLOSED):

1 10001344 10001344 PANEL, RIGHT, STAND
2 10001345 10001345 PANEL, SIDE, LEFT, STAND

Page 5/9 (EXIT, TABLE):

1 10005921 10002433 EXTENSION, TABLE, EXIT
2 10005918 10002432 TABLE, EXIT
3 10002429 10002429 BRACKET, TABLE, EXIT
4 60881 60881 SUPPORT, TABLE, EXIT

continues

0945 Service Manual - Plate Processors 68-85

 Appendix A:
A-2
Additional spare parts

Pos.No 68 85 Specification

Page 5/11 (FEED, TABLE):

1 10009059 10009048 TABLE, FEED
2 10009056 10009042 SUPPORT, TABLE, FEED
5 10060310 10060111 PANEL, FRONT, COMMON

Page 5/17 (PUMP / CIRCULATION):

50 15770 15770 INSERT, FILTER 50MY

Page 5/25 (DEVELOPER):

8 10005179 10004680 TUBE, SPRAY, DEV, FRONT, COMPLETE

INDICATION OF SPRAY TUBE DIRECTION

8

8 10007602 10007601 TUBE, SPRAY, DEV, FRONT, COMPLETE

16 10007183 10007181 TUBE, SPRAY, DEV, REAR, COMPLETE

16

INDICATION OF SPRAY TUBE DIRECTION

INDICATION OF SPRAY TUBE DIRECTION

8

continues

Service Manual - Plate Processors 68-85 1135

 Appendix A:
A-3
Additional spare parts

Pos.No 68 85 Specification

Page 5/25 (DEVELOPER):

8 85749 88145 TUBE, SPRAY, DEV, FRONT, COMPLETE
16 10008009 10007894 TUBE, SPRAY, DEV, REAR, COMPLETE

16

INDICATION OF SPRAY TUBE DIRECTION

INDICATION OF SPRAY TUBE DIRECTION

8

Page 5/27 (DEVELOPER):

45 88958 98233 ROLLER, SH30, STRAIGHT, WITH GEAR
46 88960 88959 ROLLER, SH40, WITH GEAR

0945 Service Manual - Plate Processors 68-85

 Appendix A:
A-4
Additional spare parts

Service Manual - Plate Processors 68-85 0945

 Appendix B:
B-1
Electrical diagrams

Appendix B: Electrical diagrams

This chapter includes all electrical diagrams for the processor.

The diagrams (6 pages) cover:

• Page 1 of 6:
Main power distribution
Fuse panel and interlocks
• Page 2 of 6:
High voltage wiring I
230V AC, control devices, HPU
• Page 3 of 6:
High voltage wiring II
230V AC, components
• Page 4 of 6:
High voltage wiring III
230V AC, control devices, LPM
• Page 5 of 6:
Low voltage wiring
Sensors and control devices
• Page 6 of 6:
Motors and internal bus wiring
8, 24 and 35V AC distribution

0945 Service Manual - Plate Processors 68-85

B-2
Main power distribution

Main power distribution

Fuse panel and interlock

Service Manual - Plate Processors 68-85 0945

 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
A
Return 3 A

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
High Voltage Wiring
X7 2 1 1 F2 15 AT
Red Red Phase3 Diagram, page 2
Phase 1
and 3
5
Field Wiring Box Main switch F4 15 AT
RV1 Return 1
6
F6 15 AT
Single Phase, 230V 2 W + PE or 1W+N+PE
B B

S21 F7 2AT
Black 12 11 Black
C2 C3 C4 F8
PE 4AT
10 9 Organge 4n7 Y2 4n7 Y2 4n7 Y2
Orange
Ground Fault Interruptor Fuse Panel X1 X2
X1 short circuit
F10 Blue 8 7 Blue
on PCB 1 2 1 2 3 4
4 Blue N
X10
I Brown 6 5 Brown Appliance coupler
3 Brown 6 5
L2(N) . . for Stacker
blue
L IN
RTN IN
blue
yl/gr

brown

Yellow 4 3 Yellow
2 Yellow 4 3 yl/gr
L1 . .

2 1 Red brown
1 2 1 Red
Red . .
To optional LPM PCB,
X7 Main switch see page 4
Field Wiring Box
X57 X1 X41
C PCB Transformer Filter C

240 OR1 Orange: 240V T1

Grey 1
230 RD1 Red: 230V To HPU, J1,1
Three Phases With Neutral, 400V, 3 W + N + PE 8.5V Grey 2
200 BN1 Brown: 200V To HPU, J1,5
White 3
240 BK1 110 °C To HPU, J1,2
S21 24V White 4
230 OR2 Black: 0V To HPU, J1,6
Black 12 11 Black
PE 200 RD2 Built-In thermoswith with
RTN OUT BN2 automatic reset Transformer secondary
Orange 10 9 Organge
Ground Fault Interruptor X2, 2 RTN IN BK2 connections
F10 C1 are shown on page 6
L OUT 100nF L1
4 Blue N N Blue 8 7 Blue X40
N X2, 1 L IN Orange: 240V T2
R2 Violet 1
I Red: 230V To HPU, J1,3
3 Brown 6 5 Brown 6 5 Brown 30V Violet 2
L3 . . Brown: 200V To HPU, J1,7
R1 Green 3
110 °C To HPU, J1,4
2 Yellow 4 3 Yellow 4 3 Yellow F17 30V Green 4
L2 . . F18 Black: 0V To HPU, J1,8
1 0.63AT
3.15AT
1 Red 2 1 Red 2 1 Red 2 Built-In thermoswith with
L1 . .
3 automatic reset
D
Option D
X7 4 Orange: 240V T3 (Only on Polymer Variant)
Field Wiring Box Main switch Red: 230V
X52 X51 X50 X43 X42 8.5V
Brown: 200V
1 2 1 2 1 2 1 2 110 °C To RRM PCB
IMPORTANT 24V
Black: 0V shown on
Check wiring at Main Terminal X7, Ground Fault Interruptor F10 and Main page 6.
Built-In thermoswith with
Switch S21 before the power supply is switched on. Rewire if necessary automatic reset
accordingly to attached column on schematics. Also set jumpers as
shown in table below.
11 21 22 12
11 12 11 12 11 12
Jumper Settings :
Line Voltage: Terminal Strip, X7 Fuse PCB GFCI

Three Phases Without Neutral, No jumpers ! X4, X5 and X6 open Jumper between S14 S16 S3 S8
230V, L1, L2, L3 + PE N and 4 Emergency Stop Cover Switch Cover Switch Cover Switch Tank
E Switch Drawer Section Prewash Section Right side E

Single Phase, Without Neutral Jumpers between 1 and 2 X4, X5 and X6 open Jumper between (Not on all Models) (Not on all Models)
230V, L1, L2 + PE Jumpers between 3 and 4 N and 4
Title: Number: Rev.:
Date: Monday, January 14, 2008
Single Phase, With Neutral Jumpers between 1 and 2 X4, X5 and X6 closed Jumper between
230V, L1, N + PE Jumpers between 3 and 4 N and 4 Main Power Distribution JW 63664 M
Constructor:
Function: ELECTRONIC AND MECHANICAL ENGINEERING
Three Phases With Neutral, No jumpers ! X4, X5 and X6 closed Doc. No.:
No jumper ! Approval: This drawing belongs to Glunz & Jens en A/S
400V, L1, L2, L3, N + PE Fuse Panel And Interlocks and m us t not be us ed or handed over to any
unauthorized pers on without our s pecific perm is s ion.
Page: 1 Of: 6 OrCAD
1 2 3 4 5 6 7 8 9 10
B-4
High voltage wiring I

High voltage wiring I

230V AC, control devices, HPU

Service Manual - Plate Processors 68-85 0945

 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

M6,3
X17,2

X16,2
X16,1
X12,2
X37,3
X37,1
X47,9
X26,4
X46,2
X47,8
X47,7
X46,1
X18,2
X15,3
X15,2
X18,1
X14,4
X20,3
X14,3
X20,2
X21,1
X14,2
X14,1

X37,4
X20,4
X15,4
X47,2
X46,8
X46,7
X47,12
X47,1
X26,2
X26,1
X47,11
X54,3
X54,1
X47,13
X47,6
X46,6
X46,5
X47,5
X47,4
X46,4
X46,3
X47,3
X12,3
X46,13
X46,12
X17,1
X47,14

X16,4
X54,4
X46,11
X46,14
X47,15

X54,2

X12,1+X16,3
X47,10+X37,2
K2,6
K2,5
K3,4
K3,3
K3,2
K3,1
K5,6
K5,5

K6,3
K4,2
K2,5
K4,6
K4,5
K4,1
K5,6
K5,5
K3,4
K3,3
K3,2
K3,1
K2,6
K2,4
X47 X46
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

K3,1
K4,2

K4,3
X54
4 3 2 1

X19,4
Plug for Wash Drawer
E9,2

X27,1 &X27,3
X19,3
X19,1
X27,2
X29,4
S13,3
X29,3
X29,2

S13,P1

S13,P3
E10
E11
X33,1

K5,3
K5,1
K6,4
K6,3

K1,1
GND

K1,2
K5,2
K5,3
K6,2
K6,1
K6,4
K6,3
K6,3
X46,1

K6,4
K6,3
X29,1

K2,2
K2,3
K1,1

K1,4
K1,3
X46,2
X46,1
X33,2

X21,2
K5,3
K5,1
X47,9
X47,8

X20,1
K4,6
K4,4
X47,15
X47,11
X47,15
X47,14

K4,5
X46,14

X46,5
X46,6
X46,4
X46,3

X12 X26 X15 X14 X20 X21 X37 X17 X19 X27
X46,11

X29 X33
3 2 1 4 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 4 3 2 1 3 2 1
4 3 2 1 3 2 1

S13

Blue
Black

Yl/grn
Brown
75 °C 75 °C P3 P2 P1
M M M M X16 M M M M
M

750W
C1
M3 M4 750W 750W M9 M6 M23 M5 K1 M10 C2
3 2 1

M27
70 °C E2 E3 M7
176 °C
Dev. Circ. Dev. Repl. Dryer Motor Capacitor Electronic Plug For Gum Circ Prewash Dev Fill Wash Circ. 3 2 1
Dryer Heating, Prewash Preheat Motor Capacitor
E1

250W
Pump Pump Blower Dryer Blower Fan Chiller Pump Motor Pump Pump
E2 : basis Pump blower Dryer Blower
Blower
E3 : reg.
Dev. Heating

Preheater

K4,6
K4,4
K4,5
X47,9

X37
X47,15
X47,11

4 3 2 1 X19 Chassis E10 E11

4 3 2 1
1350W 1350W

Prewash
K1
1350W E11
Plate travel
Gum Circ 1350W E10
Pump Entry
OPTION: Valid for model without quickfill-up pump
THIS DIAGRAM IS VALID FOR THE MODELS
MENTIONED IN THE TABLE BELOW
Power components mounted on :

HPU K1,1+2 K1,3+4 K2,1/2+3 K2,4/5+6 K3,1+2 K3,3+4 K4,1/2+3 K4,4/5+6 K5,1+3 K5,2+3 K5,4/5+6 K6,1+2 K6,3+4
Variant
M9+10
Thermal, Standard M3 E1 Chiller None None None K1 M23 M6 M4 None E3
+E2
Polymer, with prewash M5+9+10
M3 E1 Chiller E9 E11 E10 K1 M23 M6 M4 M7 E3
and/or preheat +E2
Title: Number: Rev.:
Polymer, with prewash, without quickfill-up pump M5+9+10 Date: Monday, January 14, 2008
M3 E1 Chiller E9 E11 E10 None K1 M6 M4 M7 E3 High Voltage wiring I
and/or preheat +E2
Constructor: TGJ 63664 M
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
SPECIAL MODEL unauthorized person without our specific permission.
Page: 2 Of: 6 OrCAD
B-6
High voltage wiring II

High voltage wiring II

230V AC components

Service Manual - Plate Processors 68-85 0945

 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

From X11,
RV418 RV419 RV417 RV420 RV424 RV421 RV423 RV422 RV428 RV425 RV427 RV426
Fusepanel
BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16

Q425 Q427 Q426 Q424 Q429 Q430 Q431 Q428 Q433 Q432 Q435 Q434

S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
F10 F11
F13 F12 F14
1AT 1AT
1AT 1AT 1AT
K6
K2 K1 K4 K3 K5
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

M6,1

X15,4
X16,3
X12,3
X46,11
X46,14
X46,8
X47,2
X47,12
X46,7
X47,1
X16,2
X16,1
X12,2
X12,1
X47,11
X37,3
X47,10
X37,1
X38,2
X38,1
X47,9
X46,6
X47,6
X47,5
X46,5
X47,4
X47,3
X20,4
X38,3
X37,4
X18,3
X46,2
X47,8
X47,7
X46,1
X18,2
X15,3
X15,2
X46,12
X44,1
X14,4
X20,3
X46,10
X47,14
X14,3
X21,1
X20,2
X46,9
X14,2
X14,1

X47,15

X47,13
X46,13

E1,4
E13,2
E13,1
K2,5

K4,2

K6,3
K5,6
K5,5
K3,4
K3,3
K3,2
K3,1
K2,6
K2,4

K4,5
K4,1

K4,6

K6,3

K6,4

K4,6
K4,4

K4,5
X47

K6,4
K6,3
K2,6
K2,5
K3,4
K3,3
K3,2
K3,1
K5,6
K5,5

K5,1

K5,3
X46 X37 X17 14 13 12 11 10 9 8 7 6 5 4 3 2 1
To HPU K1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 4 3 2 1 3 2 1

4 3 2 1

K1
connector
C3 40uF in cable
1
X47,6
X47,5
X47,6
X47,5

2
F1
X47,8
X47,7
X47,2
X47,1

X47,12

X47,11
X47,10
X47,11
X47,10

4 3 2 1 X23 X24 X39 X25 X22 X28

- + X62
3 2 1 3 2 1 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1
1 0,8AT
2 D1 3 E15,1
RRM PCB, 4 E15,2
X64 Rectifier
board
Wiring on Eco Variant M
M M M
750W
750W

M15 M14 M18

70 °C 70 °C
Circ. Pump: Circ. Pump: Additive Pump:
Finisher : Rinse Wash-off : M18
250W
250W

M15
Repl. Pump:
Finisher M19,
See Table below for mounted Dev2 K12
Heating element: Heating element:

K2,2
K2,3
K1,1

GND
Finisher E4 Rinse E8

K1,2
K1,1
K4,3
K3,1
K4,2
heating element

K1,4
K1,3
K5,2
X21,2

K5,3
K6,2
K6,1
X20,1

K6,4
K6,3
K6,3

K6,4
K6,3
K5,3
K5,1
X26 X26 X15 X14 X20 X21 X16 X54 Wash-off-2 E5
X12 X26
X61 3 2 1 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 4 3 2 1 3 2 1 4 3 2 1 4 3 2 1
4 3 2 1
Con. on 3 2 1 X54
Pump
K2,5

K4,2

K6,3
K5,6

Plug For
K5,5
K3,4
K3,3
K3,2
K3,1
K2,6
K2,4

K4,5
K4,1

K4,6

Chiller
K4,3
K3,1
K4,2

X47

Yl/grn
Black

Blue
Brown
100°C 14 13 12 11 10 9 8 7 6 5 4 3 2 1
M M M M
Plug for
Wash
Drawer
C1
75 °C
K2 M3 M9 M6
Plug for Wash
1
(Raptor ECO)

Dev. Repl. Plugs at Wash Drawer

Dev. Circ. Pump : M4

750W
Dev. Coating Pump 75 °C Dryer Motor Capacitor Electronic
Pump Dev. Coating Blower Dryer Blower Fan
K1,4
K1,3

Clean Pump : M24

70 °C X38
X34 X38
X47,11
X47,13

3 2 1 3 2 1
4 3 2 1 3 2 1

400W
250W
500W
75 °C 75 °C
X47,8
X47,7
X47,2
X47,6
X47,5

X47,12

X23 X39 X25 X22

X47,11
X47,10

Dev. Heating, E13 Dev. Heating, E1 Preheat, E15 750W 750W

3 2 1 4 3 2 1 4 3 2 1 4 3 2 1
M
E2 E3
70 °C
M17 M
Dryer Heating,
E2 : basis High
Pressure M17
750W

1200W

E3 : reg.
Pump
Heating element:
Wash-off E6 70 °C Circ. pump: M M M M
Wash drawer Wash-off-1
M15 M20 M26 M25
250W

X47 wiring only for Circ. Pump: Wash appl. Gum Water Dev Roller
Wash 1 Heating, E7 Gum Pump Repl. Pump Clean Pump
Components mounted on : Eco variant
HPU
K1,1+2 K1,3+4 K2,1/2+3 K2,4/5+6 K3,1+2 K3,3+4 K4,1/2+3 K4,4/5+6 K5,1+3 K5,2+3 K5,4/5+6 K6,1+2 K6,3+4
Variant
Silver M3, Chiller E13 Chiller M19 E6 E4, E8 M17 M14+15 M6 M4 M18 E3 M9+E2
Title: Number: Rev.:
Date: Monday, January 14, 2008
Eco K2 E15 None M26 E7 M25 M17 M15 M6 M24 M20 E3 M9+E2 High Voltage Wiring II
Constructor: TGJ 63664 M
Function: ELECTRONIC AND M ECHANICAL ENGINEERING
Doc. No.:
Approval: This drawing belongs to Glunz & Jensen A/S
230 VAC Components and must not be used or handed over to any

unauthorized person without our specific permission.

Page: 3 Of: 6 OrCAD
B-8
High voltage wiring III

High voltage wiring III

230V AC, control devices, LPM

Service Manual - Plate Processors 68-85 0945

 A B C D E F G H I J

10 10

Low Power Module, LPM

(Optional, not on all
Models)

9 9

These components may not be

mounted

X2 F1 3.15AT
1
2
8 8

RV2 RV4 RV6 RV7 RV1 RV3 RV5 RV8

X1 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16 BTA 16
X57,L OUT 1
230 VAC Q2 Q4 Q6 Q7 Q1 Q3 Q5 Q8
X57,RTN OUT 2

S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275
S14K275

from
page 1

D2 D3 D4
J2 D1 J3 J4
7 3 1 2 4 6 5 3 1 2 6 4 5 3 1 2 4 6 5 7

Ground in
Electronics

X72,8
X68,1
X68,2
6 6

X69,1
X69,2
X71,1
X71,2

X70,1
X70,2

Gnd

J2,1
J2,3
J2,5
J2,6
J3,1
J3,3
J3,6
J3,4
5 5

X72 2 1 3 5 4 6 7 8 9 10 12 11 13 15 14

4 4

Bracket Bracket Bracket Bracket

X68 4 3 2 1 X69 4 3 2 1 X70 4 3 2 1 X71 4 3 2 1

3 3

M M M M

M29 M30 M31 M32

Water Repl. Water Repl. Water Repl. Pump, Water Repl. Pump,
Pump, Pre-wash Pump, Dev Wash Gum
2 2
Optional, may Optional, may not
not be be mounted
mounted

Title: Number: Rev.:

Date: Monday, January 14, 2008
High Voltage Wiring
1
Constructor: JW
ELECTRONIC AND MECHANICAL ENGINEERING
63664 M 1
Function:
Doc. No.:
Approval: This drawing belongs to Glunz & Jens en A/S
230 VAC Control Devices, LPM and m us t not be us ed or handed over to any
unauthorized pers on without our s pecific perm is s ion.
Page: 4 Of: 6 OrCAD
A B C D E F G H I J
B-10
Low voltage wiring

Low voltage wiring

Sensors and control devices

Service Manual - Plate Processors 68-85 0945

 J1
Main Processor Unit, MPU Processor Interface
Module, PIM

P1

J4,1 J4,2 J4,3 J4,4 8 20

3b 3c 4b 4c 2b 2c 2b 2c 5b 5c 2b 2c 4b 4c 5b 5c 1b 1c 2b 2c 3b 3c 4b 4c 5b 5c 6b 6c

1
2

X55,3
X55,4
R3/4/7,1
R3/4/7,2
S1,2

R1,1
R1,2
R2,1

R8/6,1
R8/6,2
S2,2

R2,2
S1, 1
S2, 1
Power components mounted on :
HPU/MPU B A Optional
Level sensors Temp. sensors Valves
Variant 4b 4c 2b 2c
5b 5c 6b 6c 1b 1c 3b 3c
2
1

Silver B1, B3, B7, B10, B12, B15, B17 R1, R2, R4, R8 K9

ECO B3, B6, B10, B14, B15, B17, B20, B21 R1, R2, R4, R6 1 1 1 1 1 1
5
3

Thermal, standard B1, B2, B9, B10, B11, B15 R1, R2 K8 X55
S1 S2
Polymer w. prewash 3 4
B1, B2, B9, B10, B11, B15, B16, B22 R1, R2, R6 K8, K6 R1 R2
and/or preheat Rntc 10K Rntc 10K Rntc 10K Rntc 10K
To Centrifuge motor NC NC Plate Setter
connector, X55
See Setter manual for actual
2 2 2 2 2 2 pin connections, or contact your
Service Suplier.
Input Output Temp Sensor: Temp Sensor: Temp Sensor: Temp Sensor:
Sensor Sensor Developer -R1 Dryer -R2 Wash off -R4 Finisher -R8,
Wash -R4 Preheat -R6
B A

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
X63,1
X63,2

B11/12/14,2
B16/17/19,1
B16/17/19,2

B1/20,1
B1/20,2
K6,1
K6,2

B10,1
B10,2
B11/12/14,1
B15,1
B15,2
B22,1
B22,2
K8/9/11,1
K8/9/11,2

B2/3/4,1
B2/3/4,2

B6/7/8/9,1
B6/7/8/9,2

J9,3
J9,5
J9,6

J9,4
J11,3
J11,4

J11,7
J11,8
J11,1
J11,2

J10,12
J10,9

J,10,11
J10,3
J10,5
J10,7

J10,4
J10,6
J10,8

J10,10
1 1 1 X63
J10,13
J10,14

1 1 1
A B C 1 2

15k
15k
15k
15k
15k

+ -

5b
5c
5b
1a
3a
1a
3a

5c

4b
4c
4b
4c
1 1 1 1 24V 24V
1 1 2
To relay
2 2 2 2 2 2 PCB, X63

15k
15k
15k
15k

15k
15k
2 2 2 2
Tank Min. Cont. Min. Cont. Min. Sensor: Cont. Max. Sensor: Cont. Min. Sensor: Water valve : Water valve :
2 2 Sensor : Sensor: Dev. fill-up - B11, Dev Waste - B15 Water - B22 Prewash - Wash - K8,
Developer - B1 Dev repl. - B10, Finisher - B12, K6 Wash off - K9,
Cont Min. Dev App. - B10 Cont. Max. Sensor: Dev2 - K11
Tank Min.
Tank Min. Tank Min. Sensor : Wash Waste - B14
Sensor : Cont. Min. Tank Min. Tank Min.
Sensor : Sensor : Dev Water
Wash - Sensor : Sensor : Sensor : Title: Number: Rev.:
Wash - B3 Rinse - B7, - B20 Date: Monday, January 14, 2008
B2 Gum - B9 Finisher - B17, Prewash
Wash-off - Wash off 2 - B8 Low Voltage Wiring
Wash app. - B6 Gum - B17 - B16
B4 Constructor: TGJ 63664 M
Cont. Min. Function: ELECTRONIC AND MECHANICAL ENGINEERING
Sensor : Doc. No.:
Approval: This drawing belongs to Glunz & Jens en A/S
Wash-off 2 - Sensors And Control Devices and m us t not be us ed or handed over to any
B19 unauthorized pers on without our s pecific perm is s ion.
Page: 5 Of: 6 OrCAD
B-12
Motors and internal bus wiring

Motors and internal bus wiring

8, 24 and 35V AC distribution

Service Manual - Plate Processors 68-85 0945

 J1 at HPU :
pin 1 & 5 : 8,5 VAC Part of High Power Unit, HPU P1
pin 2 & 6 : 24 VAC
pin 3 & 7 : 30 VAC 4 #4
TX
pin 4 & 8 : 30 VAC 8 #8
TX
J1
2 #2
F2 D45 RX
5 - +
X52,5 7 #7
RX
1 + C113 DC supply to
1 AT 3 #3
X52,1 mikroprocessor GND
4700uF/25V
1 #1
6
X52,6 6 #6
2 5 #5

#1
#2
#3
#4
#5
#6
#7
#8
X52,2 #9
From X40 & X41
9 #9
on page 1 7
X52,7

1
2
3
4
5
6
7
8
9

F405
3 4AT
X52,3 P1
8 F403 F401 Part of Main Processor Unit, MPU
X52,8 D420 D421 D416 D417 1 #1
TX

4
3
1
10AF 10AF D425 D426 2 #2 See page 5 of 6 for connection to input
C456 C454 . . TX 47 K and temperature sensors

+
+
3 #3

1
3
4
3
Q4112 RX

3
1
4
.
4 #4

+
+
RX
9
8
7
6
5
4
3
2
1

. .
5 #5
4 C457 C455 D427 D428 GND

4
1
3
X52,4
6 #6
D422 D423 D418 D419

2 X 10uF/100V
2 X 10uF/100V
#9
#8
#7
#6
#5
#4
#3
#2
#1

7 #7
DC supply to valves
and solenoids 8 #8
Dual Motor Controller 0V See page 5 of 5 +24V 9 #9
J5 J4

Terminator plug
G&J no. 85514
1 4 2 6 3 5 1 4 2 6 3 5

3
2
1
3
2
1

M2,1
M2,2
M1,1
M1,2
M21,1

M21,2

RRM PCB - Rectifier board with relay

X64 X65
X62 F1 D1
1 - +
1 1
24VAC from

J5,2
J5,3
J5,5
J4,2
J4,3
J4,5
Transformer T3 on + C1
2 2AT
page 1 4700uF
M
#1
#2
#3
#4
#5
#6
#7
#8
#9

3 2 1 3 2 1 2 2
2 x T filter

3
LS1 M8
1
2
3
4
5
6
7
8
9

4
S7 S6 24V
Opto interrupter Opto interrupter Prewash Brush Motor

Man Machine Interface, MMI

F18 F17 X63
J5,4 J4,4 1
2 2 From HPU J6-3, 2b+2c
4AT Red Red 2
4 or 5AT
M M
relay on
Brush Motor Transport Motor

2 X T filter
2 X T filter
Black M2 Black M1
J5,1 J4,1
Not standard
1 1

Option
To MPU

J5,4
J5,1
J4,3 2b+2c

Connector for
X55 dismounting
Centrifuge cover
X56 with motor
F9

2 Red
6AT
Centrifuge
M
Motor

2 X T filter
Black M21
Not standard
1
S17

Switch is shown as
Centrifuge the drawer is open.
Title: Number: Rev.:
Wash Centrifuge Date: Monday, January 14, 2008
Switch Motors And Internal Bus Wiring
Constructor: JW 63664 M
Function: ELECTRONIC AND M ECHANICAL ENGINEERING
Doc. No.:
Approval: This drawing belongs to Glunz & Jensen A/S
8, 24 and 35 VAC Distribution and must not be used or handed over to any

unauthorized person without our specific permission.

Page: 6 Of: 6 OrCAD