Grafmac W-PTP-32CDN User manual

M
Ma ai in nt te en na an nc ce e M Ma an nu ua al l
T
Th he er rm ma al l P Pr ro oc ce es ss so or r
W
W- -P PT TP P- -3 32 2C CD DN N / / W W- -P PT TP P- -4 45 5C CD DN N / / W W- -P PT TP P- -5 53 3C CD DN N
PS Plate Processor
W
W- -P PT TP P- -3 32 2S SN N / / W W- -P PT TP P- -4 45 5S SN N / / W W- -P PT TP P- -5 53 3S SN N
20080923A

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Table of Contents
1Basic Maintenance Guidelines
2Daily maintenance
3Weekly Maintenance
4Other Maintenance
5Maintenance check list
6Assembly and Parts List
7Service Contact Information

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1Basic Maintenance Guidelines：
1.1 Do not use sandpaper or grinders to remove stains or foreign objects from the Plate
Processor.
1.2 During periodic replacement of the developer solution, use fresh water to wash away the
residual solutions to prevent affecting the quality of the plates.
1.3 Use the Manual Mode to activate following functions to check if they are functioning
normally.
• Roller motor
• Brush motor
• Water washing system
• Gum Switch
• Dry fan and Heater
• Developer circulating
1.4 Do not wear gloves during maintenance work to prevent from being caught in the Plate
Processor.
2Daily Maintenance：
2.1 Wipe the plate feeder, upper cover, and the Plate Processor.
2.2 Use a clean, dump cloth to clean the rollers.
2.3 Check whether the quality of the developer solution has deteriorated.
2.4 Check whether the developer solution in the developer tank is sufficient.
2.5 Check whether the gum solution is sufficient.
2.6 Check whether the quality of the gum solution has deteriorated.
2.7 Check whether the concentration of developer solution in developer tank is acceptable.
Note: When the upper cover is opened while the Plate Processor is operational,
beware of the machine’s standby operation. Keep fingers or sleeves away from the
rollers to prevent accidents.

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3Weekly Maintenance：
3.1 Filter Replacement：
3.1.1 Turn off the power supply.
3.1.2 Close the valves at both sides of the filter enclosure to
prevent the developer solution from flowing through
the filter.
3.1.3 Place a container (capacity about 2 liters) under the
filter drainage valve.
3.1.4 Open the drainage valve to drain the developer in the
filter enclosure.
3.1.5 Remove the filter enclosure with the special filter
wrench by turning it counterclockwise. Take care not
to lose the O-ring when removing the filter.
3.1.6 Remove the used filter and insert a new one. Replace
the filter enclosure to its original position. Before
closing the enclosure, make sure
that the O-ring is placed properly on the O-shaped
receptacle, and the enclosure is
sealed evenly to prevent leakage.
3.1.7 Open the valves on both sides of the filter enclosure to allow the developer solution
to flow into the filter.
Note: The valves have to be completely opened; otherwise, the solution in the
developer tank will not be able to circulate
3.1.8 Turn on the power supply and start the Plate Processor. Check whether the
developer solution has entered the filter enclosure. If necessary, press the red button
on top of the filter to let air out and hasten the flow of the developer solution into
the filter.
3.1.9 Check whether the developer solution in the developer tank is circulating. Observe
for slight wave motions on the surface of developer solution to confirm circulation.
3.1.10 Filter replacement is now complete.

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3.2 Developer Solution Replacement and Tank Cleaning:
3.2.1 Apart from inspecting its concentration daily, the
developer solution should be replaced whenever
necessary. (Referring to the chemical supplier)
3.2.2 Turn off the power supply.
3.2.3 Open the drainage valve at the bottom of the Plate
Processor to drain the developer solution.
Note: The developer solution should be drained in accordance with the safety
information provided by the supplier and the safety standards guidelines prevailing
in different countries.
3.2.4 Wash the developer tank with fresh water and drain the water completely.
3.2.5 Remove the crystallized particles in all flexible
pipes to prevent blockage of the
drainage system.
3.2.6 Use the outlet valve at the lower part of the Plate
Processor to completely drain the residual solution
and the wastewater after cleaning.
3.2.7 Use a clean towel to wipe the residual water inside the tank .
3.2.8 Remove the filter enclosure and the residual solution inside. (Refer to 3.1, Filter
Replacement, for the steps to remove the filter enclosure.)
3.2.9 Close the drainage valve after cleaning to prevent leakage of developer solution.
3.2.10 Open the low level drainage valve to drain out the remnants of developer in the
pipe. Close the valves after finished drainage.
3.2.11 Open the valves on both sides of the filter enclosure; otherwise, the solution in the
developer tank will not be able to circulate.
3.2.12 Pour the newly mixed solution into the developer tank.
3.2.13 The capacity of the developer tank is 50 L.
3.2.14 After filling the developer tank, turn on the power supply and start the Plate
Processor. Check for slight wave motions on the surface of the developer solution.
Check for developer solution inside the filter enclosure to verify whether the
developer solution is circulating normally.
3.2.15 Wait for the developer temperature to heat up or cool down to the operational
temperature. The replacement of the developer solution is now complete.
Chemical drainage valve
Lowest chemical
drainage valve

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4Other Maintenance
4.1 Cleaning the Rollers
Roller cleaning can be executed following the period of developer changing. If there are
crystallize or contaminate status occurred and affect the processing result, adjust the cleaning
period as needed.
4.1.1 Turn off the power supply
4.1.2 Loosen the screws on the roller base. (see picture 1 , picture 2)
4.1.3 Take out the upper-roller in chemical tank, then, take out the underside-roller. Put them
smoothly. (see picture 3)
4.1.4 Hold the roller by one hand, and take out the base by the other hand. (picture 4, picture 5)
4.1.5 Take apart each roller sets according to the above mentioned instruction, use a mild
liquid detergent to clean each roller assembly; rinse the roller assemblies with fresh water.
After cleaning, reassemble each set of rollers to its original form.
Note: (1). After assemble the rollers and roller bases, the holes in roller base should be in the
right direction. (see picture 7)
(2). The roller set which with a red ring (see picture 8) should be put in the last position
(dry section) and the one should be in the under.
Picture 1 ：Picture 2: Picture 3
Picture 4 : Picture 5:
Upper roller
Underside
roller
Upper roller base,
Small hole upward，big
hole downward.
Underside roller,
Small hole downward，big
hole u
p
ward.
Picture 7：Picture 8
Red roller should be put in the last
situation and in underside.

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Roller sets are put in order; please check it by the above list before operation. (see picture 6)
The first brush in develop tank (R1 & L1) is for CTP only.
NO. Description NO. Description
A1, A2 First roller set D1, D2 4th roller set (wash-section)
B1, B2 2nd roller set R3, L3 Wash brush
R1, L1 Dev. Brush 1 E1, E2 5th roller set (wash section)
R2, L2 Dev. Brush 2 F1, F2 6th roller set (gun section)
C1, C2 3rd roller set (dev. tank)
Picture 6：
Each roller set roller and connecter has it
own corresponding number
Tank Right
Tank Left

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4.1.6 Turn the adjustment screw on top of the roller base to tighten until the tip of the screw
just touches the lock; turn the screw halfway round to tighten.
4.1.7 Let two persons catch the upper galvanized iron axel of the assembled roller
simultaneously using the J-shaped wrench, lift the rollers up with synchronized motion
and replace them to their original positions tank. Make sure that the gears connect to each
other perfectly.
4.1.8 Turn on the power supply and start the Plate Processor. Check whether the
Plate Processor is running normally.
4.1.9 The adjustment screw on the roller base can be used to adjust the proximity of the upper
and lower rollers. If the rollers are unable to squeeze water properly, there are two
possibilities:
1. The screw adjustment might be too tight, and the pressure on both sides of the
rollers is significantly larger than that on the middle section. If there are unequal
pressures on the rollers, the water squeezing function will not be good. Loosen the
adjustment screw and screw it until the tip touches the lock; turn the screw
halfway round to tighten.
2. The screw adjustment might be too loose, and there is gap between the rollers.
Tighten the screw by small increments. Check whether the result of water
squeezing has improved, and decide whether to tighten or loosen the screw.
4.1.10 Finished roller set cleaning.。
4.2 Cleaning the Brush Rollers set:
4.2.1 Use Hex Wrench to loosen the screws on the fixer and take out them. (picture 1)。
4.2.2 Take out the brush from the slot and put them in a flat surface carefully.
4.2.3 Each roller set takes off according to the above mentioned
step, washed by detergent and washing by clean water. After
finishing the all steps, put the all brush sets back to the
Roller fixe
r
Fixer with red label is
only for gum section.
Picture 1 ：

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original sites.
Attention: if the pressure of the brushes need to adjust, please use Hex Wrench and
10mm thickness Open-End Wrench to loosen the upper and the lower adjustment screw
nut. (Please refer to picture 2 and picture 3)
4.3 Cleaning and Maintaining the Gum Solution Tank:
4.3.1 Clean the gum solution tank with fresh water, and drain the water out of the Plate
Processor.
4.3.2 Remove the metallic mesh of gum solution tank. Clean it with fresh water and check
whether there is any obstruction in the mesh holes.After cleaning, replace the mesh to its
original location.
4.3.3 Turn on power supply and start the Plate Processor. Use Manual Mode to start the gum
circulating pump and check whether the gum solution is being sprayed normally.
4.4 Maintenance of Transmission Parts:
4.4.1 Remove the covers on both sides of the Plate Processor. Check whether the transmission
chains of the rollers and brush are loose. If they are loose, use the idle pulley to adjust
them for proper tightness.
4.4.2 Apply a small amount of lubricant on the chains of the rollers and brush
4.5 Clean the water pipe and hose with clean agent.
※ Use fine sand paper processing on the guide plate：use 400# sand paper for first processing
step. Than use 1200# for second processing step. It’s important to prevent the guide plate
occurred with scratch on plate back.
Picture 2 ：Picture 3 ：

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5Maintenance check list:

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6Assembly and Parts List：
6.1 Electric parts
For 32 / 45CDN, 32 / 45SN Electric parts list
For 53CDN / 53SN Electric parts list
10
26
1
5
14
1 2
2 (Roller)
4
5
6
6
7
8
911 12
13
16
1
7
21
1
8
1
9
20
222
3
24
25
2
3
2 (Brush)
4
66
3
7
9
10
11 12 14 15
16
17 18
19
20
2122
23
24

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Item Part number Part name Quantity Remark
01 EL350 Drive board (GR-MIC9A-180C) 65W
02 EL354 Drive board (GR-MIC9A-180D) 100W
03 EL065-1 Fuse socket (rail type) 2P 3
04 EL385 Fuse 25A 30mm 1
05 EL064 Fuse 20A 1
06 EL066 Fuse 10A 2
07 EL386 Fuse 5A 30mm 2
08 EL956 Fuse 30A 30mm 1
09 EL294 Magnetic contactor 220V CN-25 (TAIAN) 1
10 EL871 Magnetic switch DC24V (LC1YD096) 3
11 EL370 Relay socket 8P (finder) 94.82 2
12 EL369 Relay DC24V 8P (finder) 2
13 PS0613 Transient Voltage Surge Suppressors
(power core) 2
14 EL367 Transformer 12V/20V/15V±9V 1
15 EL689-1 Filter 250V/30A 30DBCS5B 1
16 EL371 CPU board 1
17 EL372 IO board 1
18 EL388 IC (27C512) 1 CPU board,U3,28pin
19 EL732 IC (W77E58-40) 1 CPU board,U1,40pin
20 EL931 IC (93C66) 1 CPU board,U6,8pin
21 EL387 IC (PIC16C505) 1 I/O board,U9,14pin
22 EL403 Relay 24TBU-5 DC24V 9
23 EL460-1 Power supplier 220V (input) DC24V (output) 1
24 PS1095 Fan (AC220V) 1
25 EL700 Interlock 1
26 EL356 Sensor 18mm (DR2N2-10) 2

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6.2 Switch and button
Item Part number Part name Quantity Remark
01 EL291-1 Main switch (CQ0120001KL6) 16A 690V
(red-yellow color) 1
02 EL295 Emergency stop (RPV/EK01×2) 2
03 EL325 Button (22mmRD-X/KE01×1) (Green color) 1
04 EL360 Switch RLWK1R-GN/EK10/GLI30 2
EL360
EL325
EL291-1
EL295

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6.3 Proximity sensor
6.4 Overheat protection device
Item Part number Part name Quantity Remark
01 EL355 Proximity sensor 12mm (TLX-12GN04E1) 1
Item Part number Part name Quantity Remark
01 61340027 Overheat protect switch (95℃) 1
61340027
EL355

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6.5 Control panel
6.6 Filter
Item Part number Part name Quantity Remark
01 PS0090-3 Filter enclosure wrench 1
02 PS0071 Valve
03 PS0090-1 Filter enclosure 1
04 PS0091-3 Filter
05 PS0115 Drainage valve 1
Item Part number Part name Quantity Remark
01 EL958 Keypad 1
02 EL374 LCD monitor 128×64dots 93×70mm 1
PS0115
PS0090-1
PS0071
EL958 EL374
PS0091-3
PS0090-3

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6.7 Temperature sensor (for dryer)
6.8 Heater (developer tank)
Item Part number Part name Quantity Remark
PS0404 Heater (dryer) 220V 1200W 1 For 32 / 45CDN
KPS0172 Heater (dryer) 220V 2000W 1 For 53CDN
6.9 Dryer fan heater and Fan
Item Part number Part name Quantity Remark
01 PS0057 Temperature sensor (for dryer) 1
Item Part number Part name Quantity Remark
01 PS0059-1 Dryer Fan heater, 220V, 4000W 1
02 PS0095-1 Fan 220V 1
PS0057
PS0095-1
PS0059-1

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6.10 Brush set
6.10.1 Developer brush (Right side)
Item Suit for (CTP) Suit for (PS) Part No. Part Name QTY Remark
1 all all KPS0176
KPS0177
Brush connector (left)
Brush connector (right) 2
32 / 45CDN 32 / 45SN KPS0045 Idle wheel fix bolt 1
2 53CDN 53SN KPS0164 Idle wheel fix bolt 1
3 all all PS0301 Bearing # 6801 (12215) 2
32 / 45CDN 32 / 45SN KPS0048 Gear (M2，25T) 1
4 53CDN 53SN KPS0167 Gear (M2，25T) 1
5 all all PS0081 E10 (E shape pin) 1
6 all all PS0368 Carbon bearing 1
32CDN 32SN PS0351 Brush (Ø50) 2 (1)
45CDN 45SN PS0334 Brush (Ø50) 2 (1)
7
53CDN 53SN PS1533 Brush (Ø50 soft) 2
32 / 45CDN 32 / 45SN PS0449 Gear (M2 17T) 1
8 53CDN 53SN KPS0144 Gear (M2 20T) 1
32 / 45CDN 32 / 45SN PS0398 Gear (M2 25T) 1
9 53CDN 53SN KPS0165 Gear (M2 25T) 1
7
8
9

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6.10.2 Washing brush (Right side)
Item Suit for (CTP) Suit for (PS) Part No. Part Name QTY Remark
32CDN 32 / 45SN PS0351 Brush (Ø50) 1
45CDN 32 / 45SN PS0334 Brush (Ø50) 1
1
53CDN 53SN PS1532 Brush (Ø50 hard) 1
32 / 45CDN 32 / 45SN PS0399 Gear (M2 17T) 1
2
53CDN 53SN KPS0162 Gear (M2 17T) 1
32 / 45CDN 32 / 45SN PS0449 Gear (M2 17T) 1
3
53CDN 53SN KPS0144 Gear (M2 20T) 1
4 all all KPS0178
KPS0179
Brush connector (left)
Brush connector (right) 2
32 / 45CDN 32 / 45SN PS0300 Idle wheel fix bolt 1
5
53CDN 53SN KPS0164 Idle wheel fix bolt 1
6 all all PS0301 Bearing (6801SUS) 2
32 / 45CDN 32 / 45SN PS0302 Gear (M2 17T) 1
7
53CDN 53SN KPS0163 Gear (M2 17T) 1
8 all all PS0081 E10 (E shape pin) 1
9 all all PS0368 Carbon bearing 1

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6.11 Roller transmission set
6.12 Auto-filling pump
Item Suit for (CTP) Suit for (PS) Part No. Part Name QTY Remark
32 / 45CDN 32 / 45SN KPS0127 Gear wheel (M2 15T) 1
1 53CDN 53SN KPS0144 Gear wheel (M2 20T) 1
32 / 45CDN 32 / 45SN KPS0123 Axle 1
2 53CDN 53SN KPS0143 Axle 1
32 / 45CDN 32 / 45SN PS0635 Bearing #SS6901 1
3 53CDN 53SN 42070004 Bearing #6903 1
32 / 45CDN 32 / 45SN PS0306 Seal #12227 1
4 53CDN 53SN PS0751 Seal #17276 1
32 / 45CDN 32 / 45SN KPS0122 Axle fixing 1
5 53CDN 53SN KPS0142 Axle fixing 1
32 / 45CDN 32 / 45SN PS0267 Bearing #SS6801 (12215) 1
6 53CDN 53SN 42070007 Bearing #6903 1
Item Part number Part name Quantity Remark
01 PS0443-1 Auto filling pump
5
3
2
1 46

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6.13 Solenoid valve (water inlet)
6.14 Solenoid valve (gum recycle)
Item Part number Part name Quantity Remark
01 PS0092-A Solenoid valve 220V 0.5-10BAR
Item Part number Part name Quantity Remark
01 PS0092-1 Solenoid valve 220V 0-5BAR
PS0092-A
PS0092-1